Key stress extraction and equivalent test method for hybrid DC circuit breaker

Firstly, relevant stress properties of millisecond level breaking process and microsecond level commutation process of hybrid HVDC circuit breaker are studied in detail on the basis of the analysis for the application environment and topological structure and operating principles of hybrid circuit breakers, and key stress parameters in transient state process of two time dimensions are extracted. The established digital simulation circuit for PSCAD/EMTDC device-level operation of the circuit breaker has verified the stress properties of millisecond level breaking process and microsecond level commutation process. Then, equivalent test method, circuits and parameters based on LC power supply are proposed on the basis of stress extraction. Finally, the results of implemented breaking tests for complete 200 kV circuit breaker, 100 kV and 50 kV circuit breaker units, as well as single power electronic module have verified the accuracy of the simulation circuit and mathematical analysis. The result of this paper can be a guide to electrical structure and test system design of hybrid HVDC circuit breaker.

The Stress Combination Method for the Fatigue Assessment of the Hatch Corner of a Bulk Carrier Based on Equivalent Waves

The stress combination method for the fatigue assessment of the hatch comer of a bulk carrier was investigated based on equivalent waves. The principles of the equivalent waves of ship structures were given, including the determination of the dominant load parameter, heading, frequency, and amplitude of the equivalent regular waves. The dominant load parameters of the hatch comer of a bulk carrier were identified by the structural stress response analysis, and then a series of equivalent regular waves were defined based on these parameters. A combination method of the structural stress ranges under the different equivalent waves was developed for the fatigue analysis. The combination factors were obtained by least square regression analysis with the stress ranges derived from spectral fatigue analysis as the target value. The proposed method was applied to the hatch comer of another bulk carrier as an example. This shows that the results from the equivalent wave approach agree well with those from the spectral fatigue analysis. The workload is reduced substantially. This method can be referenced in the fatigue assessment of the hatch comer of a bulk carrier.

Additive manufacturing of Ni-based superalloys: Residual stress, mechanisms of crack formation and strategies for crack inhibition

The additive manufacturing(AM)of Ni-based superalloys has attracted extensive interest from both academia and industry due to its unique capabilities to fabricate complex and high-performance components for use in high-end industrial systems.However,the intense temperature gradient induced by the rapid heating and cooling processes of AM can generate high levels of residual stress and metastable chemical and structural states,inevitably leading to severe metallurgical defects in Ni-based superalloys.Cracks are the greatest threat to these materials’integrity as they can rapidly propagate and thereby cause sudden and non-predictable failure.Consequently,there is a need for a deeper understanding of residual stress and cracking mechanisms in additively manufactured Ni-based superalloys and ways to potentially prevent cracking,as this knowledge will enable the wider application of these unique materials.To this end,this paper comprehensively reviews the residual stress and the various mechanisms of crack formation in Ni-based superalloys during AM.In addition,several common methods for inhibiting crack formation are presented to assist the research community to develop methods for the fabrication of crack-free additively manufactured components.

A review on stress determination and control in metal-based additive manufacturing

Metal additive manufacturing(MAM)is an emerging and disruptive technology that builds three-dimensional(3D)components by adding layer-upon-layer of metallic materials.The complex cyclic thermal history and highly localized energy can produce large temperature gradients,which will,in turn,lead to compressive and tensile stress during the MAM process and eventually result in residual stress.Being an issue of great concern,residual stress,which can cause distortion,delamination,cracking,etc.,is considered a key mechanical quantity that affects the manufacturing quality and service performance of MAM parts.In this review paper,the ongoing work in the field of residual stress determination and control for MAM is described with a particular emphasis on the experimental measurement/control methods and numerical models.We also provide insight on what still requires to be achieved and the research opportunities and challenges.

Analysis and Research on Mechanical Stress and Multiobjective Optimization of Synchronous Reluctance Motor

The mechanical strength of the synchronous reluctance motor(SynRM)has always been a great challenge.This paper presents an analysis method for assessing stress equivalence and magnetic bridge stress interaction,along with a multiobjective optimization approach.Considering the complex flux barrier structure and inevitable stress concentration at the bridge,the finite element model suitable for SynRM is established.Initially,a neural network structure with two inputs,one output,and three layers is established.Continuous functions are constructed to enhance accuracy.Additionally,the equivalent stress can be converted into a contour distribution of a three-dimensional stress graph.The contour line distribution illustrates the matching scheme for magnetic bridge lengths under equivalent stress.Moreover,the paper explores the analysis of magnetic bridge interaction stress.The optimization levels corresponding to the length of each magnetic bridge are defined,and each level is analyzed by the finite element method.The Taguchi method is used to determine the specific gravity of the stress source on each magnetic bridge.Based on this,a multiobjective optimization employing the Multiobjective Particle Swarm Optimization(MOPSO)technique is introduced.By taking the rotor magnetic bridge as the design parameter,ten optimization objectives including air-gap flux density,sinusoidal property,average torque,torque ripple,and mechanical stress are optimized.The relationship between the optimization objectives and the design parameters can be obtained based on the response surface method(RSM)to avoid too many experimental samples.The optimized model is compared with the initial model,and the optimized effect is verified.Finally,the temperature distribution of under rated working conditions is analyzed,providing support for addressing thermal stress as mentioned earlier.

Numerical simulation on residual stress and deformation for WAAM parts of aluminum alloy based on temperature function method

Wire arc additive manufacture(WAAM) is a new technique to fabricate large-scale complex aluminum alloy components.However, the performance of the parts is critically influenced by residual stresses and deformation. A sequentially thermal-mechanical coupled model of residual stress and deformation for aluminum alloy WAAM parts was established based on commercial FE software ABAQUS. The temperature field was calculated by the moving heat source(MHS) method. The temperature function was obtained according to the distribution of the peak temperature. Furthermore, the MHS method and segmented temperature function(STF) method were used to calculate the residual stress and deformation. The results show that the STF method satisfies both the efficiency and accuracy requirements. 1-segment, 3-segment, and 5-segment STF methods can shorten the time for mechanical analysis by 91%, 79%, 63%, respectively.The error of the residual stress and deformation are all less than 20%. STF method provides an effective way to predict the residual stress and deformation of large-scale WAAM parts.

Calculating method of contact stress for non-circular gears

According to Hertz theory, the difference of contact stress for non-circular gears and equivalent gears is compared in the paper, a calculating method of contact stress for non-circular gears by using equivalent gears is researched, and computing formulas of power and rotation speed for equivalent gears are deduced. A numerical simulation of contact stress for non-circular gears has also been conducted based on the finite element method. By the comparison of fitting curves, the feasibility of using equivalent gears instead of non-circular gears to calculate the contact stress is testified.

RPC应力-应变曲线系数与塑性损伤因子无量纲化计算模型研究

为了方便活性粉末混凝土(Reactive Powder Concrete,RPC)等效矩形应力图系数与塑性损伤因子的计算与取值,对RPC应力-应变曲线系数与塑性损伤因子的计算模型进行了理论研究。通过对现有的计算方法进行无量纲化转化,推导了决定计算模型的四个原函数条件;对一个实际的应力-应变关系进行了计算,将得到的结果进行了分析;并对受弯矩形梁非极限状态下截面内力和力矩的推定计算进行了演示。针对应力-应变关系式含有非整次有理分式的情况提出了曲线拟合方法;研究了拟合次数、拟合区间和拟合函数类型对拟合精度与稳定性的影响。比较了4种典型的RPC本构模型在同种材料下的应力-应变曲线系数与损伤因子取值模型曲线,结果显示:拟合曲线得到的取值模型与其他原始曲线得到的取值模型在曲线上具有较高的相似度,证明了曲线拟合方法的准确可靠性;最后给出了一种RPC受压应力-应变曲线系数与塑性损伤因子无量纲化取值模型。

超大跨劲性骨架拱桥缩尺模型试验方案设计研究

为对超大跨劲性骨架拱桥缩尺模型试验方案进行合理设计,以计算跨径600 m的劲性骨架拱桥——天峨龙滩特大桥为背景,围绕模型缩尺比、结构设计、材料及加载系统等关键环节,开展主拱圈缩尺模型试验方案设计研究。最终确定模型拱缩尺比为1∶10,劲性钢骨架采用单肋形式,采用与实桥主拱圈性能相近、便于施工的材料,采用阵列式滑轮组加载系统实现模型拱和实桥主拱圈的应力等效,还原外包混凝土分环分段浇筑施工,并简化劲性钢骨架与管内混凝土施工。将模型拱外包混凝土应力实测值、ANSYS建模计算得到的模型拱理论值及实桥主拱圈理论值进行对比,结果表明:模型拱和实桥主拱圈外包混凝土在施工阶段的应力变化趋势基本相同,最大绝对误差在2 MPa以内,模型拱应力实测值和理论值也吻合较好,缩尺模型试验方案设计合理。

有效减小大细长比微结构电铸层残余应力的兆声辅助微电铸方法

在利用微电铸工艺制作微机电系统(MEMS)开关的过程中,针对离心保险锁结构因电铸层残余应力大而出现翘曲、扭转等变形问题,采用兆声辅助微电铸方法减小电铸层残余应力。为探究兆声波对电铸层残余应力的影响,基于等效参考温度(ERT)法,建立兆声作用下离心保险锁微结构电铸层残余应力的仿真模型以优选兆声辅助微电铸的工艺参数——兆声功率密度。仿真结果表明,随着兆声功率密度的增大,离心保险锁的残余应力呈现先减小后增大的趋势,当兆声功率密度为2.54 W/cm^(2)时,离心保险锁的最大残余应力为52.58 MPa,相较于无兆声作用时减小了85.4%。在数值模拟的基础上进行微电铸实验验证研究。实验结果表明:兆声功率密度为2.54 W/cm^(2)时,大细长比微结构的变形量减小了88.6%,实验结果与仿真结果一致。在上述仿真结果和实验研究的基础上,制作出了高800μm、细长比高达1∶70的离心保险锁结构,并完成MEMS开关的制作与装配。

基于应力梯度和附加强化的多轴疲劳寿命建模

鉴于Manson-Coffin方程未考虑应力梯度和附加强化的影响,以及缺口附近非均匀应力场和非比例附加强化对疲劳损伤演化过程的影响,建立了适用于多轴缺口件的疲劳寿命预测模型.首先,考虑裂纹萌生和扩展的物理机制,借助坐标变换原理和临界面理论,以最大剪切应变幅为损伤参量确定临界面位置;其次,分别对临界面的正应力和剪应力进行归一化处理,提出了考虑多轴应力集中系数和应力梯度影响指数的等效应力梯度因子;同时,考虑相位差、路径非比例和材料非比例对疲劳寿命的影响,提出了新的非比例附加强化因子;最后,结合Manson-Coffin方程建立了考虑应力梯度和非比例附加强化的多轴疲劳寿命预测模型,并将该模型、Manson-Coffin方程、LV模型和FS模型的预测寿命与实验寿命进行对比,结果表明该模型的预测精度优于其它3种模型的.

正交异性钢桥面板双轴疲劳性能评估

为精确评估正交异性钢桥面板在双轴应力状态下的疲劳性能,以东营胜利黄河大桥为背景,建立该桥正交异性钢桥面板顶板、U肋、横隔板交叉连接部位焊缝的节段三维有限元模型,采用等效结构应力法对正交异性钢桥面板体系的双轴疲劳问题进行研究;通过模型试验验证正交异性钢桥面板体系的双轴疲劳特性,并进行其构造细节疲劳寿命评估。结果表明:弧形切口起焊点的疲劳裂纹萌生位置在横隔板下方焊趾处,经历裂纹萌生、裂纹稳定扩展和裂纹失效3个阶段,最终失效阶段裂纹形式为Ⅱ型裂纹主导的Ⅰ-Ⅱ型复合裂纹,此为该桥正交异性钢桥面板结构体系的主导疲劳失效模式;顶板焊缝焊趾及弧形切口起焊点焊趾处于双轴应力状态,面内剪切结构应力幅对疲劳应力的影响显著,按单轴疲劳应力进行寿命预测误差较大,按单轴疲劳应力状态对结构进行疲劳寿命设计偏于不安全;基于组合等效结构应力法的计算值与试验值吻合较好,各焊接细节计算得到的最大值下的疲劳裂纹起裂位置均与试验结果一致,按双轴疲劳应力预测疲劳寿命与试验值吻合较好,疲劳寿命评价精确度较高。

基于流固耦合的膜塞阀多目标优化设计

膜塞阀由于结构简单、流通性强和检漏及时等优点被广泛应用于电解液灌装系统中,膜片的受力情况影响着膜塞阀和灌装系统的可靠性。文中基于有限元法和双向流固耦合方法,对膜塞阀开启过程膜片的受力特点进行了可视化数值研究,以膜片的质量和等效应力为目标进行了多目标优化。研究结果表明:膜片在开启过程中受到的等效应力与开度成线性关系,在最大开度应力达到32.73 MPa,膜片失效的主要因素是膜片开启过程中机械拉伸引起的,膜片经过优化后最大等效应力减小了17.5%,质量减小了7.4%,在保证使用寿命的情况下实现了轻量化。研究结果可为电解液灌装阀的优化提供数据参考。

多轴非比例加载下考虑附加损伤的疲劳寿命预测

与比例载荷加载相比,在非比例载荷加载时由于附加损伤的产生,机械构件会出现明显的寿命缩短。本文通过分析非比例载荷作用下影响疲劳寿命的因素,提出一个新的非比例损伤因子,以最大剪切面为临界面,建立新的基于等效应变的疲劳寿命预测模型。新的多轴疲劳寿命预测模型不仅考虑法向应力对材料裂纹萌生与裂纹扩展的影响,而且通过引入材料附加强化系数与载荷路径的非比例度反映非比例载荷加载对多轴疲劳寿命的影响。采用5种材料在多轴载荷下的实验数据来验证本文模型的准确性,同时与两种经典模型进行对比,验证与对比分析说明,本文所提模型预测精度较好。

多点点焊件疲劳寿命分析

根据ST12钢的双点及三点拉剪电阻点焊试件的恒幅疲劳测试结果,分别使用缺口应力法和等效结构应力法进行疲劳寿命预测。在使用缺口应力法时,按试件的实际尺寸和国际焊接学会(International institute of welding, IIW)推荐标准,分别建立了双点和三点拉剪试件的三维实体有限元模型进行弹性应力分析,从有限元分析结果提取von Mises最大应力变化值,结合IIW推荐标准中的S-N曲线对试件进行疲劳寿命分析预测;在使用结构应力法时则采用梁壳混合单元进行有限元应力分析,并且根据主S-N曲线进行疲劳寿命预测。结果表明,在低周疲劳范围内,缺口应力法和等效结构应力法预测的结果相对于试件的实际寿命有较好地相关性,其中等效结构应力法的结果更接近实验寿命结果。

盾构隧道内堆载对基坑开挖引起的隧道上浮量的控制效果研究

基坑开挖会引起下卧盾构隧道产生上浮,隧道内堆载可以有效控制上浮量。本文采用两阶段方法,推导隧道内堆载措施下基坑开挖引起的盾构隧道上浮量计算公式。首先,基于影像源法计算基坑开挖坑底隆起引起的隧道附加应力,采用能够考虑土质条件的方法计算得到隧道内堆载引起的隧道附加应力,叠加得到总的附加应力;其次,采用转动与错台协同模型计算得到隧道受力与变形;使用Midas有限元软件对具体工况进行三维建模,并将隧道纵向隆起量数值模拟结果与公式计算结果进行对比。研究结果表明:本文方法计算结果与有限元模拟结果较吻合,验证了本文方法的合理性;假设基坑开挖长度为L,最佳堆载范围为距离堆载中心±L/3范围内,超出最佳范围时堆载控制效果减弱;土体内摩擦角对隧道变形影响较大,土体内摩擦角越小,堆载对隧道变形的控制效果越好。

基于等效结构应力法的高强钢焊接结构低温主S-N曲线

现有的疲劳S-N曲线已不再适用于北极的低温环境,为了评估北极海洋工程设备材料的低温疲劳寿命,有必要建立金属结构尤其是焊接结构的低温疲劳S-N曲线。本文基于等效结构应力法,计算出Q690高强钢管环焊缝的主S-N曲线,并通过共振疲劳试验对该方法进行了验证。在此基础上,结合大量的高强钢焊接结构试验结果,将温度敏感因子c引入到低温疲劳主S-N曲线的推导中,首次建立了基于低温金属焊接结构的主S-N曲线,并对文献中的疲劳S-N试验数据和ASME中的修正方法进行了对比和验证。结果表明,等效结构应力法能够较准确地计算出焊缝疲劳S-N曲线,推导出的金属焊接结构低温主S-N曲线与试验曲线吻合较好,能够满足低温地区工程要求,可为高强钢焊接结构在北极地区低温环境中的广泛应用提供理论指导。该方法可以为金属焊接结构的低温疲劳研究节省大量的成本,减少非标准试验操作造成的不必要的误差。这对北极海洋工程设备的设计、安全运行和疲劳评估具有重要意义。

常规岛汽机旁路调节阀抗震性能研究

为防止常规岛汽机旁路调节阀在地震期间发生共振,致使调节阀与连接管道受到破坏,使用ANSYS软件中Modal模块,对DN 300 Class900汽机旁路调节阀进行模态分析,得到调节阀各阶自振频率。当调节阀的基频高于33 Hz时,使用等效静力法。对调节阀进行抗震分析,得到阀门整体及各部件的等效应力和变形。根据ASME BPVC-Ⅲ中对核级设备抗震的规定,对调节阀在承受地震载荷时的应力强度进行评定,结果表明:阀体、阀盖、阀杆、支架最大应力分别为133.63、77.52、29.46、71.54 MPa,中法兰螺栓最大拉应力为183.23 MPa,最大剪应力为15.36 MPa,均满足抗震强度要求。

Novel method for measuring surface residual stress using flat-ended cylindrical indentation

Instrumented indentation is a promising technique for estimating surface residual stresses and mechanical properties in engineering components.The relative difference between the indentation loads for unstressed and stressed specimens was selected as the key parameter for measuring surface residual stresses in flat-ended cylindrical indentations.Based on the equivalent material method and finite element simulations,a dimensionless mapping model with six constants was established between the relative load difference,constitutive model parameters,and normalized residual stress.A novel method for measuring the surface residual stress and constitutive model parameters of metallic material through flat-ended cylindrical indentations was proposed using this model and a mechanical properties determination method.Numerical simulations were conducted using numerous elastoplastic materials with different residual stresses to verify the proposed model;good agreements were observed between the predicted residual stresses and those previously applied in finite element analysis.Flat-ended cylindrical indentation tests were performed on four metallic materials using cruciform specimens subjected to various equibiaxial stresses.The results exhibited good conformance between the stress–strain curves obtained using the proposed method and those from traditional tensile tests,and the absolute differences between the predicted residual stresses and applied stresses were within 40 MPa in most cases.

五对置柱塞泵曲轴的多工况分析及优化

针对五对置柱塞泵曲轴在实际工况下存在的失效、共振问题,以五对置柱塞泵曲轴为例,采用理论分析和有限元分析的方法,对曲轴进行了仿真分析、结构优化和强度校核。首先,采用了ANSYS有限元分析法,研究了5DW150/16对置式柱塞泵曲轴多工况下的应力应变云图与模态响应云图,分析了曲轴不同工况下的危险截面和共振问题;然后,采用了支撑结构优化与响应面法优化两种优化方法,研究了支撑方式与结构参数对曲轴应力应变的影响;最后,采用了理论公式强度校核方法,对优化前后的曲轴是否满足设计要求进行了验证。研究结果表明:五拐两支撑结构曲轴的危险截面出现在曲柄销的过渡圆角处,不会出现共振现象;采用全支撑结构增强了曲轴的抗冲击能力,降低了曲轴的颤动,提高了整体载荷能力,保证了泵的平稳运行;采用响应面法优化后的曲轴,最大等效应力减小了15.8%,最大变形量减小了14.04%;优化前后的曲轴可以满足强度要求。