摘要
全焊接球阀凭借其优秀的一体化设计,常用于高压等极端环境下的管道运输场景,其阀体焊接质量是整体加工质量的重要指标。针对全焊接球阀焊接质量较难预测的问题,以焊后残余应力、形变量、焊缝熔宽与余高为焊接质量指标,采用L25正交试验设计方法,基于Abaqus对球阀埋弧焊焊接过程进行高精度数值模拟,探究焊接电流、焊接电压与焊接速度对焊接质量的影响,并建立了基于BP神经网络的焊接质量预测模型。为提升数值模拟精度,引入了生死单元技术,以保证在不同焊接工艺下热源模型的精确性。考虑到焊后残余应力与形变主要是由焊接过程中温度场的分布不均和剧烈变化引起,因此考虑引入温度分布梯度以提升焊接质量预测精度,并通过设置对照组模型进行对比论证。结果显示,引入温度分布梯度可以显著提升焊接质量预测模型的预测精度,其中焊后形变量的准确率提升了8.11%,焊后残余应力准确率提升了11.48%。
Fully welded ball valves,distinguished by their superior integrated design,are extensively employed in pipeline transportation systems under high-pressure and other extreme operational conditions,where the welding quality of valve bodies constitutes a pivotal determinant of overall manufacturing performance.Addressing the challenge of predicting welding quality in fully welded ball valves,comprehensive evaluation metrics encompassing post-weld residual stress,deformation,weld bead width,and reinforcement height is established.An L25 orthogonal experimental design is employed to conduct high-precision numerical simulations of the submerged arc welding process using Abaqus,systematically investigating the effects of welding current,voltage,and speed on welding quality.A BP neural networkbased predictive model for welding quality is subsequently developed.To enhance the fidelity of numerical simulations,the element birth and death technique is integrated to ensure precise thermal source modeling across diverse welding parameters.Recognizing that post-weld residual stress and deformation primarily stem from non-uniform distribution and abrupt variations in the temperature field during welding,temperature distribution gradients are incorporated into the predictive framework.Comparative experiments with control groups demonstrates significant improvements in prediction accuracy:deformation prediction accuracy increases by 8.11%,while residual stress prediction accuracy improves by 11.48%.
作者
何纳川
陈俊
黄志慧
陈刚
徐雷
He Nachuan;Chen Jun;Huang Zhihui;Chen Gang;Xu Lei(School of Mechanical Engineering,Sichuan University,Chengdu 610065,China;Sichuan Feiqiu Group,Zigong,Sichuan 643000,China)
出处
《机电工程技术》
2025年第21期15-20,共6页
Mechanical & Electrical Engineering Technology
基金
四川大学自贡校地科技合作项目(2023CDZG-10)。
关键词
全焊接球阀
焊接质量预测
生死单元技术
有限元分析
BP神经网络
fully welded ball valve
welding quality prediction
element birth and death technique
finite element analysis
BP neural network
