Safety estimation of high-pressure hydraulic cylinder using FSI method

Hydraulic cylinder is a primary component of the hydraulic valve systems.The numerical study of hydraulic cylinder to evaluate the stress analysis,the life assessment and the performance of operation characteristics in hydraulic cylinder were described.The calculation of safety factor,fatigue life,piston chamber pressure,rod chamber pressure and the change of velocity of piston with flow time after the beginning of hydraulic cylinder were incorporated.Numerical analysis was performed using the commercial CFD code,ANSYS with unsteady,dynamic mesh model,two-way FSI(fluid-structure interaction)method and k-εturbulent model.The internal pressure in hydraulic cylinder through stress analysis show higher than those of the yield strength.

Investigation on the temperature distribution and strength of flat steel ribbon wound cryogenic high-pressure vessel

By analyzing heat transfer on the wall of fiat steel ribbon wound vessel （FSRWV）, a numerical model of temperature distribution on the entire wall （including inner core wall, flat steel ribbons, outside cylinder of jacket and insulating layer） was established by the authors. With the model, the temperature distribution and the length change in the vessel walls and flat steel ribbons in low temperature are calculated and analyzed. The results show that the flat steel ribbon wound cryogenic high-pressure vessel is simpler in structure, safer and easier to manufacture than those of conventional ones.

Drivability of Large Diameter Steel Cylinders During Hammer-Group Vibratory Installation for the Hong Kong–Zhuhai–Macao Bridge

The Hong Kong–Zhuhai–Macao Bridge(HZMB)involved the installation of 120 mega-cylinders with a diameter of 22 m,weights up to 513 t,and penetration depths up to 33 m using an eight-vibratory hammer group.Due to the lack of engineering experience on the drivability of large-diameter cylinders under multiple vibratory hammers,predicting the penetration rate and time of steel cylinders is an open challenge that has a considerable impact on the construction control of the HZMB.In this study,the vibratory penetration of large-diameter steel cylinders in the HZMB is investigated based on geological surveys,field monitoring,and drivability analysis.The vibratory penetration rate,installation accuracy,and dynamic responses of the steel cylinders at both the eastern and western artificial islands are analyzed.The dynamic soil resistance has a great influence on the cylinder drivability.However,the current design methods for estimating the vibratory driving soil resistance are proven inaccurate without considering the scale effects.Therefore,a modified method with a normalized effective area ratio A_(r,eff)is proposed in this study to calculate the vibratory soil resistance for open-ended thin-wall cylinders under unplugged conditions.Considering the scale effects on the vibratory driving soil resistance,the proposed method leads to closer results to the measured data,providing a reference for future engineering practice.

Numerical simulation and experimental verification of a novel double-layered split die for high-pressure apparatus used for synthesizing superhard materials

Based on the principles of massive support and lateral support, a novel double-layered split die(DLSD) for high-pressure apparatus was designed to achieve a higher pressure-bearing capacity and larger sample cavity. The stress distributions of the DLSDs with different numbers of divided blocks were investigated by the finite element method and compared with the stress distributions of the conventional belt-type die(BTD). The results show that the cylinders and first-layer supporting rings of the DLSDs have dramatically smaller stresses than those of the BTD. In addition, increasing the number of divided blocks from 4 to 10 gradually increases the stress of the cylinder but has minimal influence on the stress of the supporting rings. The pressure-bearing capacities of the DLSDs with different numbers of divided blocks, especially with fewer blocks, are all remarkably higher than the pressure-bearing capacity of the BTD. The contrast experiments were also carried out to verify the simulated results. It is concluded that the pressure-bearing capacities of the DLSDs with 4 and 8 divided blocks are 1.58 and 1.45 times greater than that of the BTD. This work is rewarding for the commercial synthesis of high-quality, large-sized superhard materials using a double-layered split high-pressure die.

Effect of Revolution on Inhomogeneous Deformation of IF Steel in High Pressure Torsion

The effect of revolution on inhomogeneous plastic deformation of HPT processed IF steel was investigated using experimental and simulation approaches. The results indicate that the degree of inhomogeneous plastic deformation increases as the revolutions increase along the radial direction on the transversal plane of disks. In addition, the hardness and the microstructure distributions verify the trend that the effective strain of the HPT processed disks at the early torsion stage is gradually deformed from the edge to the center with the revolutions increases.

The comprehensive utilization of Baosteel steel slag

Summarizes the processes and development of Baosteel slag processing techniques such as the instantaneous slag chill （ISC） process, the tank-type hot disintegrating process and the rotary drum process. A detailed introduction of the slag comprehensive utilization at Baosteel is given. The details of Baosteel＇ s comprehensive utilization in the fields of simering materials, returned slag for steelmaking, road construction, cement production, mixed concrete, new construction materials, ground-filling materials and reinforced material for soft earth are given. Emphasis is placed on source management and ensuring that from both organizational and managerial perspectives, Baosteel＇ s slag processing techniques are safe and energy-saving, thus constantly demonstrating the issue of sustainable development.

Inhomogeneous Hardness Distribution of High Pressure Torsion Processed IF Steel Disks

The inhomogeneous hardness distribution of high pressure torsion (HPT) processed IF steel disks along different directions is investigated. The results indicated that there exists inhomogeneous distribution in HPT processed IF steel disks, giving lower hardness in the center and higher hardness in the edge regions. However, on the axisymmetrical section testing plane of the disks’ thickness direction, there is a soft zone near the surface of disks. Further results from radius testing plane of different depths from the surface of HPT processed disks show that the inhomogeneity rules of hardness distribution on the radius direction are similar to that on the thickness direction. Compared with the initial state, different stages of HPT (compression and compression + torsion) can both remarkably increase the hardness of IF steel disks. Microstructure investigation results can give a well support to verify the rules of hardness distribution, showing hardly no change of grains in center and sever plastic deformation in edge. The inhomogeneous distribution of stress and strain with the huge friction between anvil and disks in the process of HPT play an important role of hardness and microstructure distribution.

大直径钢筒圆度异常区快速检测方法

大直径钢筒在制作、运输、安装及运行时均可能因某些原因导致其出现一个或多个圆度异常区,以至于不满足设备验收和运行的相关要求。目前,针对大直径钢筒圆度异常的检测方法均较为复杂,并不适合快速检出。为此,本文基于三坐标测量原理,结合高精度全站仪的非接触自动测量模式,并采用Matlab编制了自动搜索程序,提出了大直径钢筒圆度异常区的快速检测方法。通过AutoCAD算例模拟和现场实测,结果表明,该检测方法不仅速度快,且可通过增加测点密度实现大幅提高检出精度,为后续修复和改进工作提供准确数据。

淬火温度对气瓶用Fe-Cr-Ni-Mo钢组织和力学性能的影响

为了优化一种气瓶用Fe-Cr-Ni-Mo钢的淬火工艺,采用SEM,TEM,EBSD和拉伸、冲击等观察和检测手段,研究了淬火温度对一种气瓶用Fe-Cr-Ni-Mo钢微观组织和力学性能的影响。结果表明,不同淬火温度处理后的合金钢,均呈现为板条马氏体组织,其碳化物析出和板条亚结构基本保持不变,而原始奥氏体晶粒则随淬火温度的提高而出现明显的粗化,由800℃的4.3µm长大到930,1200℃的29.6,371.1µm,同时有效晶粒尺寸(EGS)也逐渐增加,800,930,1200℃的EGS分别为0.60,1.20,3.22µm。淬火温度对合金钢的室温抗拉、屈服强度和断后伸长率影响较小,而随着淬火温度的提高,冲击吸收能量则出现了显著的下降,由800℃的119 J,下降到930,1200℃的68,38 J。EGS增大导致冲击断裂时出现解理断裂,是较高淬火温度合金钢冲击吸收能量下降的主要原因。淬火温度为800~860℃时,Fe-Cr-Ni-Mo钢具有良好的强韧性匹配,该研究结果对Fe-Cr-Ni-Mo钢制气瓶的工业化生产具有指导意义。

深水FPSO吸力锚建造工艺

以某深水浮式生产储卸油装置(FPSO)的吸力锚建造为例,对吸力锚的钢制筒体、顶盖结构、内部切泥板、铸造吊耳及锚链等主要结构预制安装流程与吸力锚整体装船工艺进行阐述。研究结果表明:深水FPSO吸力锚在建造过程中通过制定合理的施工顺序、严格控制组对尺寸公差和焊接参数等措施,对整个项目的质量管控和工效提升至关重要,也为后期同类大型管状结构物的建造提供了有益的参考。

关于钢质无缝气瓶热处理工艺评定规范性的思考

在钢质无缝气瓶的制造工序中,热处理工序对产品的安全性能起着至关重要的作用。TSG 23—2021《气瓶安全技术规程》和钢质无缝气瓶的制造标准均明确提出气瓶的热处理应按评定合格的热处理工艺进行。目前,国内还没有相应的规范或标准能够明确指导钢质无缝气瓶热处理工艺评定的制定过程,各制造厂在生产中的热处理工艺评定制定标准和水平也参差不齐。提出了钢质无缝气瓶的热处理工艺评定涵盖的内容及相应要求,并通过试验进行了举例。

钢支撑轴向力伺服油缸优化设计

针对钢支撑轴力伺服油缸在大腔压力波动时无法定性监测围护变形量的问题,采用内置压力传感器和MT磁致式位移传感器优化钢支撑伺服油缸结构,同时采集油缸大腔压力和位移信号,当大腔压力变化量ΔP、油缸活塞杆位移ΔS均超过预设量时,系统发出预警信号,实践证明,此方案能极大地降低原系统误预警的频率,并能保证施工围护的变形量,验证了设计模型的可行性,可为钢支承轴向力伺服油缸的结构设计提供参考。

高速激光熔覆马氏体不锈钢涂层与电镀层性能对比与研究

为对比研究不同液压缸服役工况下高速激光熔覆涂层替代电镀硬铬层的可行性,分别制备了马氏体不锈钢熔覆层XG-1、XG-2和电镀硬铬涂层,开展了三种涂层组织、硬度、腐蚀性能及模拟不同工况(划伤磨损、干砂摩擦磨损、滑动摩擦磨损)下磨损性能测试,探讨了涂层失效行为及其应用工况。结果表明:XG-1、XG-2涂层微观组织致密且均匀,平均显微硬度为720.5 HV、653 HV;电镀硬铬涂层分布孔隙和裂纹等缺陷,自腐蚀电流密度为10.45μA/cm^(2),耐腐蚀性能最差;三种磨损形式下电镀硬铬涂层均发生了开裂及剥落,高速激光熔覆涂层表现出更优异的耐磨性能,适用于活塞杆易拉伤、外界富集硬质颗粒污染物、大侧向载荷等液压缸服役工况。

黏土中大直径钢圆筒在桩靴贯入时的稳定性研究

某在建水下生产系统附近有自升式平台的频繁桩靴插拔作业,采用了大直径薄壁钢圆筒作为水下生产系统的保护结构,因此钢圆筒在自升式平台桩靴插拔过程中的受力与变形备受关注。开展了离心模型试验,揭示了桩靴贯入过程导致的钢圆筒受力与变形规律;进而应用经离心试验验证的耦合欧拉与拉格朗日数值模拟方法,开展了筒-靴不同相对位置工况下,桩靴贯入对钢圆筒稳定性的影响分析。结果表明:桩靴贯入导致的筒壁附加应力及位移随筒-靴间距的增加而衰减,其衰减程度随筒靴间距的增加而减小,且由于筒靴间距的不同,钢圆筒对应存在两种受力模式。筒靴间距为2倍桩靴直径时,筒身附加应力可达110 MPa,表明桩靴对钢圆筒的影响距离可达2倍桩靴直径以上。

水压和波浪荷载作用下钢圆筒护岸结构变形研究

针对水压和波浪荷载作用下大直径钢圆筒护岸结构的受力和变形特性,开展了离心模型试验研究,分析了耦合荷载作用下的筒体位移和转角,采用PIV技术分析了土体的流动机制。试验结果表明:在开挖施工期,土体孔压迅速上升,开挖完成后孔压逐渐趋于平缓,但是孔压的变化具有迟滞性,开挖完成一段时间后土体孔压才能保持平稳;随着开挖施工的进行,筒体发生向陆侧的旋转,在开挖进行旋转速度最快,开挖完成后转角变化逐渐趋缓,筒体最大转角为0.32°,最大水平位移为358 mm,方向指向陆侧;在筒体旋转的影响下,地基土发生显著的水平位移,但当距筒的距离超过30 m后,土体的位移较小可忽略不计。总的来说,筒体在施工期位移和变形较小,未发生倾覆和滑移破坏,表明采用该结构能够满足工程要求。

水下防护设施插桩响应的离心模型试验研究

某拟建水下油气生产系统采用大直径薄壁钢圆筒作为防护设施。自升式钻井船进行钻修井作业时,桩靴插拔会产生较大范围的挤土作用,当钻井船插拔桩位置靠近水下生产系统的防护设施时,会导致钢圆筒产生附加的应力和变形,从而对水下生产系统产生影响。为此开展离心模型试验,研究黏土中不同桩靴插桩深度,不同间距对水下生产系统防护设施钢圆筒的影响。研究表明,钢圆筒的筒壁应变、筒顶变形及筒壁土压力均随筒靴间距的增加而减小,随桩靴贯入深度的增加而增加,与桩靴下压阻力同步发展。插桩引起的筒身应变主要集中在正对桩靴一侧,当筒靴间距小于0.9倍桩靴直径时,钢圆筒筒壁发生屈服;筒顶位移主要为向筒内发展的水平向位移;筒壁土压力增量约为静止土压力的0.6倍。桩靴插桩对钢圆筒的影响范围超过了1.3倍的桩靴直径。

大容积全海深环境模拟装置结构及低温控制分析

深海环境模拟装置是开展深海技术与装备研发中必不可少的试验系统。本文基于预应力钢丝缠绕技术,将传统的单层筒体拆分成双层结构,并在内套筒和外套筒间设有冷却通道。以筒体内径1 000 mm、筒深2 500 mm、最高设计压力200 MPa的深海环境模拟装置为例,进行筒体结构和低温控制过程的初步计算分析。通过计算结果可知:在筒体结构设计上,缠绕预紧系数η=1.13时,筒体外半径r0=795 mm,芯筒总厚度为177 mm,所需缠绕钢丝层厚度为118 mm;在低温控制过程,增压器等熵效率为0.6时,需要通过制冷系统将初始状态的工质水冷却至0℃,并保持筒内不少于4.6%的含冰量,且制冷系统总制冷量不低于24.62 kW,则可以实现筒内200 MPa下4℃及以下低温控制。研究结果可以为大型全海深环境模拟装置的低温控制策略研究提供参考。

Heat Treatment of Centrifugally Cast High-Vanadium Alloy Steel for High-Pressure Grinding Roller

The roller is one of the main parts of a high-pressure grinding roller, which is a type of highly efficient ore crushing equipment. Its working life is strongly affected by the materials used. In this paper, a new kind of roller material, the high-vanadium alloy steel （HVAS）, was investigated. The results showed that the as-cast microstructures of the HVAS roller contained martensite, residual austenite, and alloy carbides. The HVAS sample quenched at 1,080 ℃ had a high hardness, and it had much higher compressive strength and abrasive wear resistance after tempering at 560 ℃ for 30 rain. The mechanical properties of the HVAS are more sufficient than the existing roller materials, which are feasible for larger machine design.

钢筋混凝土梁锈胀开裂计算研究

【目的】钢筋锈蚀引起的钢筋混凝土构件锈胀开裂是混凝土结构退化的重要原因,有必要对锈胀裂缝机理进行探究。【方法】基于人工通电锈蚀试验对钢筋混凝土梁进行锈胀开裂计算,通过计算锈蚀钢筋混凝土梁锈胀开裂锈蚀深度,从而得到锈胀裂缝宽度值。【结果】研究结果表明,考虑电流腐蚀密度与电解液浓度的锈胀裂缝计算公式能有效预测钢筋混凝土梁的锈胀开裂宽度。【结论】钢筋混凝土梁的锈胀开裂机理十分复杂,裂缝宽度受到的影响较多,结合电流腐蚀密度与电解液浓度所修正的裂缝计算公式为裂缝研究提供了一种有效的思路。

水下振沉大型钢圆筒施工技术研究及应用

水下钢圆筒防护结构施工技术是渤海通航区新型水下海洋开发、海底石化类开采等防护工程的关键。以在通航区水深22 m处,振沉1个直径φ24 m,高度14.5 m的大型钢圆筒水下防护结构为研究对象,通过分析最不利地质环境,比选不同作业环境下振沉特性,并通过有限元建模分析联动锤组系统水下振沉钢圆筒可行性,合理分析振沉关键工序控制内容。该研究在渤海湾首例水下钢圆筒振沉项目中得到有效应用,最终以钢圆筒振沉精度高于设计钢圆筒姿态指标的50%顺利完成,有效证明该水下振沉钢圆筒技术的有效性与可靠性,总结出水下振沉大型钢圆筒施工技术新理论。