Prediction and reduction of out-of-plane welding distortion of typical block in fabrication of semi-submersible lifting and disassembly platform
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摘要:
目的 半潜式起重拆解平台的分段焊接变形直接影响着整个平台的尺寸精度和建造周期。 方法 为此，以典型的B514分段为研究对象，首先预测其焊接面外变形的趋势及数值，分析反变形施加以及焊接顺序优化的影响，提升分段结构的建造精度；然后，依据焊接规范梳理平台结构的主要接头类型及焊接工艺，并通过高效的热−弹−塑性有限元分析，研究典型接头的热−力学响应，获得对应的焊接固有变形；最后，将焊接固有变形作为力学载荷，通过弹性有限元计算，预测B514分段的整体建造精度，同时研究施加反变形和不同焊接顺序对分段建造精度的影响。 结果 基于固有变形的弹性有限元分析，所预测的面外变形与实际测量结果基本吻合，给出了面外变形的产生机理。 结论 通过高效的有限元分析，可以获得并构建焊接固有变形数据库，从而用于复杂分段结构的焊接变形预测，并且施加反变形和焊接顺序优化能有效降低焊接面外变形。 Abstract:Objectives The welding distortion of block structures in the fabrication of semi-submersible lifting and disassembly platforms influences their dimensional accuracy and production schedule. Methods Thus, taking a B514 block as the research object, the tendency and magnitude of its out-of-plane welding distortion are predicted in advance, and the influence of inverse deformation and welding sequence are examined for fabrication accuracy enhancement. Next, typical welded joints and their welding conditions are summarized, and effective thermal-elastic-plastic finite element (FE) computation is carried out to examine the thermal-mechanical response and evaluate the inherent welding deformation. With inherent deformation as mechanical loading, elastic FE analysis is then employed to predict the dimensional accuracy of the B514 block. Moreover, the influences of inverse deformation application and different welding sequences on dimensional accuracy are also examined. Results Based on elastic FE analysis with inherent deformation, the computed out-of-plane welding distortion is found to be in good agreement with the measurement, and its generation mechanism is also clarified. Conclusions Effective FE analysis can be employed to predict the inherent deformation and distortion of complex welded structures; moreover, inverse deformation application and an optimized welding sequence can significantly reduce welding distortion. -
图 1 焊缝处固有变形的加载示意图
Figure 1. Schematic diagram of welding inherent deformation loading on welding line
图 3 AH36和EQ51钢随温度变化的热物理性能参数
Figure 3. Variation of thermophysical parameters of AH36 and EQ51 steels with temperature
图 6 T6角接接头的残余塑性应变分布云图
Figure 6. Distribution of residual plastic strain of T6 fillet welding joints
图 9 B1对接接头的残余塑性应变分布云图
Figure 9. Distribution of residual plastic strain of B1 butt welding joints
图 10 焊接热输入与焊接固有变形的线性拟合
Figure 10. Linear fitting of welding inherent deformation with heat input
图 11 B514分段的壳单元模型及边界条件
Figure 11. Shell elements model and boundary condition of B514 section
图 12 实际焊接顺序下B514分段的面外变形云图
Figure 12. Out-of-plane welding distortion of B514 section with actual welding sequence
图 13 计算的焊接面外变形与测量数据对比
Figure 13. Comparison of computed out-of-plane welding distortion and measured data
图 14 考虑反变形的T6角接接头有限元模型
Figure 14. Finite element model of T6 fillet welding joints with considering inverse deformation
图 15 考虑反变形的T6角接接头计算结果
Figure 15. Computational results of T6 fillet welding joints with considering inverse deformation
图 16 考虑反变形的焊接面外变形对比
Figure 16. Comparison of out-of-plane welding distortion with considering inverse deformation
图 17 不同焊接顺序的底板面外变形对比
Figure 17. Comparison of out-of-plane welding distortion of skin plate with different welding sequence
表 1 B514分段典型的角接接头
Table 1. Typical fillet welding joints of B514 section
接头编号 腹板 底板 坡口形式 焊接工艺
规范编号厚度/mm 材料 厚度/mm 材料 T1 15 AH36 10 AH36 V WPS1 T2 15 AH36 15 AH36 V T3 15 AH36 20 AH36 V T4 10 AH36 10 AH36 V T5 20 AH36 15 AH36 K WPS2 T6 25 AH36 10 AH36 K T7 15 EQ51 15 EQ51 V WPS3 T8 15 EQ51 20 EQ51 V T9 15 EQ51 30 EQ51 V T10 20 EQ51 20 EQ51 K WPS4 T11 20 EQ51 30 EQ51 K 
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表 2 B514分段典型的对接接头
Table 2. Typical butt welding joints of B514 section
接头编号 左 右 坡口形式 焊接工艺
规范编号厚度/mm 材料 厚度/mm 材料 B1 10 AH36 10 AH36 I型 WPS5 B2 15 AH36 15 AH36 I型 WPS6 B3 15 AH36 25 AH36 I型 B4 20 AH36 20 AH36 I型 B5 15 AH36 15 EQ51 I型 WPS7 B6 20 AH36 20 EQ51 I型 B7 20 AH36 30 EQ51 I型 B8 15 EQ51 15 EQ51 I型 WPS8 B9 15 EQ51 20 EQ51 I型 B10 20 EQ51 30 EQ51 I型
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表 3 典型角接接头的焊接工艺（FCAW）
Table 3. Welding condition of typical fillet welding with FCAW
焊接工艺
规范编号电流/A 电压/V 速度
/(cm·min−1)最大热输入量
/(kJ·mm−1)WPS1 171~220 22.9~28.2 15.4~33.5 1.94 WPS2 171~220 22.9~26.4 9.5~29 1.59 WPS3 165~220 23.5~27.5 8.0~13.0 2.87 WPS4 128~165 22.6~26.2 5.8~12.5 2.85
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表 4 I型坡口的对接接头焊接工艺（SAW）
Table 4. Welding condition of butt welding joints of I-type groove with SAW
焊接工艺
规范编号电流/A 电压/V 速度
/(mm·min−1)最大热输入量
/(kJ·mm−1)WPS5 460~580 28~34 470~630 1.82 WPS6 540~682 29.4~35.5 390~526 3.37 WPS7 540~735 31.5~37.5 465~690 2.34 WPS8 540~710 30~36 425~630 2.45
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表 5 热输入与焊接接头固有变形间的经验公式
Table 5. Empirical formula between welding inherent deformation and heat input
变量 对接接头 角接接头 纵向收缩力 −4.74×1010+9.87×107×
焊接热输入4.47×1011+7.34×106×
焊接热输入横向收缩×板厚 6.97−1.09×10−4×
焊接热输入翼板：−1.18+3.54×10−4×
焊接热输入腹板：−22.15+4.92×10−3×
焊接热输入横向弯曲×板厚3 −122.91+3.22×10−2×
焊接热输入翼板：−109.03+2.16×10−2×
焊接热输入腹板：151.77+7.77×10−3×
焊接热输入
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