基于解析算法与<i>J</i>积分法的耐候钢接头疲劳裂纹扩展分析

李宁; 王宗正; 赵子豪; 王晖; EkkarutViyanit

doi:10.12073/j.hjxb.20220121003

基于解析算法与J积分法的耐候钢接头疲劳裂纹扩展分析

1.
中车青岛四方机车车辆股份有限公司, 青岛, 266111
2.
National Science and Technology Development Agency, Bangkok 10700, Thailand

基金项目: 国家重点研发计划(2020YFE0204900)

详细信息

作者简介:
李宁，1980年出生，博士，教授级高级工程师; 主要从事轨道车辆相关试验技术及测试评估技术等工作; Email: lining@cqsf.com

中图分类号: TG 457.14
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出版历程
- 收稿日期: 2022-01-20
- 网络出版日期: 2022-04-28
- 刊出日期: 2022-10-30

Fatigue crack growth analysis of weathering steel joints based on analytical algorithm and J-integral method

1.
CRRC Qingdao Sifang Corporation Limited, Qingdao 266111, China
2.
National Science and Technology Development Agency, Bangkok 10700, Thailand

摘要

摘要: 为准确描述焊接接头疲劳裂纹在扩展中的动态过程，借助多阵元超声相控阵设备对12 mm厚耐候钢对接接头的表面裂纹扩展动态进行实时监测，得到半椭圆形裂纹深度、长度与寿命的演化关系.借助Abaqus建立有限元分析模型，将裂纹几何变化历程输入，计算裂纹尖端7个方向的能量释放率，获得裂纹尖端应力强度因子幅值.将裂纹尖端(θ = 90º)的K值与BS7910标准中推荐解析公式对比分析，其结果吻合性好.在此基础上，分别采用简化公式与两阶段扩展模型计算试样的疲劳寿命. 结果表明，两阶段裂纹扩展模型能准确地预测对接接头裂纹的疲劳寿命，且与试验结果高度吻合.
- 耐候钢对接接头 /
- 疲劳寿命 /
- J积分法 /
- 裂纹扩展解析算法
Abstract: The surface crack propagation dynamics of 12 mm thick weathering steel butt joints were monitored by using multi-element ultrasonic phased array to accurately describe the dynamic process of fatigue crack propagation in welded joints, and the geometric evolution between semi-elliptical crack depth, length relating with fatigue life was obtained. By using Abaqus, the finite element analysis model was established, with the geometric dimension of the crack as the input, the energy release rate G in seven directions of the crack tip was calculated, and then the range of stress intensity factor of the crack tip was calculated. The K value of the crack tip (θ = 90°) is compared with the analytical formula recommended in the BS7910, and the results were in good agreement with each other. Furthermore, the fatigue life of the specimen was calculated by using the simplified formula and the two-stage propagation formula, respectively. The results show that the two-stage crack growth model could accurately predict the fatigue life of butt joints and was in good agreement with the experimental results.
- weathering steel butt joints /
- fatigue life /
- J integral /
- crack growth analytical solution

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图 1 试件尺寸图及实物图

Figure 1. Schematic diagram of test piece. (a) dimension of specimen; (b) workpiece physical drawing

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图 2 疲劳试样加载图

Figure 2. Diagram of fatigue loading. (a) MTS-100 t test system; (b) loading of specimen

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图 3 C2-1试件的疲劳断口

Figure 3. Fracture of C2-1 specimen

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图 4 相控阵设备及扫查工作原理示意图

Figure 4. Phased array equipment and working principle. (a) UPA test equipment; (b) reflection diagram of scan wave

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图 5 根部余高处的稳定回波点

Figure 5. Echo point at the weld root

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图 6 试件C2-1裂纹深度a与长度c的拟合曲线

Figure 6. Fitting curve of crack depth a and length c of specimen C2-1

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图 7 试件C2-1 有限元计算模型

Figure 7. FEA model of specimen C2-1. (a) Mesh and Modeling of specimen; (b) mesh at crack tip and cracking path definition

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图 8 裂纹扩展方向的确定

Figure 8. Determination of crack propagation direction

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图 9 单元节点号图

Figure 9. Element node number graph

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图 10 半椭圆形表面裂纹表征示意图

Figure 10. Schematic diagram of semi-elliptical surface crack characterization

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图 11 试样C2-1的FAD图及临界裂纹尺寸

Figure 11. FAD diagram and critical crack size of C2-1 sample

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表 1 SMA490BW与CHW-55CNH的合金成分(质量分数，%)

Table 1 Chemical compositions of SMA490BW and CHW-55CNH

材料	C	Mn	Si	P	S	Cr	Cu	Ni
SMA490BW	0.18	1.4	0.55	0.035	0.035	0.30～0.35	0.20～0.35	－
CHW-55CNH	0.08	1.4	0.45	0.012	0.008	0.65	0.25	0.35

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表 2 TIG焊接工艺参数

Table 2 TIG welding process parameters

焊接电压U/V	焊接电流I/A	焊接速度v/(mm·s⁻¹)
22.6	227	2.87

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表 3 C2-1试件的疲劳试验参数

Table 3 Fatigue test loading parameters of C2-1

板厚 t/mm	加载宽度 b/mm	名义应力 R_n /MPa	应力比 R	最小加载力 F_min /kN	最大加载力 F_max /kN	实际寿命 N/周次
12	80	230	0.1	30.67	306.67	312154

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表 4 试件C2-1裂纹尺寸数据表

Table 4 Data of crack size of specimen C2-1

循环次数 N/万次	裂纹深度 a/mm	裂纹长度 2c/mm	循环次数 N/万次	裂纹深度 a/mm	裂纹长度 2c/mm
0	0	0	28	12.5	30.3
5	0.9	3.1	29	12.5	33.6
10	1.2	3.3	29.5	12.5	37.2
13	1.5	4.2	30	12.5	40.2
16	1.8	5.2	30.5	12.5	42.3
18	2	10.2	30.7	12.5	45.1
20	2.6	12.1	30.9	12.5	47.6
22	2.8	15.6	31	12.5	51.6
24	3.8	19.1	31.05	12.5	56.3
25	7.1	20.5	31.1	12.5	61.3
26	9.2	23.5	31.11	12.5	62.1
27	10.5	27.1	31.12	12.5	65.3

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表 5 裂纹尖端扩展位移δ及K_i(Δσ = 104 MPa,节点38357)

Table 5 Displacement δ and stress intensity factor K_i of crack tip

扩展位移 δ/mm	应力强度因子 (K_i /MPa·mm^0.5)	扩展位移 δ/mm	应力强度因子 (K_i /MPa·mm^0.5)	扩展位移 δ/mm	应力强度因子 (K_i /MPa·mm^0.5)
0.01	160	1.40	204	6.89	369
0.05	161	2.04	225	7.71	392
0.14	164	2.85	251	8.46	414
0.30	169	3.85	282	9.30	445
0.55	177	5.01	316	10.10	504
0.91	188	6.02	345

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表 6 基于BS7910的K_i值

Table 6 Stress intensity factor K_i of BS7910

节点号	应力范围Δσ = 287.5 MPa		应力范围Δσ = 104 MPa
节点号	裂纹深度a/mm	应力强度因子K_i /(MPa·mm^0.5)	裂纹深度a/mm	应力强度因子K_i /(MPa·mm^0.5)
38357	0.9	414.60	0.9	149.98
	1.2	437.85	1.2	158.39
	1.5	494.56	1.5	178.90
	1.8	550.83	1.8	199.26
	2.0	706.97	2.0	255.74
	2.6	798.47	2.6	288.84
	2.8	876.50	2.8	317.06
	3.8	1032.25	3.8	373.41
	7.1	1236.15	7.1	447.16
	9.2	1376.04	9.2	497.77
	10.5	1538.23	10.5	556.44

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表 7 SMA490BW焊接接头的裂纹扩展速率常数(R > 0.5)

Table 7 Crack growth rate constant of SMA490BW welded joint (R > 0.5)

阶段B		转折点	简化曲线
系数A	系数m	ΔK/(N·mm^−1.5)	系数A	系数m
1.29 × 10⁻¹²	2.88	144	5.21 × 10⁻¹³	3

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表 8 基于BS7910的裂纹寿命分析

Table 8 Crack life analysis based on BS7910

公式	初始裂纹深度a_i₁/mm	临界裂纹深度a_f1/mm	临界前循环次数N₁/周次	临界裂纹深度a_f/mm	裂纹最终深度a_F/mm	临界后循环次数N₂/周次	裂纹扩展总寿命N₃/周次	试验寿命 N₄/周次
简化公式	0.001	4	1206190	4	12	8190	1214380	312154
两阶段公式	0.001	4	345830	4	12	3539	349370	312154

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