基于随机振动理论的焊接结构疲劳寿命概率预测方法研究

为了能够在设计阶段对承受随机载荷作用的焊接结构的焊缝进行疲劳寿命预测,该文以随机振动理论为基础,结合主S-N曲线法,通过推导证明了用于焊接结构疲劳寿命评估的等效结构应力与激励载荷之间存在线性传递关系,从而提出了一个频域的焊接结构随机振动疲劳寿命概率预测新方法。该方法能够解决多随机载荷作用下复杂焊接结构振动疲劳寿命预测问题。通过T型接头的算例对比分析,证明了该方法能够考虑激励载荷的频率对焊缝疲劳寿命的影响。直接以线路实测随机加速度谱做为激励载荷,对某轨道集装箱平车车体结构关键焊缝的振动疲劳寿命进行预测,结果表明:该方法的预测结果与实际情况吻合,便于工程应用。     

高温合金焊接接头疲劳损伤演化试验

该文采用应力控制的方式对GH4169焊接接头试件进行疲劳试验,得到了GH4169焊接接头在不同载荷下的寿命。通过对焊接接头疲劳应变幅变化的测量,了解了GH4169焊接接头的疲劳损伤演化过程。该文还对不同载荷下焊接接头宏观损伤演化曲线进行了分析。研究结果可为GH4169焊接结构疲劳寿命预测提供参考。     

热声激励下金属薄壁结构的随机疲劳寿命估算

金属薄壁结构在热声载荷作用下会发生复杂的大挠度非线性响应,结构内部快速变化的复杂应力严重降低了结构的疲劳寿命。在结构热声激振非线性响应分析基础上,采用雨流循环计数法对应力响应时间历程进行疲劳循环计数,通过Morrow TFS,SWT平均应力模型将疲劳循环进行零均值等效处理,结合Miner线性损伤累积理论,计算结构的热声疲劳寿命。以2024-T3型铝合金薄板为研究对象,计算得到了屈曲前后四种温度条件有限带宽高斯白噪声载荷作用下的非线性动态响应,并估算了疲劳寿命。分析结果表明,屈曲前结构的疲劳寿命随着温度升高下降,屈曲后结构持续跳变时的疲劳寿命持续下降直至最低,结构进入间歇跳变区域后疲劳寿命上升,结构热声疲劳寿命与非线性响应特征具有特定的对应关系。     

热声载荷下薄壁结构非线性振动响应分析及疲劳寿命预测

基于时域分析法研究了金属薄壁结构在热声载荷下的非线性振动响应特性,并采用四种应力寿命模型预测了薄板梁的热声疲劳寿命。以典型薄板梁为研究模型,首先研究了单一噪声激励下薄板梁的时域响应特性及热载荷对其响应特性的影响机理,并仿真分析了薄板梁在热声激励下的非线性响应特性。在此基础上,运用雨流法统计了薄板梁根部的应力响应,并基于Miner线性累积损伤理论采用Goodman、Morrow、Walker和修正Walker应力寿命模型预测了薄板梁在不同工况下的热声疲劳寿命。研究结果表明：薄板梁的热模态基频在其热声疲劳问题中起主导作用;薄板梁热屈曲后的非线性跳变响应将增大应力幅值,从而严重削弱结构的预期寿命;噪声载荷是影响屈曲前薄板梁热声疲劳寿命的主要因素,而热载荷是影响屈曲后热声疲劳寿命的主要因素。因此在薄壁结构抗热声疲劳设计中必须重点考虑热声载荷联合作用的影响。     

随机振动载荷下塑封球栅阵列含铅焊点疲劳寿命模型

对塑封球栅阵列(PBGA)封装器件Sn37Pb焊点进行了正弦振动、随机振动实验,得到各个载荷下焊点的疲劳寿命结果.建立了三维有限元模型,进行与实验条件一致的有限元分析,计算焊点的应力;将实验结果与有限元计算相结合,并基于Steinberg寿命预测模型,发展了随机振动载荷下焊点疲劳寿命预测方法.结果表明,疲劳寿命模型预测...     

船舶工程焊接接头完整性评估与疲劳寿命预测技术综述

介绍了船体结构中含缺陷的焊接接头完整性评估以及疲劳寿命预测方法，对结构完整性评估的K准则、COD准则、J积分准则、SINTAP/FITNET安全性评定方法以及评定流程、国内外标准进行介绍。并对焊接接头的疲劳强度影响因素，如平均应力、残余应力以及接头几何形状应力集中等进行了分析；介绍了焊接接头疲劳寿命预测的常用方法，如基于名义应力的评估方法、基于断裂力学的评估方法、基于损伤力学的评估方法以及其它疲劳评估方法等。此外，还对基于断裂力学法建立的焊接残余应力与疲劳裂纹扩展寿命之间的函数关系进行了介绍，该方法实现了对含残余应力的焊接结构疲劳寿命的精确预测。     

基于应力概率密度和功率谱密度法的随机声疲劳寿命预估方法研究

针对航空发动机燃烧室火焰筒结构的声疲劳问题,研究了一种用于随机载荷下结构疲劳寿命预估的有效方法。首先,对薄壁结构在随机载荷作用下的Von Mises应力过程的概率分布作了研究,给出了应力峰值概率密度函数的表达式。基于Miner线性理论,提出了基于应力概率密度和功率谱密度法的随机声疲劳寿命预估方法,并建立了疲劳寿命预估模型。以某型航空发动机燃烧室火焰筒结构为例,在采用耦合的有限元和边界元方法计算出随机声疲劳应力基础上,应用所建立的模型进行了疲劳寿命估算,并对计算结果进行了宽带修正。结果表明,该方法对航空薄壁结构随机疲劳寿命分析具有实用性。     

钢丝绳拉伸疲劳寿命仿真分析与试验研究

为研究钢丝绳在拉伸载荷下的疲劳寿命预测问题,以6×36 WS结构钢丝绳为研究对象,建立了钢丝绳的有限元模型,仿真分析了其在轴向拉伸载荷下的应力分布。对仿真结果中应力最大的钢丝进行拉伸疲劳试验,得到钢丝试件的载荷寿命曲线。在此基础上进行了钢丝绳疲劳寿命的仿真分析,并通过钢丝绳的疲劳试验进行了验证。钢丝绳疲劳仿真结果表明,在轴向拉伸载荷作用下,最大应力位于相邻两个绳股接触区域,对应的此处区域疲劳寿命最短。钢丝绳疲劳寿命仿真与试验结果具有较好的吻合度,由仿真数据拟合的载荷寿命曲线为钢丝绳疲劳寿命的预测提供了依据。     

一般应力比时焊接结构S—N曲线的预测方法

本文考虑了焊接结构的几何形状，受载形式，应力比，残余应力，尺寸效应以及材料等因素对疲劳寿命的影响，利用Ｐｅｔｅｒｓｏｎ公式和极值疲劳切口系数概念，建立了一般应力比时焊接结构Ｓ－Ｎ曲线的预估模型，文中对几类典型的焊接结构的Ｓ－Ｎ曲线进行了预测，预测值与实验结果符合较好，本文方法可以大量减少疲劳实验，具有一定的工程实用价值。     

一般应力比时焊接结构S－N曲线的预测方法

本文考虑了焊接结构的几何形状、受载形式、应力比、残余应力、尺寸效应以及材料等因素对疲劳寿命的影响，利用Ｐｅｔｅｒｓｏｎ公式和极值疲劳切口系数概念，建立了一般应力比时焊接结构Ｓ－Ｎ曲线的预估模型．文中对几类典型的焊接结构的Ｓ－Ｎ曲线进行了预测，预测值与实验结果符合较好．本文方法可以大量减少疲劳实验，具有一定的工程实用价值．     

一种多轴向随机激励下结构疲劳寿命分析方法

提出了一种多轴向随机激励下结构疲劳寿命估计的频域分析方法。首先,对结构进行频响分析,得到在基础加速度激励下的应力频响函数矩阵,通过随机振动分析,得到结构应力的功率谱密度矩阵;其次,采用等效的Von Mises应力功率谱密度将多轴应力问题转化为单轴应力问题;最后,利用单轴应力疲劳寿命估计的频域分析方法对结构疲劳寿命进行估计。对一典型构件在多轴向随机激励下的疲劳寿命进行了计算,并与实验结果进行了对比。另外,对构件在多轴向同时激励与单轴分别激励的疲劳损伤结果进行了对比分析,表明多轴向同时振动具有明显的多轴效应,因此进行多轴向振动疲劳研究十分必要。     

CONSIDERATIONS OF THE EFFECT OF RESIDUAL STRESSES ON FATIGUE OF WELDED ALUMINIUM ALLOY STRUCTURES

A new class of large, high-speed seagoing ferry-boat is under development for service around the world. The ships, which are built entirely of aluminium-alloy plate and stiffeners, show a propensity for fatigue cracking of the welded structure. Cracks may occur in both the hulls and the superstructure early in their 20-year service life. Early appearance of fatigue cracks is shown to result from the combined stress and strain fields set up in weld zones by the static residual stresses and cyclic loads, beyond the effects of weld and detail geometry.  A numerical example demonstrates that conventional methods of fatigue analysis overestimate the lifetime of the welded aluminium structure, while damage tolerance analysis based on fracture mechanics leads to improved prediction.     

循环荷载作用下钢桥面铺装疲劳损伤失效行为研究

针对钢桥面铺装工程中普遍采用的改性沥青(Stone Matrix Asphalt,SMA)、浇筑式沥青(Guss asphalt,GA)、环氧沥青(Epoxy asphalt,EP)混合料双层铺装结构,进行了循环车载作用下钢桥面与沥青混凝土铺装疲劳损伤特性理论分析与试验研究。基于疲劳损伤度,研究了钢桥面铺装疲劳损伤失效行为和疲劳开裂过程中损伤场、应力和应变场动态演变机制,推导出疲劳失效时的损伤场、应力和应变场计算表达式,并给出钢桥面铺装疲劳寿命理论公式。以三座钢箱梁桥桥面铺装(润扬长江大桥2005,南京长江三桥2005,苏通大桥2008)为例,对不同铺装结构组合方案下的复合梁进行疲劳试验分析和使用寿命理论预测。实例研究结果表明,钢桥面铺装疲劳损伤失效行为预估模型合理可行;相较于改性沥青、浇筑式沥青,环氧沥青混合料具有较强高的强度低变形能力,更适合于大跨径钢桥面铺装抗疲劳的设计要求;由环氧沥青混合料组合而成的“双层环氧沥青混凝土”和“浇注式沥青混凝土(下层)+环氧沥青混凝土(上层)”的抗疲劳性能优于其它沥青混合料铺装结构组合方案,同等厚度组合情况下疲劳使用寿命可延长1倍~2倍以上;“双层环氧沥青混凝土”已应用于润扬长江大桥、南京长江三桥和苏通长江大桥钢桥面工程,并已成功运行10年以上,其跟踪观测结果良好。     

Fatigue of fillet welded A515 steel

A study has been made of the fatigue behavior of fillet welded ASTM A515 steel. As-welded and stress-relieved skip fillet weld specimens were tested under pulsed tension and altering cyclic load to determine stress-life and crack propagation behavior. Crack initiation and propagation features were determined from sectioned surfaces. All fatigue cracks were semi-elliptic and initiated from weld end toes. The length/depth ratio was approximately constant during propagation. There was no consistent effect of tensile residual stress on fatigue life under pulsed tension but there was a detrimental effect under alternating loads. An equivalent crack model has been proposed to quantify the stress concentration effect at the crack initiation site based on the application of the Paris equation. The test results show that the equivalent crack can give a reasonable prediction of the fatigue life of a welded structure and is a potentially convenient tool in fatigue design.     

Fatigue crack initiation and growth in AlMg4.5Mn butt weldments

The fatigue life of full-penetration and partial-penetration 5 and 25  mm thickness AlMg4.5Mn (AA5083) aluminium alloy butt weldments was investigated under ( R = 0 and R = − 1) constant amplitude loading. The fatigue lives of the tested specimens were predicted using an analytical model which estimated both the crack initiation and crack growth portions of the total fatigue life. The fatigue life of partial-penetration weldments was found to be substantially less than that of full-penetration weldments because of the greater stress concentrations of the incomplete joint penetration and the consequent absence of a substantial crack-initiation life period. Tensile mean stresses ( R = 0 versus R = − 1-test conditions) markedly reduced the fatigue life of the weldments studied and greatly diminished the duration of the fatigue crack growth period. The extra material provided by the weld reinforcement noticeably increased the fatigue life of the partial-penetration weldments. Weld angular distortion-induced bending stresses greatly affected the smaller thickness (5  mm) full-penetration weldments offsetting the fatigue strength bonus anticipated for small-size weldments. Except for the predictions for R = − 1 full-penetration weldments at long life, which the analytical model underestimated, the agreement between experiment and analytical prediction was within a factor of 2, that is, as good as can be generally expected.     

Stress intensity factor solutions for estimation of fatigue lives of laser welds in lap-shear specimens

Fatigue behavior of laser welds in lap-shear specimens of high strength low alloy (HSLA) steel is investigated based on experimental observations and two fatigue life estimation models. Fatigue experiments of laser welded lap-shear specimens are first reviewed. Analytical stress intensity factor solutions for laser welded lap-shear specimens based on the beam bending theory are derived and compared with the analytical solutions for two semi-infinite solids with connection. Finite element analyses of laser welded lap-shear specimens with different weld widths were also conducted to obtain the stress intensity factor solutions. Approximate closed-form stress intensity factor solutions based on the results of the finite element analyses in combination with the analytical solutions based on the beam bending theory and Westergaard stress function for a full range of the normalized weld widths are developed for future engineering applications. Next, finite element analyses for laser welded lap-shear specimens with three weld widths were conducted to obtain the local stress intensity factor solutions for kinked cracks as functions of the kink length. The computational results indicate that the kinked cracks are under dominant mode I loading conditions and the normalized local stress intensity factor solutions can be used in combination with the global stress intensity factor solutions to estimate fatigue lives of laser welds with the weld width as small as the sheet thickness. The global stress intensity factor solutions and the local stress intensity factor solutions for vanishing and finite kinked cracks are then adopted in a fatigue crack growth model to estimate the fatigue lives of the laser welds. Also, a structural stress model based on the beam bending theory is adopted to estimate the fatigue lives of the welds. The fatigue life estimations based on the kinked fatigue crack growth model agree well with the experimental results whereas the fatigue life estimations based on the structural stress model agree with the experimental results under larger load ranges but are higher than the experimental results under smaller load ranges.     

薄壁结构高温随机振动疲劳寿命估算方法

为了研究涡轮转子叶片在高温环境中气流激振力作用下随机振动疲劳失效机理,从基础研究出发,采用薄壁板件为研究对象。基于高温试验台与振动台联合试验,结合数值仿真,得到了不同温度和不同振动量级组合下试验件根部与颈部的轴向动应力响应规律。基于疲劳累积损伤理论,采用改进的雨流计数法预估试验件的疲劳寿命。通过高温随机振动试验,同时参照常温随机振动试验,获得试验件在实际工况下的应力、应变、频率等动力学响应和寿命数据,并对各个试验组的响应与寿命进行数据统计,仿真与试验结果比较发现:数值仿真对试验件破坏位置判断准确,应力响应误差在5.6%以内,频率响应相差1%左右,疲劳寿命相差28.6%以内,证明了高温条件下随机振动疲劳分析方法是有效的而且精确的。     

基于非概率集合理论的屋面板风致疲劳寿命估计

现有疲劳分析中,通常将结构材料参数、几何尺寸等定义为确定性参数;实际结构中,相关参数均为有界但不确定变量,如按确定性参数估计结构的疲劳寿命是偏于不安全的。该文将结构体系中不确定参数定义为区间变量,在线性疲劳损伤累积理论基础上,提出一种仅需一次动力响应分析即可计算不确定结构在动力荷载作用下疲劳损伤的新方法。该方法将金属屋面板弹性模量和屋面板板厚等由于施工误差等因素引起的不确定参数定义为区间变量,通过摄动法和区间动力响应分析,计算屋面板在脉动风荷载作用下的应力响应区间;结合屋面板材料的S-N曲线,采用修正Miner疲劳线性累积准则对屋面板的疲劳损伤和寿命区间进行估计。结果表明:该文方法可有效计算考虑结构参数不确定条件下金属屋面板的疲劳损伤和寿命区间;与顶点法比较,该文方法仅需一次动力响应分析就可计算金属屋面板风致疲劳损伤和寿命区间。