公路钢拱桥新型不锈钢吊杆疲劳性能研究
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摘要
近年来,由于国民经济的持续快速发展,公路交通量、重车数量和车速都大幅提高,公路桥梁的建设也进入一个快速发展时期。钢桥由于具有轻质高强以及便于工厂化生产等优点,在桥梁建设中日益受到青睐。轻质高强材料在桥梁工程中的广泛应用,以及公路交通量的大幅提高,使得活荷载所占比例越来越大,疲劳问题日益突出。我国现行的《公路桥涵钢结构及木结构设计规范》(JTJ025-86)自开始实施至今已超过二十五年,其技术水平已无法满足我国公路钢桥发展的需要。本文结合一座三连续坦拱钢结构桥所采用的新型不锈钢吊杆的疲劳分析项目和国家高技术研究发展计划(863计划)项目(2007AA11Z133),开展了一系列工作,主要内容如下：
(1)对一根直径55mm和两根直径70mm的不锈钢吊杆进行了常幅正弦波加载的疲劳试验,吊杆所用材料为05Cr17Ni4Cu4Nb不锈钢。得到了吊杆的疲劳寿命、疲劳破坏位置以及断口外貌。
(2)采用理论方法估算了不锈钢吊杆杆体的对称拉一压疲劳极限,直径55mm和70mm的不锈钢吊杆杆体的疲劳极限分别为226MPa和250MPa。根据试验实测的吊杆杆体应变,分析了吊杆杆体应变变程随荷载循环次数的变化关系,结果表明,其中一根直径70mm的吊杆杆体在约300万次循环荷载后杆体内部出现了微小损伤,其它两根吊杆杆体在疲劳试验过程中未出现损伤。
(3)总结国内外对不锈钢本构模型的研究成果,得出了05Cr17Ni4Cu4Nb不锈钢的三折线本构模型。采用有限元分析软件ANSYS对不锈钢吊杆U型接头和吊杆杆体之间的螺纹联接进行了有限元分析。分析了每一扣螺纹齿所承担的荷载,计算了螺纹齿根的最大Von Mises应力和应变的数值。
(4)对中、低合金钢的Seeger算法进行修正,得出了高合金钢的Seeger算法,并该用该方法估算出了05Cr17Ni4Cu4Nb不锈钢的Manson-Coffin公式。用名义应力法估算出直径为70mm两根吊杆的疲劳寿命分别为976500次和2365130次；用基于Manson-Coffin公式的局部应力应变法估算出直径70mm的两根吊杆的疲劳裂纹萌生寿命分别为314230次和444919次；使用疲劳分析软件FE-SAFE估算出直径70mm的两根吊杆的疲劳裂纹萌生寿命分别为441165次和695132次。结果表明,用名义应力法准确预测某一特定构件的疲劳寿命几乎是不可能的,局部应力应变法相对于名义应力法精度高,FE-SAFE软件对疲劳裂纹萌生寿命的估算精度更高,适用于具有丰富疲劳强度分析理论知识的使用者。
(5)总结前人的研究成果,得出了不锈钢吊杆螺纹根部裂纹应力强度因子的计算公式。对不锈钢吊杆的疲劳裂纹扩展寿命进行了研究,提出了描述05Cr17Ni4Cu4Nb不锈钢疲劳裂纹扩展速率的Paris公式参数的推荐参考值为：m=3,C=3.96x10-13。
(6)对英国BS5400规范、美国AASHTO规范、欧洲规范Eurocode1和Eurocode3以及TB10002.2-2005规范中的抗疲劳设计部分进行了对比分析,从疲劳荷载模型、疲劳细节分类与设计疲劳曲线以及抗疲劳设计方法三个方面提出了对我国公路钢桥抗疲劳设计的建议,可为编制我国公路钢桥抗疲劳设计规范提供参考。
对不锈钢吊杆螺纹联接的疲劳细节等级进行了研究,推荐取71MPa作为不锈钢吊杆螺纹联接这种构造细节的疲劳细节等级,且当公称直径d>30mm时,应考虑尺寸效应的影响,尺寸效应系数Ks=(30／d)0.25。
采用有限元分析软件Midas Civil建立实际桥梁主桥结构的有限元模型,分析了桥梁在欧洲规范Eurocode1中的疲劳荷载模型3作用下的吊杆内力。以欧洲规范Eurocode3中的简单疲劳验算方法为基础,采用本文所确定的不锈钢吊杆螺纹联接的疲劳细节等级,对不锈钢吊杆进行了疲劳验算。结果表明：直径为70mm的不锈钢吊杆满足抗疲劳设计要求,直径为55mm的不锈钢吊杆中只有9根吊杆满足抗疲劳设计要求,其余45根吊杆均不满足抗疲劳设计要求。提出了设计修改建议,经验算,改进后的设计方案中的吊杆螺纹联接满足抗疲劳设计要求。
In recent years, due to the sustained and rapid development of the national economy, highway traffic volume, number of heavy vehicles and speed has increased significantly. The construction of highway bridge has also entered a period of rapid development. Due to the advantages of lightweight, high strength and easy to factory production, steel bridge becomes popular. The proportion of live load has increased because of the widely used of lightweight, high strength materials and substantial increase of highway traffic volume. Then, fatigue problems have become increasingly prominent. The current code "Specification for Design of Steel Structure and Timber Structure Highway Bridges and Culverts"(JTJ025-86) has been implemented more than25years. It has long been unable to meet the needs of the development of highway steel bridge in our country. In this paper, on the basis of a project of stainless steel suspender fatigue analysis of a three-span continuous steel arch bridge and a project of863Program (2007AA11Z133), a series of work has been done. The main contents are as follow:
(1) The constant amplitude sine wave fatigue tests had been done on a stainless steel suspender with a diameter of55mm and two stainless steel suspenders with a diameter of70mm. Material of these suspenders is stainless steel of05Cr17Ni4Cu4Nb. The fatigue life, fatigue failure locations and fracture appearance were obtained.
(2) The symmetric tension-compression fatigue limits had been estimated by theoretical methods, and the value was226MPa for the stainless steel suspender body with a diameter of55mm and250MPa for the stainless steel suspender body with a diameter of70mm, respectively. On the basis of the measured stress and strain of suspender body, the variation relationship of strain range with load cycles had been analyzed. The results showed that one of the stainless steel suspender body with a diameter of70mm appeared tiny damage after about3million cyclic loading, and no damage was found in other two suspender bodies.
(3) The trilinear constitutive model was proposed. The stress analysis had been performed on the threaded connections of suspenders with finite element software ANSYS. The conclusive results were drawn from the analysis including load distributions on the thread teeth and the locations and values of maximum Von Mises stress and strain.
(4) The Manson-Coffin formula of05Cr17Ni4Cu4Nb stainless steel was proposed. The fatigue lives of the two suspenders with a diameter of70mm had been estimated with the nominal stress method, and the value were976500cycles and2365130cycles, respectively. The fatigue crack initiation lives of the two suspenders with a diameter of70mm had been estimated with the local stress-strain method and the value were314230cycles and444919cycles, respectively. Then, the fatigue crack initiation lives of the two suspenders with a diameter of70mm were estimated with FE-SAFE, and the value were441165cycles and695132cycles, respectively. The results showed that the nominal stress method to accurately predict the fatigue life of a particular component is almost impossible, FE-SAFE has higher accuracy than local stress-strain method on estimating the fatigue initiation life, and it suitable for the user with rich theoretical knowledge of fatigue analysis.
(5) The stress intensity factor formula for thread root was proposed. An analysis of the fatigue crack propagation lives of stainless steel suspenders had been performed. The recommendation values of Paris equation parameters of05Cr17Ni4Cu4Nb stainless steel were proposed as m=3, C=3.96×10-13.
(6) The comparative analysis had been performed on the anti-fatigue design of BS5400, AASHTO, Eurocode1and Eurocode3, as well as TB10002.2-2005. The suggestions of fatigue load model, detail categories and design fatigue curves, as well as anti-fatigue design method were proposed on the anti-fatigue design of China's highway steel bridge.
The detail category of threaded connection of stainless steel suspender was recommended to be taken as71MPa, and considered size effect when the nominal diameter d>30mm. The size effect factor is ks=(30/d)0.25.
The finite element model of arch bridge was established with finite element software Midas Civil to perform an axial force analysis of the suspenders of arch bridge under the fatigue load model3of Eurocode1. The fatigue assessment had been performed on the stainless steel suspenders with the simple fatigue assessment method of Eurocode3and the detail category of threaded connection of stainless steel suspender recommended in this paper. The results showed that the fatigue resistance of the stainless steel suspenders with a diameter of70mm meet design requirement, and only9of the stainless steel suspenders with a diameter of55mm meet the anti-fatigue design requirement, the fatigue design requirements of the remaining45stainless steel suspenders with a diameter of55mm are not met. The suggestions of dedign modification were proposed and met the anti-fatigue design requirement.
(1)对一根直径55mm和两根直径70mm的不锈钢吊杆进行了常幅正弦波加载的疲劳试验,吊杆所用材料为05Cr17Ni4Cu4Nb不锈钢。得到了吊杆的疲劳寿命、疲劳破坏位置以及断口外貌。
(2)采用理论方法估算了不锈钢吊杆杆体的对称拉一压疲劳极限,直径55mm和70mm的不锈钢吊杆杆体的疲劳极限分别为226MPa和250MPa。根据试验实测的吊杆杆体应变,分析了吊杆杆体应变变程随荷载循环次数的变化关系,结果表明,其中一根直径70mm的吊杆杆体在约300万次循环荷载后杆体内部出现了微小损伤,其它两根吊杆杆体在疲劳试验过程中未出现损伤。
(3)总结国内外对不锈钢本构模型的研究成果,得出了05Cr17Ni4Cu4Nb不锈钢的三折线本构模型。采用有限元分析软件ANSYS对不锈钢吊杆U型接头和吊杆杆体之间的螺纹联接进行了有限元分析。分析了每一扣螺纹齿所承担的荷载,计算了螺纹齿根的最大Von Mises应力和应变的数值。
(4)对中、低合金钢的Seeger算法进行修正,得出了高合金钢的Seeger算法,并该用该方法估算出了05Cr17Ni4Cu4Nb不锈钢的Manson-Coffin公式。用名义应力法估算出直径为70mm两根吊杆的疲劳寿命分别为976500次和2365130次；用基于Manson-Coffin公式的局部应力应变法估算出直径70mm的两根吊杆的疲劳裂纹萌生寿命分别为314230次和444919次；使用疲劳分析软件FE-SAFE估算出直径70mm的两根吊杆的疲劳裂纹萌生寿命分别为441165次和695132次。结果表明,用名义应力法准确预测某一特定构件的疲劳寿命几乎是不可能的,局部应力应变法相对于名义应力法精度高,FE-SAFE软件对疲劳裂纹萌生寿命的估算精度更高,适用于具有丰富疲劳强度分析理论知识的使用者。
(5)总结前人的研究成果,得出了不锈钢吊杆螺纹根部裂纹应力强度因子的计算公式。对不锈钢吊杆的疲劳裂纹扩展寿命进行了研究,提出了描述05Cr17Ni4Cu4Nb不锈钢疲劳裂纹扩展速率的Paris公式参数的推荐参考值为：m=3,C=3.96x10-13。
(6)对英国BS5400规范、美国AASHTO规范、欧洲规范Eurocode1和Eurocode3以及TB10002.2-2005规范中的抗疲劳设计部分进行了对比分析,从疲劳荷载模型、疲劳细节分类与设计疲劳曲线以及抗疲劳设计方法三个方面提出了对我国公路钢桥抗疲劳设计的建议,可为编制我国公路钢桥抗疲劳设计规范提供参考。
对不锈钢吊杆螺纹联接的疲劳细节等级进行了研究,推荐取71MPa作为不锈钢吊杆螺纹联接这种构造细节的疲劳细节等级,且当公称直径d>30mm时,应考虑尺寸效应的影响,尺寸效应系数Ks=(30／d)0.25。
采用有限元分析软件Midas Civil建立实际桥梁主桥结构的有限元模型,分析了桥梁在欧洲规范Eurocode1中的疲劳荷载模型3作用下的吊杆内力。以欧洲规范Eurocode3中的简单疲劳验算方法为基础,采用本文所确定的不锈钢吊杆螺纹联接的疲劳细节等级,对不锈钢吊杆进行了疲劳验算。结果表明：直径为70mm的不锈钢吊杆满足抗疲劳设计要求,直径为55mm的不锈钢吊杆中只有9根吊杆满足抗疲劳设计要求,其余45根吊杆均不满足抗疲劳设计要求。提出了设计修改建议,经验算,改进后的设计方案中的吊杆螺纹联接满足抗疲劳设计要求。
In recent years, due to the sustained and rapid development of the national economy, highway traffic volume, number of heavy vehicles and speed has increased significantly. The construction of highway bridge has also entered a period of rapid development. Due to the advantages of lightweight, high strength and easy to factory production, steel bridge becomes popular. The proportion of live load has increased because of the widely used of lightweight, high strength materials and substantial increase of highway traffic volume. Then, fatigue problems have become increasingly prominent. The current code "Specification for Design of Steel Structure and Timber Structure Highway Bridges and Culverts"(JTJ025-86) has been implemented more than25years. It has long been unable to meet the needs of the development of highway steel bridge in our country. In this paper, on the basis of a project of stainless steel suspender fatigue analysis of a three-span continuous steel arch bridge and a project of863Program (2007AA11Z133), a series of work has been done. The main contents are as follow:
(1) The constant amplitude sine wave fatigue tests had been done on a stainless steel suspender with a diameter of55mm and two stainless steel suspenders with a diameter of70mm. Material of these suspenders is stainless steel of05Cr17Ni4Cu4Nb. The fatigue life, fatigue failure locations and fracture appearance were obtained.
(2) The symmetric tension-compression fatigue limits had been estimated by theoretical methods, and the value was226MPa for the stainless steel suspender body with a diameter of55mm and250MPa for the stainless steel suspender body with a diameter of70mm, respectively. On the basis of the measured stress and strain of suspender body, the variation relationship of strain range with load cycles had been analyzed. The results showed that one of the stainless steel suspender body with a diameter of70mm appeared tiny damage after about3million cyclic loading, and no damage was found in other two suspender bodies.
(3) The trilinear constitutive model was proposed. The stress analysis had been performed on the threaded connections of suspenders with finite element software ANSYS. The conclusive results were drawn from the analysis including load distributions on the thread teeth and the locations and values of maximum Von Mises stress and strain.
(4) The Manson-Coffin formula of05Cr17Ni4Cu4Nb stainless steel was proposed. The fatigue lives of the two suspenders with a diameter of70mm had been estimated with the nominal stress method, and the value were976500cycles and2365130cycles, respectively. The fatigue crack initiation lives of the two suspenders with a diameter of70mm had been estimated with the local stress-strain method and the value were314230cycles and444919cycles, respectively. Then, the fatigue crack initiation lives of the two suspenders with a diameter of70mm were estimated with FE-SAFE, and the value were441165cycles and695132cycles, respectively. The results showed that the nominal stress method to accurately predict the fatigue life of a particular component is almost impossible, FE-SAFE has higher accuracy than local stress-strain method on estimating the fatigue initiation life, and it suitable for the user with rich theoretical knowledge of fatigue analysis.
(5) The stress intensity factor formula for thread root was proposed. An analysis of the fatigue crack propagation lives of stainless steel suspenders had been performed. The recommendation values of Paris equation parameters of05Cr17Ni4Cu4Nb stainless steel were proposed as m=3, C=3.96×10-13.
(6) The comparative analysis had been performed on the anti-fatigue design of BS5400, AASHTO, Eurocode1and Eurocode3, as well as TB10002.2-2005. The suggestions of fatigue load model, detail categories and design fatigue curves, as well as anti-fatigue design method were proposed on the anti-fatigue design of China's highway steel bridge.
The detail category of threaded connection of stainless steel suspender was recommended to be taken as71MPa, and considered size effect when the nominal diameter d>30mm. The size effect factor is ks=(30/d)0.25.
The finite element model of arch bridge was established with finite element software Midas Civil to perform an axial force analysis of the suspenders of arch bridge under the fatigue load model3of Eurocode1. The fatigue assessment had been performed on the stainless steel suspenders with the simple fatigue assessment method of Eurocode3and the detail category of threaded connection of stainless steel suspender recommended in this paper. The results showed that the fatigue resistance of the stainless steel suspenders with a diameter of70mm meet design requirement, and only9of the stainless steel suspenders with a diameter of55mm meet the anti-fatigue design requirement, the fatigue design requirements of the remaining45stainless steel suspenders with a diameter of55mm are not met. The suggestions of dedign modification were proposed and met the anti-fatigue design requirement.
引文
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