重型铸钢万向铰支座性能分析与设计研究
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摘要
万向铰支座是具有万向承载和万向转动能力的一种支座型式,由于其能够多向受力并能发生微小转动,而具有广阔的应用前景。但目前已有的万向铰支座通常抗拉和抗剪承载能力较低,尚不能满足工程需求。另一方面,目前关于铸钢节点的设计规程《铸钢节点应用技术规程》(CECS 235:2008)刚刚颁布,重型万向铰支座的设计和应用经验较少。基于此,本文首次实现了一种6000kN级重型铸钢万向铰支座,完成了6000kN级重型铸钢万向铰支座的设计、足尺试验和工程应用,并通过理论分析和设计实践,对新颁布的《铸钢节点应用技术规程》(CECS 235:2008)中的部分条文进行了讨论分析,提出了补充建议。主要进行了以下几方面工作:
(1)利用实体建模软件SolidWorks、前处理软件HyperMesh和有限元分析软件ANSYS建立了能够考虑材料非线性、几何非线性和接触非线性影响的万向铰支座的有限元分析模型,并利用已有的试验结果验证了有限元模型的正确性。探讨了四面体网格划分、六面体网格划分和混合网格划分的实现方式,比较了三种网格划分方式的优缺点。
(2)设计并研究了一种目前国内承载能力最大的新型6000kN级重型铸钢万向铰支座,并将其成功应用于实际工程中。分析了支座在三种典型荷载工况下的力学性能以及加载角度和初始变形对支座受力性能的影响,并按照规程对支座进行了校核。分析校核表明所设计支座能够满足规程要求,且支座受力明确、传力直接、性能可靠。
(3)研究制作了自相平衡重型多向受力加载装置,实现了6000kN级重型铸钢万向铰支座的足尺静力性能试验。试验研究表明所设计支座受力明确、传力直接、性能可靠,所设计的加载系统适合复杂节点重型受力试验。进行了有限元分析结果和试验结果的对比验证,验证表明本文的有限元模型能够较好地模拟铸钢万向铰支座的力学性能。
(4)对支座进行了受拉、受剪和受压力学性能参数分析和经济性比较,找出了主要影响因素、影响规律和影响大小。分析了上支座球饼厚度、下支座顶板厚度、材料屈服强度等参数对支座受压、受剪和受拉时力学性能、经济性以及等强设计的影响。分析表明:在所研究的参数范围内,下支座顶板厚度、下支座加劲肋厚度和材料屈服强度对支座的受压力学性能影响较大;上支座球饼厚度和材料屈服强度对支座的受剪力学性能和受拉力学性能影响较大。
(5)对影响支座纯弹性设计的接触问题和应力集中问题进行了分析,研究了影响接触应力大小的主要因素,提出了减小应力集中的构造措施,并对规程中部分条文进行了探讨,提出了补充建议。研究表明:减小两接触体半径之差对减小接触应力最为有效;对应力集中区域进行局部加强、改变传力模式和改变局部刚度分布均能有效地降低应力集中,三种方法中局部加强法最为有效。在依据规程计算节点极限承载力时,不能仅依据规程条文说明取荷载-变形曲线中刚度首次减小为初始刚度10%时的荷载为极限承载力,而要同时校核节点在极限承载力作用下的最大应力点的折算应力不应超过材料的抗拉强度。弹塑性双折线模型的强化模量在规程给定范围内取值时对支座的极限承载力影响较大,建议结合实测的铸钢材性数据确定。对由若干部件串联而成的铸钢节点,在极限承载力计算时建议分别计算各组成部件的极限承载力,并取其中的最小值作为节点的极限承载力。
Heavy-duty universal hinged supports are being more and more widely used in modern large-span structures. They offer extremely huge individual load carrying capacity and universal rotation ability which are preferable to release temperature effects and to improve boundary conditions of lower structures. Yet the bearing capacities of the currently available universal hinged supports under tension and shear are relative low, which is hard to satisfy the increasing engineering requirements. On the other hand, the Chinese code about cast steel node design has just been released, and there are issues needed to be further investigated. So, this dissertation presents the design, full-scale experiment and analysis on a kind of heavy duty cast steel universal hinged supports with the bearing capacity up to 6000kN. The main research contents are as follows:
(1) A three-dimensional finite element model is developed by using the 3D entity modeling software SolidWorks, the preprocessing software HyperMesh, and the commercial software ANSYS with consideration on material, geometrical and contact nonlinearities. The model is validated against the experimental results reported in a reference and the verification suggests that the model can well predict mechanical behaviors of the supports.
(2) With reference to the available universal hinged supports and based on a patented design, an innovative heavy duty cast steel universal hinged support with the bearing capacity up to 6000kN is designed. The supports designed in this dessertation are of the largest bearing capacity in China. The performance of the supports under three typical load combinations is analyzed and evaluated against the Chinese national code‘Technical specification for application of connections of structural casting steel (CECS 235:2008)’. The effects of loading angle and initial deformation are also discussed. It is concluded that the designed supports can satisfy the requirements of the Chinese code under the design load combinations.
(3) An innovative self-balanced loading system is designed and realized by updating the available loading ring in the Lab. Full-scale experiments in three load cases are carried out successfully. Tests results show the support has reasonable design and manufacture details, direct force path, and reliable performance. The three tests also verify the numerical model, and the verification further confirms the applicability of the model.
(4) The effects on the mechanical performance and economical efficiency are duscussed for supports under compression, tension and shear; the parameters include depth of the cake of the upper component, depth of the top plate of the bottom component, yield strength of the material etc. The analysis shows that, in the range of the parameters analyzed, when the support is in compression, the parameters such as depth of the top plate, depth of the ribs of the bottom component and yield strength of the material have great effects on the mechanical performance of the support. When the support is under shear, the parameters such as depth of the cake of the upper component and yield strength of the material have a great effects on the mechanical performance of the support. When the support is in tention, the parameters such as depth of the cake of the upper component and yield strength of the material have a great effect on the mechanical performance of the support.
(5) Methods for reducing stress in contact regions and stress concentration regions are investigated, and the research is also carried out for the ultimate bearing capacity calculation considering the effects of the material strengthening modulus in the model. It is shown that the difference between the radiuses of the two contact objects has the largest effect on the contact stress. The proper design of local refinement, force path change, and local stiffness distribution modification can effectively reduce stress concentration. And among the above three methods, the local refinement method is the most effective. When the Code is used to determine the bearing capacity of cast steel nodes, it is suggested to check stress state of the nodes. The material strengthening modulus in the calculation model has great effect on the bearing capacity of the supports, therefore the material strengthening modulus from coupon tests is highly recommended in the calcultion. When cast steel nodes are made up of several cascade connected components, it is suggested to determine bearing capacity of each components separately, and select the minimum one as the bearing capacity of the cast steel nodes.
(1)利用实体建模软件SolidWorks、前处理软件HyperMesh和有限元分析软件ANSYS建立了能够考虑材料非线性、几何非线性和接触非线性影响的万向铰支座的有限元分析模型,并利用已有的试验结果验证了有限元模型的正确性。探讨了四面体网格划分、六面体网格划分和混合网格划分的实现方式,比较了三种网格划分方式的优缺点。
(2)设计并研究了一种目前国内承载能力最大的新型6000kN级重型铸钢万向铰支座,并将其成功应用于实际工程中。分析了支座在三种典型荷载工况下的力学性能以及加载角度和初始变形对支座受力性能的影响,并按照规程对支座进行了校核。分析校核表明所设计支座能够满足规程要求,且支座受力明确、传力直接、性能可靠。
(3)研究制作了自相平衡重型多向受力加载装置,实现了6000kN级重型铸钢万向铰支座的足尺静力性能试验。试验研究表明所设计支座受力明确、传力直接、性能可靠,所设计的加载系统适合复杂节点重型受力试验。进行了有限元分析结果和试验结果的对比验证,验证表明本文的有限元模型能够较好地模拟铸钢万向铰支座的力学性能。
(4)对支座进行了受拉、受剪和受压力学性能参数分析和经济性比较,找出了主要影响因素、影响规律和影响大小。分析了上支座球饼厚度、下支座顶板厚度、材料屈服强度等参数对支座受压、受剪和受拉时力学性能、经济性以及等强设计的影响。分析表明:在所研究的参数范围内,下支座顶板厚度、下支座加劲肋厚度和材料屈服强度对支座的受压力学性能影响较大;上支座球饼厚度和材料屈服强度对支座的受剪力学性能和受拉力学性能影响较大。
(5)对影响支座纯弹性设计的接触问题和应力集中问题进行了分析,研究了影响接触应力大小的主要因素,提出了减小应力集中的构造措施,并对规程中部分条文进行了探讨,提出了补充建议。研究表明:减小两接触体半径之差对减小接触应力最为有效;对应力集中区域进行局部加强、改变传力模式和改变局部刚度分布均能有效地降低应力集中,三种方法中局部加强法最为有效。在依据规程计算节点极限承载力时,不能仅依据规程条文说明取荷载-变形曲线中刚度首次减小为初始刚度10%时的荷载为极限承载力,而要同时校核节点在极限承载力作用下的最大应力点的折算应力不应超过材料的抗拉强度。弹塑性双折线模型的强化模量在规程给定范围内取值时对支座的极限承载力影响较大,建议结合实测的铸钢材性数据确定。对由若干部件串联而成的铸钢节点,在极限承载力计算时建议分别计算各组成部件的极限承载力,并取其中的最小值作为节点的极限承载力。
Heavy-duty universal hinged supports are being more and more widely used in modern large-span structures. They offer extremely huge individual load carrying capacity and universal rotation ability which are preferable to release temperature effects and to improve boundary conditions of lower structures. Yet the bearing capacities of the currently available universal hinged supports under tension and shear are relative low, which is hard to satisfy the increasing engineering requirements. On the other hand, the Chinese code about cast steel node design has just been released, and there are issues needed to be further investigated. So, this dissertation presents the design, full-scale experiment and analysis on a kind of heavy duty cast steel universal hinged supports with the bearing capacity up to 6000kN. The main research contents are as follows:
(1) A three-dimensional finite element model is developed by using the 3D entity modeling software SolidWorks, the preprocessing software HyperMesh, and the commercial software ANSYS with consideration on material, geometrical and contact nonlinearities. The model is validated against the experimental results reported in a reference and the verification suggests that the model can well predict mechanical behaviors of the supports.
(2) With reference to the available universal hinged supports and based on a patented design, an innovative heavy duty cast steel universal hinged support with the bearing capacity up to 6000kN is designed. The supports designed in this dessertation are of the largest bearing capacity in China. The performance of the supports under three typical load combinations is analyzed and evaluated against the Chinese national code‘Technical specification for application of connections of structural casting steel (CECS 235:2008)’. The effects of loading angle and initial deformation are also discussed. It is concluded that the designed supports can satisfy the requirements of the Chinese code under the design load combinations.
(3) An innovative self-balanced loading system is designed and realized by updating the available loading ring in the Lab. Full-scale experiments in three load cases are carried out successfully. Tests results show the support has reasonable design and manufacture details, direct force path, and reliable performance. The three tests also verify the numerical model, and the verification further confirms the applicability of the model.
(4) The effects on the mechanical performance and economical efficiency are duscussed for supports under compression, tension and shear; the parameters include depth of the cake of the upper component, depth of the top plate of the bottom component, yield strength of the material etc. The analysis shows that, in the range of the parameters analyzed, when the support is in compression, the parameters such as depth of the top plate, depth of the ribs of the bottom component and yield strength of the material have great effects on the mechanical performance of the support. When the support is under shear, the parameters such as depth of the cake of the upper component and yield strength of the material have a great effects on the mechanical performance of the support. When the support is in tention, the parameters such as depth of the cake of the upper component and yield strength of the material have a great effect on the mechanical performance of the support.
(5) Methods for reducing stress in contact regions and stress concentration regions are investigated, and the research is also carried out for the ultimate bearing capacity calculation considering the effects of the material strengthening modulus in the model. It is shown that the difference between the radiuses of the two contact objects has the largest effect on the contact stress. The proper design of local refinement, force path change, and local stiffness distribution modification can effectively reduce stress concentration. And among the above three methods, the local refinement method is the most effective. When the Code is used to determine the bearing capacity of cast steel nodes, it is suggested to check stress state of the nodes. The material strengthening modulus in the calculation model has great effect on the bearing capacity of the supports, therefore the material strengthening modulus from coupon tests is highly recommended in the calcultion. When cast steel nodes are made up of several cascade connected components, it is suggested to determine bearing capacity of each components separately, and select the minimum one as the bearing capacity of the cast steel nodes.
引文
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