液压支架顶梁焊接变形控制研究(1).pdf

学校代码 10289 分类号 TG444 密 级 公开 学 号 092060070 江苏科技大学江苏科技大学 硕硕 士士 学学 位位 论论 文文 液压支架顶梁焊接变形控制研究液压支架顶梁焊接变形控制研究 研 究 生 姓 名 孟晓辉 导 师 姓 名 方臣富 教授 申请学位类别 工学硕士 学位授予单位 江苏科技大学 学 科 专 业 材料加工工程 论文提交日期 2012 年 4 月 25 日 研 究 方 向 焊接质量控制及装备 论文答辩日期 2012 年 5 月 26 日 答辩委员会主席 徐玉松 评 阅 人 盲审 盲审 2012 年 5 月 26 日 液 压 支 架 顶 梁 焊 接 变 形 控 制 研 究 孟 晓 辉 江 苏 科 技 大 学 分类号 TG444 密 级 公开 学 号 092060070 工学 硕士学位论文 液压支架顶梁焊接变形控制研究 学生姓名 孟晓辉 指导教师 方臣富 教授 江苏科技大学 二 O 一二年五月 A Thesis ted in Fulfillment of the Requirements for the Degree of Master of Engineering Research on welding deation control of the hydraulic support beam ted by Meng Xiaohui Supervised by Professor Fang Chenfu Jiangsu University of Science and Technology May, 2012 江苏科技大学学位论文原创性声明江苏科技大学学位论文原创性声明 本人郑重声明所呈交的学位论文，是本人在导师的指导下，独立进 行研究工作所取得的成果。除文中已经注明引用的内容外，本论文不包含 任何其他个人或集体已经发表或撰写过的作品成果。 对本文的研究做出重 要贡献的个人和集体，均已在文中以明确方式标明。本人完全意识到本声 明的法律结果由本人承担。 学位论文作者签名 年 月 日 江苏科技大学学位论文版权使用授权书江苏科技大学学位论文版权使用授权书 本学位论文作者完全了解学校有关保留、使用学位论文的规定，同意 学校保留并向国家有关部门或机构送交论文的复印件和电子版， 允许论文 被查阅和借阅。 本人授权江苏科技大学可以将本学位论文的全部或部分内 容编入有关数据库进行检索，可以采用影印、缩印或扫描等复制手段保存 和汇编本学位论文。 本学位论文属于 1保密□，在 年解密后适用本授权书。 2不保密□。 学位论文作者签名 指导教师签名 年 月 日 年 月 日 摘要 I 摘要 液压支架已成为煤矿机械化综采的主要设备之一，除液压元件以外，其主体部件 基本上都是形状比较复杂的方格型焊接结构件。因此，焊接是液压支架产品制造中的 主要的加工工艺。 液压支架中的顶梁、掩护梁是受力最大的两个关键部件，顶梁主要作用是承接岩 石及煤的载荷、反复支撑顶煤并对较硬的顶煤起破碎作用、为回采工作面提供足够的 安全空间； 掩护梁主要作用是承受顶梁的水平分力和侧向力， 以增强支架的抗扭性能。 高端液压支架顶梁中顶板与主筋板的焊接在整个顶梁焊接工作量中占很大比例。 现有液压支架顶梁顶板与主筋板的焊接生产模式是先将立板点装成方格结构进行强约 束，然后采用手工 MAG 焊焊接。高端液压支架自动化焊接生产线项目拟将顶板与主 筋板点装后采用 TANDEM 双丝焊接工艺进行焊接生产，从而极大地提高焊接生产效 率和焊接自动化水平。由于焊接时没有隔板的约束作用，必然会引起顶板和主筋板的 焊后变形。因此以 Z106 梁用 Q690 钢板为依据，采用 ANSYS 仿真模拟顶板与主筋板 TANDEM 双丝焊产生的变形量，其结果与实际测量数据基本吻合, 为焊接变形的优化 控制提供了依据；采用 TANDEM 双丝焊焊接工艺方法，研究其焊接性能并控制顶板 与主筋板的焊接变形量，通过使用胎架固定顶板可以有效控制主筋板之间的焊后变形 量；采用 TANDEM 双丝焊焊接 Q690 钢板，对焊缝进行力学试验和组织分析，同时对 液压支架用 Q690 钢的 TANDEM 双丝焊与 GMAW 双丝焊进行对比研究，结果表明 TANDEM 双丝焊焊接接头焊缝及热影响区晶粒相对细小，热影响区宽度窄，接头力学 性能优于 GMAW 双丝焊接头；TANDEM 双丝焊的主从脉冲推挽过渡方式使其熔滴过 渡、热流分布、电弧相互作用不同于 GMAW 双丝焊，焊接速度得以提高，焊缝成形 得以改善，降低了焊接变形；同时，TANDEM 双丝焊脉冲电流能对熔池产生强烈振荡 搅拌，起到了细化晶粒的作用。所以确定采用 TANDEM 双丝焊接工艺焊接顶板与主 筋板的可行性及变形控制方案。 关键词关键词液压支架；Q690 钢；TANDEM 双丝焊；焊接接头；焊接性能。 Abstract II Abstract Hydraulic support is the main equipment of fully-mechanized mining face, besides hydraulic components, its main body parts are basically box type welding structure with quite complex shape. Therefore, welding is the major processing technology of hydraulic support products. The top beam and cover beam are two key components of Hydraulic support, the main function of top beam is to undertake roof rock and load of coal, repeatedly support top-coal and have crushing effect to harder top-coal, provide enough safe space to actual mining; the main function of cover beam is to undertake level component and yawing force of apical plate, in order to enhance the anti-wrest perance of the support. The welding of High-end hydraulic support beams of stiffened plate and baseplate has a large proportion in the entire top beam welding workload accounting. The existing welding production mode in hydraulic support beams of stiffened plate and baseplate is to change vertical board point-like into grid structure in order to restrain strongly, and then use manual MAG welding. So welding production efficiency is low, the environment of welding is bad, the welders are intensity, the stability of product quality is poor. High-end hydraulic support automation welding production line project will make stiffened plate and baseplate point-like and then use the TANDEM double wire welding process, thus greatly improve the welding efficiency and welding automation level. Because there is no restriction of clapboard during welding, it will inevitably lead to deation of stiffened plate and baseplate. So based on Z106 beam used Q690 steel plates, first use ANSYS simulation deation of stiffened plate and baseplate in TANDEM double wire welding, the simulation results and the practical measurement data results are mainly the same; Use TANDEM double wire welding and control deation when welding ribbed slab and baseboard, through the use bed-jig can control the deation between ribbed slab ;Use the TANDEM double wire welding to weld Q690 steel plate and analyse the weld line mechanics experiments and organization; At the same time compare the TANDEM double wire welding with GMAW double wire welding, The results showed that, compared with GMAW double-wire welding process, the weld under the TANDEM welding has higher strength, narrower HAZ, thinner grain, smaller deation and higher welding efficiency.to determine the feasibility and deation control scheme of TANDEM double Abstract III wire welding weld stiffened plate and apical plate. Keywords hydraulic support; Q690 steel; TANDEM double wire welding; welding joint; welding perance. 目录 IV 目录 摘要 .......................................................................................................................................... I Abstract .................................................................................................................................. II 第 1 章 绪论 ............................................................................................................................ 1 1.1 选题的意义 ................................................................................................................... 1 1.2 液压支架国内外发展概况及趋势 ............................................................................... 1 1.2.1 国内液压支架发展概况 .................................................................................. 1 1.2.2 国外液压支架发展概况 .................................................................................. 2 1.2.3 我国液压支架和发达国家的差距 .................................................................. 2 1.3 自动化焊接发展概况 ................................................................................................... 3 1.4 双丝焊发展概况 ........................................................................................................... 5 1.5 数值模拟技术的发展现状 ........................................................................................... 7 1.6 本文研究内容 ............................................................................................................... 8 第 2 章 试验材料、设备及方法 .......................................................................................... 10 2.1 试验材料 ..................................................................................................................... 10 2.2 试验设备 ..................................................................................................................... 10 2.3 试验方法 ..................................................................................................................... 11 第 3 章 焊接工艺试验 .......................................................................................................... 14 3.1 Q690 钢焊接力学性能试验 ....................................................................................... 14 3.1.1 Q690 钢焊接性分析 ....................................................................................... 14 3.1.2 Q690 钢对接焊缝试验 ................................................................................... 15 3.2 Q690 钢 TANDEM 双丝焊与 GMAW 双丝焊对比试验 .......................................... 20 3.2.1 试验工艺参数 ................................................................................................ 20 3.2.2 焊接接头的对比 ............................................................................................ 21 3.2.3 焊缝宏观形貌及微观组织 ............................................................................ 21 3.2.4 接头力学性能 ................................................................................................ 22 3.2.5 焊接接头变形 ................................................................................................ 23 3.2.6 焊接线能量 .................................................................................................... 23 3.2.7 熔滴过渡方式 ................................................................................................ 24 3.2.8 焊接电弧的相互作用力 ................................................................................ 24 3.2.9 电弧热的影响 ................................................................................................ 25 3.3 本章小结 ..................................................................................................................... 26 第 4 章 ANSYS 模拟计算 ..................................................................................................... 28 4.1 引言 .............................................................................................................................. 28 4.2 焊接温度场的有限元分析 ......................................................................................... 28 4.2.1 热传导方程 ..................................................................................................... 29 4.2.2 温度场的表征 ................................................................................................ 29 4.2.3 瞬时温度场非线性的有限元分析 ................................................................ 31 4.3 热源模型种类及选择 ................................................................................................. 33 4.3.1 Rosenthal 的解析模式 .................................................................................... 33 4.3.2 高斯热源分布模式 ........................................................................................ 33 目录 V 4.3.3 半球状热源分布函数 .................................................................................... 34 4.3.4 椭球形热源分布函数 .................................................................................... 34 4.3.5 双椭球形热源分布函数 ................................................................................ 34 4.4 热源的叠加和移动处理 ............................................................................................. 35 4.5 焊接温度场的 ANSYS 模拟 ...................................................................................... 38 4.5.1 几何模型的建立 ............................................................................................ 38 4.5.2 单元的选取和网格划分 ................................................................................ 38 4.5.3 焊道的处理 .................................................................................................... 39 4.5.4 边界的换热系数处理 .................................................................................... 39 4.5.5 定义材料的属性 ............................................................................................ 40 4.5.6 加载和求解 .................................................................................................... 41 4.6 温度场及应变模拟结果 ............................................................................................. 41 4.6.1 温度场模拟结果 ............................................................................................ 41 4.6.2 应变模拟结果 ................................................................................................ 42 4.6.3 液压支架变形预测 ........................................................................................ 43 4.7 本章小结 ..................................................................................................................... 45 第 5 章 焊接结构变形原理及控制 ...................................................................................... 46 5.1 内应力及其产生原因 ................................................................................................. 46 5.2 焊接残余应力对结构件的影响 ................................................................................. 47 5.3 焊接变形特点的分类 .................................................................................................. 48 5.4 控制焊接变形的工艺措施 .......................................................................................... 51 5.5 液压支架 TANDEM 双丝焊接头变形控制 ............................................................... 52 5.5.1 焊接工装设计 ................................................................................................ 52 5.5.2 焊接试验 ........................................................................................................ 53 5.6 本章小结 ..................................................................................................................... 57 结论 ........................................................................................................................................ 58 参考文献 ................................................................................................................................ 59 致谢 ........................................................................................................................................ 63 攻读硕士期间发表的论文 .................................................................................................... 63 附录 1 ..................................................................................................................................... 64 Contents VI Contents Chinese abstract ..................................................................................................................... I Abstract .................................................................................................................................. II Chapter 1 Introduction .......................................................................................................... 1 1.1 Significance of Subject ................................................................................................ 1 1.2 Hydraulic support general situation and trend at home and abroad ..................... 1 1.2.1 Hydraulic support general situation at home ..................................................... 1 1.2.2 Hydraulic suppot general situation at abroad .................................................... 2 1.2.3 Hydraulic suppot gap between china and abroad .............................................. 2 1.3 Automation welding development situation ............................................................... 3 1.4 Double wire welding development situation ............................................................. 5 1.5 Welding simulation situation ....................................................................................... 7 1.6 Main content of this subject study ............................................................................ 8 Charpter 2 Experimental material、、equipment and .......................................... 10 2.1 Experimental material ................................................................................................. 10 2.2 Experimental equipment ............................................................................................. 10 2.3 Experimental ............