Mechanism analysis and model parameters estimation of welding residual stress measurement based on modal test method
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摘要: 为避免残余应力对焊接结构的不利影响，保证其可靠性，需要探究残余应力分布. 模态试验法因具有快速和无损的特点，逐渐应用于残余应力测试. 为实现模态试验法测试焊接残余应力，通过振动理论分析了模态试验法的机理，获得了薄板焊件中残余应力与固有频率的关系；薄板焊件中的残余拉应力使固有频率减小，残余压应力使固有频率增大. 在此基础上，将钻孔法和模态试验相结合，借助数据拟合的方法，估计了模态试验法测试6 mm 7A52铝合金试板 VPPA-MIG(variable polarity plasma arc-metal inert gas)复合焊接残余应力的模型参数，确立了固有频率与残余应力的数值关系. 依据确立的数值关系，测得了7A52铝合金试板在不同复合焊接参数下的纵向残余应力分布. 结果表明，接头各区域的残余应力分布特征与钻孔法测得的结果基本一致，偏差在4%范围之内，估计出的模型参数能够保证模态试验法测试结果的可靠性，实现了焊接残余应力的快速和无损测试.
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关键词:
- 模态试验 /
- 残余应力 /
- 固有频率 /
- 模型参数估计 /
- 变极性等离子弧-熔化极气体保护复合焊接
Abstract: To reduce the negative influence of welding residual stress on the welded structure and guarantee the reliability of structure, it is necessary to explore the distribution of residual stress in the welded structure. Modal test method has been gradually applied in the measurement of residual stress due to its fast and non-destructive characteristics. In order to measure welding residual stress by modal test method, the mechanism of modal test method was analyzed by vibration theory, and the relationship between residual stress and natural frequency in thin plate welded structure was obtained. The residual tensile stress in the thin plate welded structure can cause the decrease of natural frequency, while the residual compressive stress can cause the increase of natural frequency. On the basis of theoretical analysis, the hole-drilling method and modal test experiment were combined, and the model parameters for measuring the residual stress of 6 mm 7A52 aluminum alloy(variable polarity plasma arc-metal inert gas, VPPA-MIG) hybrid welded plate using modal test method were estimated through the method of data fitting. The numerical relationship between natural frequency and residual stress was established. According to the established numerical relationship, the longitudinal residual stress distribution of 7A52 aluminum alloy plates under different hybrid welding parameters were measured through modal test experiment. The results illustrate that the distribution characteristics of residual stress measured by modal test method in each zone of the hybrid welded joint of 7A52 aluminum alloy plates are consistent with the results measured by hole-drilling method, and the deviation between the residual stress values measured by the two methods is within the range of 4%. Therefore, the estimated model parameters can guarantee the reliability of the measurement results of the modal test method. It has been achieved fast and non-destructive measurement of the welding residual stress using modal test method. -
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图 1 残余应力与固有频率的关系曲线
Figure 1. Relation curve between residual stress and natural frequency
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图 2 焊接残余应力与固有频率的拟合过程
Figure 2. Fitting process of welding residual stress and natural frequency
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图 3 四边自由条件下模态试验过程
Figure 3. Modal test procedure under the condition of four sides free
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图 5 纵向残余应力与第5阶固有频率的拟合曲线
Figure 5. Fitting curves between the longitudinal residual stress and the fifth order natural frequency
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图 6 模态试验法与钻孔法测试结果对比
Figure 6. Comparison between the results measured by modal test method and hole-drilling method. (a) comparison of longitudinal residual stress; (b) error of longitudinal residual stress
表 1 7A52铝合金薄板VPPA-MIG复合焊接电流参数
Table 1 Hybrid welding current parameters for 7A52 aluminum alloy thin plates
试验
组别VPPA正极性电流
I + /AVPPA反极性电流
I− /AMIG电流
IMIG/ A1 120 139.2 268 2 130 150.8 258 3 150 174.0 235 4 160 185.6 219 5 180 208.8 194 
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表 2 铝合金VPPA-MIG复合焊板前7阶固有频率测量值
Table 2 Measured value of seventh-order natural frequencies for aluminum alloy VPPA-MIG hybrid welding plates
试验组别 试件编号 固有频率f /Hz 1阶 2阶 3阶 4阶 5阶 6阶 7阶 ① 283 384 821 951 1 511 1 672 1 816 1 ② 285 384 820 952 1 509 1 670 1 816 ③ 286 385 822 952 1 510 1 672 1 815 ① 282 378 813 946 1 505 1 664 1 819 4 ② 281 379 813 947 1 504 1 664 1 819 ③ 280 379 815 947 1 505 1 664 1 820 ① 264 350 798 936 1 487 1 646 1 798 5 ② 265 350 800 936 1 487 1 646 1 798 ③ 266 351 799 936 1 488 1 646 1 779
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表 3 纵向残余应力测量值
Table 3 Measured value of longitudinal residual stress
试验组别 试件编号 距离焊缝中心线不同位置的纵向焊接残余应力σx /MPa −60 mm −45 mm −20 mm −6 mm 0 mm 6 mm 20 mm 45 mm 60 mm ① −19 49 151 201 119 197 153 53 −24 1 ② −25 54 155 205 115 202 161 52 −22 ③ −24 51 149 197 118 198 154 51 −26 ① −28 45 179 226 141 223 182 46 −34 4 ② −34 42 185 231 140 226 186 45 −29 ③ −25 43 186 225 132 222 182 43 −33 ① −48 36 205 248 164 247 205 38 −47 5 ② −48 35 204 250 162 249 210 35 −41 ③ −48 35 202 252 160 255 208 33 −42
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表 4 拟合判定系数
Table 4 Fitting determination coefficients
固有频率阶次 纵向焊接残余应力与固有频率的拟合判定系数 R2 A点 B点 C点 D点 E点 3 0.967 0.986 0.982 0.928 0.911 4 0.980 0.973 0.954 0.928 0.913 5 0.981 0.991 0.984 0.957 0.916
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