Rapid welding simulation method for large thick plate structural member
Through virtual weld joint calibration and result mapping technology, combined with adaptive grid strategy, the problem of low computational efficiency and nonlinearity in welding simulation of large thick plate structural parts is solved, and rapid and efficient welding deformation prediction and optimization are achieved, improving the reliability and economicality of engineering applications.
Patent Information
- Application Number
- CN202510594760.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-05-09
- Publication Date
- 2025-08-15
AI Technical Summary
Traditional thermal coupled welding simulation has a long calculation time, high cost, difficult nonlinear convergence, and complex pre-processing in large thick-plate structural parts, resulting in limited feasibility of welding simulation in actual engineering applications.
Virtual weld joint calibration and result mapping technology are adopted, combined with adaptive and hybrid grid strategies, and pre-processing is simplified, and the mapping thermal coupling results are calculated through elastic structures, and a database is established to achieve rapid prediction and optimization of welding deformation.
It significantly improves computing efficiency and accuracy, simplifies mesh division, enhances convergence and stability, reduces computing resource consumption, promotes rapid prediction and optimization iteration of welding deformation, and improves the quality and engineering application value of structural parts.
Smart Images
Figure CN120493438A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to a rapid welding simulation method for a large thick plate structural member, belonging to the technical field of welding. Background Art
[0002] In engineering practice, welding deformation may cause subsequent assembly errors, geometric distortion, and fatigue performance degradation. Welding simulation can predict and optimize welding deformation in advance, thereby reducing problems such as decreased assembly accuracy and subsequent service fatigue reliability caused by deformation during the assembly process.
[0003] Traditional thermal-mechanical coupling welding simulation calculations have the following problems in the simulation calculations of large thick plate structures:
[0004] 1. The calculation time of thermal coupling welding simulation is long and the calculation cost is high: Large thick plate structural parts are huge in size and have numerous welds. Not only does each weld need to be calculated separately for temperature, deformation and stress fields, but the impact of each weld on the heat conduction, mechanical stress and deformation of the entire structure also needs to be considered. Therefore, the simulation calculation time is extremely long and the computing resource consumption is extremely high.
[0005] 2. Thermomechanical coupling welding simulation is highly nonlinear and difficult to converge: During the thermal coupling simulation calculation, the material nonlinearity, geometric nonlinearity and boundary nonlinearity are present, so the calculation behavior is a highly nonlinear behavior of multi-physical field coupling. During the solution process, numerical non-convergence is very likely to occur, resulting in calculation failure.
[0006] 3. The pre-processing of thermal coupling welding simulation is difficult and time-consuming: Thermal coupling simulation requires high-quality hexahedral meshes to ensure calculation accuracy and convergence. However, the hexahedral mesh division is complex, especially for large thick plate structures with complex forms and many welds, which places high demands on the operator's skills. Poor mesh division quality during pre-processing will lead to decreased calculation accuracy and poor convergence, thus affecting the subsequent thermal coupling welding simulation solution.
[0007] Due to the above problems, thermal-mechanical coupling welding simulation has great limitations in its application in the welding simulation of large thick plate structures. It is difficult to complete the rapid prediction and iteration of welding deformation within a reasonable time, which limits the feasibility of welding simulation in actual engineering applications. Summary of the Invention
[0008] In view of the problems existing in the above-mentioned prior art, the present invention provides a rapid welding simulation method for large thick plate structural members, which improves the practicability of welding simulation technology in deformation prediction of large thick plate structural members.
[0009] In order to achieve the above object, the present invention adopts a rapid welding simulation method for large thick plate structural parts, comprising the following steps:
[0010] 1) Construct the geometric structure of the large thick plate structure to be welded and add the weld geometry model;
[0011] 2) Identify all welds of large thick plate structures and determine the calibration parameters of virtual weld joints;
[0012] 3) Perform thermal-mechanical coupling welding simulation on virtual weld joints;
[0013] 4) Obtain the thermal-mechanical coupled strain evolution results of the calibrated virtual weld joint;
[0014] 5) Mapping of thermal-mechanical coupling results of virtual weld joints;
[0015] 6) forming a calibration weld virtual weld joint mapping database;
[0016] 7) After completing the virtual weld joint simulation calibration list, identify the key positions of the overall model of the large thick plate structure and perform corresponding processing on the key positions and secondary positions;
[0017] 8) Identify the type and characteristics of the welds of large thick plate structural components, find the closest match in the calibration weld virtual weld joint mapping database, introduce the initial load or equivalent stress field in the mapping database for each weld in the elastic structure calculation model of large thick plate structural components, and complete the calibration virtual weld joint strain mapping to the corresponding structural component weld area;
[0018] 9) Carry out deformation solution of the global structural model of large thick plate structural parts, compare and correct it with the actual on-site post-weld deformation, and carry out rapid optimization prediction and iteration of welding deformation based on actual conditions.
[0019] As an improvement, in step 1), a three-dimensional model of a large thick plate structural member is obtained, geometric cleaning is performed, a weld model is constructed, and the connection relationship between the weld and the structure is processed.
[0020] As an improvement, in the step 2), all welds in the structural parts are identified, and typical welds that have a greater impact on structural strength, residual stress and deformation are covered in combination with engineering experience and failure data. The geometric characteristics of the welds are counted, welds with similar sizes and shapes of the same plate thickness are summarized, and a virtual weld joint simulation calibration list is formed; virtual weld calibration parts are used to perform virtual weld joint simulation calibration according to the virtual weld joint simulation calibration list.
[0021] As an improvement, in step 3), according to the virtual weld joint simulation calibration list, a fine modeling method is adopted for the virtual weld joint to be calibrated, an adaptive and hybrid grid strategy is adopted, a local encrypted grid is used in the welding area, a transition grid is used in the heat-affected zone, and the grid accuracy is reduced in the non-critical area. A heat source model and process parameters that are close to those in the actual welding of large structural parts are selected, the temperature field and strain field during the welding process are calculated, and strain data is provided for subsequent deformation mapping.
[0022] As an improvement, in step 4), several reference points are selected and the calibrated virtual weld joint thermo-mechanical coupling strain evolution data is obtained by measurement method for subsequent calibrated virtual weld joint result mapping.
[0023] As an improvement, for butt welds, no less than 4 strain measurement points are selected, and for T-type welds, no less than 6 strain measurement points are selected.
[0024] As an improvement, in the step 5), the grid model used for the thermal-mechanical coupling weld joint simulation in step 3) is imported into the structural calculation software. In the elastic structure calculation, the imported grid model is adjusted by applying an initial load or stress field to achieve the same result as the strain field in the thermal-mechanical coupling welding simulation, thereby completing the corresponding virtual weld joint thermal-mechanical coupling result mapping, and in the corresponding virtual weld joint elastic structure calculation result, the strain evolution result of the corresponding measurement point in the calibrated virtual weld joint is measured according to the measurement point in step 4). If the difference in the strain result of the measurement point exceeds 10%, the initial load or stress field data is adjusted to make the measurement point results of the corresponding virtual weld joint thermal-mechanical coupling algorithm and the elastic structure algorithm close.
[0025] As an improvement, in step 6), based on the virtual weld joint simulation calibration list, the thermal-mechanical coupling results of the calibrated weld virtual weld joints are mapped to the elastic structure calculation of the corresponding calibrated weld virtual weld joints, and a virtual weld joint mapping database for large structural parts is established. During the welding simulation of large thick plate structural parts, the database is accessed to match the strain results and the corresponding initial load or equivalent stress field of the weld joint corresponding to each weld of the large thick plate structural parts.
[0026] As an improvement, after completing the virtual weld joint simulation calibration list in step 7), the key positions of the overall model of the large thick plate structural member are identified, and according to the stress characteristics and assembly requirements of the structural member, the key positions with greater overall impact are refined, and the secondary positions are simplified by reducing the order.
[0027] As an improvement, the specific operations of step 8) are as follows:
[0028] (1) Identify each weld in a large thick plate structure, retrieve the best matching weld joint from the virtual weld joint mapping database, and read the corresponding initial load or stress field;
[0029] (2) In the elastic calculation model of large thick plate structural parts, the matched initial load or stress field is applied to the corresponding welds in sequence, and the boundary conditions of the calculation model are strictly kept consistent with the actual structure to ensure the calculation accuracy;
[0030] (3) Using the elastic structure calculation method, the calculation of each weld is performed in sequence according to the actual welding sequence, under the premise of ensuring that the initial load or stress field of each weld of the large thick plate structural member is correctly matched from the virtual weld joint mapping database.
[0031] Compared with the prior art, the present invention has the following beneficial effects:
[0032] 1. Improve computing efficiency and accuracy
[0033] By employing typical weld joint calibration and result mapping techniques, this invention effectively reduces redundant calculations during welding simulation, significantly improving computational efficiency. Furthermore, the core goal of accurately predicting welding deformation is achieved, significantly improving the accuracy of deformation predictions. This allows for a more realistic reflection of deformation during welding, providing engineers with more reliable data support.
[0034] 2. Simplify pre-processing and meshing
[0035] The present invention simplifies the pre-processing process by adopting adaptive meshing and hybrid meshing strategies, reduces the strict requirements for traditional hexahedral meshes, reduces the difficulty and time of meshing, makes the simulation process more flexible and fast, and adapts to more complex structural parts and welding processes.
[0036] 3. Improve convergence and computational stability
[0037] The present invention solves the common thermal-mechanical coupling nonlinear problem in welding simulation. Through the optimized calculation method, the convergence of the simulation process is enhanced, the numerical instability problem caused by nonlinearity in traditional methods is avoided, and the stability and reliability of the simulation results are improved.
[0038] 4. Reduce computing resource consumption
[0039] By reducing unnecessary calculation processes and optimizing calculation flows, the present invention significantly reduces the consumption of computing resources during the simulation process, reduces the demand for high-performance computing resources, thereby reducing the overall simulation cost and calculation time, and improving the economy and operability of the simulation method.
[0040] 5. Promote rapid prediction and optimization iteration of welding deformation of large thick plate structural parts, thereby improving the quality of structural parts
[0041] By efficiently and rapidly predicting welding deformation, the present invention can identify potential deformation issues in advance, thereby reducing assembly errors and structural distortion caused by welding deformation during the design phase. This not only improves the quality of structural components but also avoids later repairs and adjustments, reducing production cycles and costs.
[0042] 6. Powerful engineering application value
[0043] This invention addresses several technical issues in traditional welding simulation methods, significantly improving the applicability and reliability of simulation technology in practical engineering applications. This method is suitable for rapidly predicting and optimizing welding deformation in complex, large, thick plate structures, supporting the efficient implementation of engineering projects and improving their overall efficiency and economic benefits. BRIEF DESCRIPTION OF THE DRAWINGS
[0044] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For those skilled in the art, other drawings can be obtained based on these drawings without paying any creative work.
[0045] Figure 1 It is a schematic diagram of the process of the present invention;
[0046] Figure 2 Schematic diagram of the virtual weld joint simulation calibration of the present invention; (a) is a virtual welding calibration piece, (b) is a schematic diagram of a butt weld, and (c) is a schematic diagram of a T-weld;
[0047] Figure 3 Schematic diagram of calibrating mesh discretization for a virtual weld joint of a certain thickness of butt weld;
[0048] Figure 4 Schematic diagram of mesh discretization calibration for a virtual weld joint of a T-type weld of a certain thickness;
[0049] Figure 5 Schematic diagram of the thermal-mechanical coupling strain field of a virtual weld joint of a certain thickness butt weld;
[0050] Figure 6 Schematic diagram of the thermal-mechanical coupling strain field of a virtual welded joint of a certain thickness T-type weld;
[0051] Figure 7Schematic diagram of the measurement points for the thermomechanical coupling strain evolution results of the virtual weld joint of the butt weld; (a) is a three-dimensional schematic diagram of the virtual weld joint of the butt weld, and (b) is a top view of the measurement point location;
[0052] Figure 8 Schematic diagram of the measurement points for the thermomechanical coupling strain evolution results of the T-shaped weld virtual weld joint; (a) is a three-dimensional schematic diagram of the T-shaped weld virtual weld joint, (b) is a top view of the measurement point position, and (c) is a left view of the measurement point position;
[0053] Figure 9 Schematic diagram of strain calculation for the elastic structure of a virtual weld joint of a certain thickness of butt weld;
[0054] Figure 10 Schematic diagram of strain calculation for the elastic structure of a virtual weld joint of a certain thickness T-weld;
[0055] Figure 11 Rapid welding simulation prediction result diagram for a large thick plate structure;
[0056] Figure 12 This is the deformation measurement diagram of a large thick plate structure after on-site welding. DETAILED DESCRIPTION
[0057] To make the purpose, technical solutions and advantages of the present invention more clear, the present invention is further described in detail below. However, it should be understood that the specific embodiments described herein are only used to illustrate the present invention and are not intended to limit the scope of the present invention.
[0058] Unless otherwise defined, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which the present invention pertains. The terms used in the specification of the present invention herein are only for the purpose of describing specific embodiments and are not intended to limit the present invention.
[0059] like Figure 1 As shown, a rapid welding simulation method for large thick plate structural parts, generally referring to thick plate structural parts with a thickness greater than 25 mm, includes the following steps:
[0060] 1) Construct the geometry of the large thick plate structure to be welded and add the weld geometry model
[0061] Obtain a 3D model of a large thick plate structural component and perform geometric cleanup, such as repairing model geometric errors, gaps, and overlapping surfaces to ensure structural closure and clear logic. Remove redundant features not relevant to the simulation, such as small fillets and holes. Build a weld model and process the connection between the weld and the structure to ensure a reasonable connection between the weld and the structure. Ensure compatibility between the weld and the structural component and check whether the geometric model is closed to avoid errors during model discretization.
[0062] 2) Identify all welds of large thick plate structures and determine the calibration parameters of virtual weld joints
[0063] Identify all welds in structural parts, combine engineering experience and failure data, cover typical welds that have a greater impact on structural strength, residual stress and deformation, count weld geometric characteristics, summarize welds with similar sizes and shapes of the same plate thickness, reduce calculation redundancy, and form a virtual weld joint simulation calibration list; use virtual welding calibration parts to perform virtual weld joint simulation calibration according to the virtual weld joint simulation calibration list.
[0064] The size of the virtual welding calibration part is determined based on the structural characteristics, stress characteristics and heat affected range, etc. Figure 2 (Because the key welds that affect deformation in engineering machinery are mainly butt welds and T-welds, this invention only uses these two types of welds as examples. If there are other types of welds on the structural parts, the method of this invention can be used as an equivalent method). Figure 2 (a) is a virtual welding calibration part; (b) is a schematic diagram of a butt weld. The virtual welding joint of the butt weld consists of two virtual welding calibration parts of the same specifications. t is the thickness of the plates on both sides of the butt weld at the location to be calibrated on the structural part. The length L is 15-18t and the width B is 8-10t (if the thickness of the butt weld plates is different, the length and width values are the median of the two plate thicknesses); (c) is a schematic diagram of a T-type weld. The virtual welding joint of the T-type weld consists of two virtual welding calibration parts of the same specifications. The groove is restored according to the actual size of the T-type weld at the location to be virtually calibrated on the structural part. t is the thickness of the plates on both sides of the T-type weld at the location to be calibrated on the structural part. The length L is 15-18t and the width B is 12-15t (if the thickness of the two plates of the T-type weld are different, the length and width values are the median of the two plate thicknesses).
[0065] 3) Thermal-mechanical coupling welding simulation of virtual weld joints
[0066] According to the simulation calibration list of virtual weld joints, a fine modeling method is used for the calibrated virtual weld joints to ensure that the characteristics of the weld groove, weld bead shape and so on are consistent with the actual welding situation. Adaptive and hybrid mesh strategies are adopted. Locally encrypted mesh is used in the welding area, transition mesh is used in the heat-affected zone, and mesh accuracy is reduced in non-critical areas. The modeling diagram of a certain thickness butt weld and T-type weld joint is shown in the figure. Figure 3 and Figure 4 , select the heat source model and process parameters close to the actual welding of large structural parts to ensure the calculation accuracy, calculate the temperature field and strain field during the welding process, and provide the necessary strain data for subsequent deformation mapping. The thermal-mechanical coupling simulation results are as follows Figure 5 、 Figure 6 shown.
[0067] 4) Obtain the thermal-mechanical coupling strain evolution results of the calibrated virtual weld joint
[0068] Select several reference points and use the measurement method to obtain the calibrated virtual weld joint thermal-mechanical coupling strain evolution data for subsequent calibration of the virtual weld joint result mapping. The measurement points are arranged on both sides of the center line of the weld (no less than 4 for butt welds and no less than 6 for T-welds). The diagram of measurement point selection and positioning dimensions is shown in Figure 7 and Figure 8 , used to obtain strain results.
[0069] For butt welds, select no less than 4 strain measurement points, and recommend measurement point locations and positioning dimensions (when selecting strain measurement points for butt welds, the locations should be symmetrically distributed along the center line of the butt weld, the distance from the edge of the length of a single butt plate is 1 / 3 of the width of a single butt plate, and the distance from the edge of the width of a single butt plate is 1 / 4 of the length of a single butt plate. When selecting strain measurement points, the strain measurement points should cover both plates of the butt weld and be symmetrically distributed along the center line of the butt weld). Figure 7 As shown, the measuring points are numbered as DA, DB, DC, and DD. For T-type welds, there are no less than 6 strain measurement points, and the recommended measuring point positions and positioning dimensions are as follows (when selecting the strain measurement points of the T-type weld, the measuring points located on the T-type weld vertical plate and the T-type weld bottom plate should be selected respectively. The position of the strain measurement point of the T-type weld vertical plate is: the distance from the length edge of the T-type weld vertical plate is 1 / 4 of the width of the T-type weld vertical plate, and the distance from the width edge of the T-type weld vertical plate is 1 / 5 of the length of the T-type weld vertical plate. The number of measuring points is 2, and they are symmetrically distributed along the length center line of the T-type weld vertical plate; the position of the strain measurement point of the T-type weld bottom plate is: the distance from the width center line of the T-type weld bottom plate is 1 / 4 of the width of the T-type weld bottom plate, and the distance from the width edge of the T-type weld bottom plate is 1 / 6 of the length of a single butt plate. The number of measuring points is 4, and they should be symmetrically distributed along the width and length center lines of the T-type weld bottom plate when selecting). Figure 8 As shown, the measuring points are numbered TA, TB, TC, TD, TE, and TF.
[0070] 5) Mapping of thermal-mechanical coupling results of virtual weld joints
[0071] Import the mesh model used in the thermomechanical coupling weld joint simulation in step 3) into the structural calculation software, transform the thermomechanical coupling nonlinear problem into an elastic mechanics problem, eliminate the complex nonlinear thermal-mechanical interactions during the welding process, and enable structural analysis to be performed in a simpler framework, thereby improving the convergence of the calculation. In the elastic structure calculation, the imported mesh model is adjusted by applying an initial load or stress field to achieve the same result as the strain field in the thermomechanical coupling welding simulation, thereby completing the mapping of the corresponding thermomechanical coupling result of the virtual weld joint. In the corresponding elastic structure calculation result of the virtual weld joint, the strain evolution results of the corresponding measurement points in the calibration virtual weld joint are measured according to the measurement points in step 4) (the corresponding measurement points for the butt weld joint are DA-DD, and the corresponding measurement points for the T-type weld are TA-TF). If the difference in the strain results of the measurement points exceeds 10%, the initial load or stress field data is adjusted to make the measurement point results of the corresponding virtual weld joint thermomechanical coupling algorithm and the elastic structure algorithm as close as possible to reduce the calibration error. The calculation process ignores unnecessary stress field mapping, which reduces the calculation time and resource consumption, while ensuring the accuracy of deformation prediction. The cloud map of the calculation results of the elastic structure of a certain thickness calibration weld joint is as follows: Figure 9 and Figure 10 shown.
[0072] When calculating the elastic structure of the virtual weld joint, the mesh model uses the mesh model used in the thermomechanical coupling weld joint simulation in step 3), and the boundary conditions are strictly maintained the same as those of the thermomechanical coupling welding simulation to ensure consistency of structural constraints. This ensures that the displacement boundaries and contact relationships of the two algorithms, the thermomechanical coupling algorithm and the elastic structure calculation algorithm, do not change, and the deformation consistency of the two algorithms is achieved only by applying the initial load or initial stress field. For the present invention, the thermal expansion coefficient of the weld area can be set to be greater than the thermal expansion coefficient of the base material. In the elastic structure calculation model, the weld area is cooled from 40°C to an ambient temperature of 20°C, which is the same temperature as the base material. By adjusting the thermal expansion coefficient of the weld area, the deformation of the two algorithms is finally made consistent. The thermal expansion coefficient of the weld area at this temperature is used as the initial load or stress field input.
[0073] 6) Form a calibration weld virtual weld joint mapping database
[0074] Based on the virtual weld joint simulation calibration list, the thermomechanical coupling results of the calibrated virtual weld joints are mapped to the corresponding elastic structure calculations of the calibrated virtual weld joints. A virtual weld joint mapping database for large structural components is established. During the welding simulation of large thick plate structural components, by accessing this database, the corresponding weld joints of each weld in the large thick plate structural component can be quickly identified and matched, and the corresponding initial load or equivalent stress field information can be extracted accordingly. Depending on the weld type, the present invention constructs measurement point mapping databases for butt welds and T-welds, respectively, as shown in Tables 1 and 2. To achieve the correspondence between the thermomechanical coupling calculation results of typical weld joints and the elastic structure calculation results, a set of representative measurement points is preset in the weld joint model (the strain measurement point positions are preset according to step 4) to record the strain response of key locations. After the thermomechanical coupling simulation is completed, the strain values at these measurement points are extracted to form a thermomechanical coupling strain data table. Subsequently, an elastic structure simulation is performed under the same model and measurement point settings, and the strain values of the corresponding measurement points are extracted to form an elastic strain data table. By comparing the strain values of the same measurement points in the two tables, once the difference between the two is within 10%, it can be determined that the initial load applied in the elastic calculation can effectively equivalent the influence of the welding thermal process. At this time, the initial load is associated with the corresponding weld joint type and recorded to form the weld joint initial load / gravitational field application data. The above measurement point data table is not only used to judge the consistency of the results, but also serves as the core basis for constructing the corresponding weld joint initial load / gravitational field application, which facilitates the rapid matching of the corresponding initial load / gravitational field application according to the weld type in the large-scale structural welding simulation, thereby achieving efficient calculation.
[0075] Table 1 Calibration of virtual weld joint mapping database for butt welds
[0076]
[0077]
[0078] Table 2 Calibration of T-weld virtual weld joint mapping database
[0079]
[0080] 7) After completing the virtual weld joint simulation calibration list, identify the key locations of the overall model of the large thick plate structural component. Based on the stress characteristics and assembly requirements of the structural component, refine the key locations with greater overall impact. For secondary locations, reduce the order and simplify them to improve computational efficiency, reduce difficulty, and maintain structural accuracy. When discretizing the large thick plate structural component model, adaptive meshing technology and hybrid meshing strategies can be used to reduce reliance on traditional hexahedral meshes. Local meshes are refined based on the characteristics of the welding area and heat-affected zone, while coarser meshes are used in areas away from the weld. This meshing strategy can automatically adjust the mesh density according to computational requirements, thereby reducing unnecessary computational complexity.
[0081] 8) Identify the types and characteristics of welds in large thick plate structural components to ensure that the closest match can be found in the calibration weld virtual weld joint mapping database. In the elastic structure calculation model of large thick plate structural components, the initial load or equivalent stress field in the mapping database is introduced for each weld, which can quickly complete the calibration of the virtual weld joint strain mapping to the corresponding structural component weld area, and solve the welding deformation under the elastic calculation framework, solving the bottleneck problem of convergence calculation of thermal-mechanical coupling nonlinear solution.
[0082] The specific operations are as follows:
[0083] (1) Identify each weld in a large thick plate structure, retrieve the best matching weld joint from the virtual weld joint mapping database, and read the corresponding initial load or stress field;
[0084] (2) In the elastic calculation model of large thick plate structural parts, the matched initial load or stress field is applied to the corresponding welds in sequence, and the boundary conditions of the calculation model are strictly kept consistent with the actual structure to ensure the calculation accuracy;
[0085] (3) Using the elastic structure calculation method, the calculation of each weld is performed in sequence according to the actual welding sequence, under the premise of ensuring that the initial load or stress field of each weld of the large thick plate structural member is correctly matched from the virtual weld joint mapping database.
[0086] 9) Carry out rapid deformation solution of the global structural model of large thick plate structural parts, which can be compared with the actual on-site post-weld deformation for correction, and carry out rapid optimization prediction and iteration of welding deformation according to actual conditions, reducing assembly errors and later repair costs caused by welding deformation. Figure 11 、 Figure 12 The simulation prediction results of rapid welding of a large structural component and the on-site deformation measurement after welding are shown. The simulation predicts that the deformation of the bottom plate edge of the structural component is about 21mm, and the actual deformation of the structural component after welding is about 20mm. Figure 12 The predicted results and positions are consistent with the actual situation on site.
[0087] This method prioritizes welding deformation as the core of simulation analysis, overcoming the limitations of traditional simulations that prioritize stress and temperature fields. It enables rapid prediction and iterative optimization of welding deformation for large, thick plate structures, providing more reliable data support for improving structural precision and fatigue reliability. This method utilizes typical weld joint calibration and result mapping technology. By calibrating the deformation of known weld joints, this method maps the deformation prediction results to the overall structural component, improving computational efficiency and reducing recalculation.
[0088] This paper addresses the complex nonlinearities of thermal-mechanical coupling during welding, using optimized computational methods to reduce numerical instabilities caused by nonlinearities, improve convergence, and make welding simulation more stable and reliable. The paper also employs adaptive meshing technology and a hybrid meshing strategy, reducing reliance on traditional hexahedral meshes. This makes meshing more flexible and rapid, significantly reducing the difficulty and computational resource consumption of pre-processing.
[0089] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions or improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.
Claims
1. A rapid welding simulation method for large thick plate structural parts, characterized in that: The following steps are involved: 1) Construct the geometric structure of the large thick plate structure to be welded and add the weld geometry model; 2) Identify all welds of large thick plate structures and determine the calibration parameters of virtual weld joints; 3) Perform thermal-mechanical coupling welding simulation on virtual weld joints; 4) Obtain the thermal-mechanical coupled strain evolution results of the calibrated virtual weld joint; 5) Mapping of thermal-mechanical coupling results of virtual weld joints; 6) forming a calibration weld virtual weld joint mapping database; 7) After completing the virtual weld joint simulation calibration list, identify the key positions of the overall model of the large thick plate structure and perform corresponding processing on the key positions and secondary positions; 8) Identify the type and characteristics of the welds of large thick plate structural components, find the closest match in the calibration weld virtual weld joint mapping database, introduce the initial load or equivalent stress field in the mapping database for each weld in the elastic structure calculation model of large thick plate structural components, and complete the calibration virtual weld joint strain mapping to the corresponding structural component weld area; 9) Carry out deformation solution of the global structural model of large thick plate structural parts, compare and correct it with the actual on-site post-weld deformation, and carry out rapid optimization prediction and iteration of welding deformation based on actual conditions.
2. A rapid welding simulation method for large thick plate structural parts according to claim 1, characterized in that: In the step 1), a three-dimensional model of a large thick plate structural member is obtained, geometric cleaning is performed, a weld model is constructed, and the connection relationship between the weld and the structure is processed.
3. The rapid welding simulation method for large thick plate structural parts according to claim 1 is characterized in that: In the step 2), all welds in the structural parts are identified, and typical welds that have a greater impact on structural strength, residual stress, and deformation are covered in combination with engineering experience and failure data. The geometric characteristics of the welds are counted, welds with similar sizes and shapes of the same plate thickness are summarized, and a virtual weld joint simulation calibration list is formed; virtual weld calibration parts are used to perform virtual weld joint simulation calibration according to the virtual weld joint simulation calibration list.
4. The rapid welding simulation method for large thick plate structural parts according to claim 1 is characterized in that: In the step 3), according to the simulation calibration list of virtual weld joints, a fine modeling method is adopted for the virtual weld joints to be calibrated, an adaptive and hybrid mesh strategy is adopted, a local encrypted mesh is used in the welding area, a transition mesh is used in the heat-affected zone, and the mesh accuracy is reduced in the non-critical area. A heat source model and process parameters that are close to those used in the actual welding of large structural parts are selected, the temperature field and strain field during the welding process are calculated, and strain data is provided for subsequent deformation mapping.
5. The rapid welding simulation method for large thick plate structural parts according to claim 1 is characterized in that: In the step 4), several reference points are selected and the calibrated virtual weld joint thermo-mechanical coupling strain evolution data is obtained by measurement method for subsequent calibrated virtual weld joint result mapping.
6. A rapid welding simulation method for large thick plate structural parts according to claim 5, characterized in that: For butt welds, strain measurement points shall be no less than 4; for T-type welds, strain measurement points shall be no less than 6.
7. The rapid welding simulation method for large thick plate structural parts according to claim 1, characterized in that: In the step 5), the mesh model used in the thermal-mechanical coupling weld joint simulation in step 3) is imported into the structural calculation software. In the elastic structure calculation, the imported mesh model is adjusted by applying an initial load or stress field to achieve the same result as the strain field in the thermal-mechanical coupling welding simulation, thereby completing the mapping of the corresponding thermal-mechanical coupling result of the virtual weld joint. In the elastic structure calculation result of the corresponding virtual weld joint, the strain evolution result of the corresponding measurement point in the calibrated virtual weld joint is measured according to the measurement point in step 4). If the difference in the strain result of the measurement point exceeds 10%, the initial load or stress field data is adjusted to make the measurement point results of the corresponding virtual weld joint thermal-mechanical coupling algorithm and the elastic structure algorithm close.
8. The rapid welding simulation method for large thick plate structural parts according to claim 1 is characterized in that: In the step 6), based on the virtual weld joint simulation calibration list, the thermal-mechanical coupling results of the calibrated weld virtual weld joints are mapped to the elastic structure calculation of the corresponding calibrated weld virtual weld joints, and a virtual weld joint mapping database for large structural parts is established. During the welding simulation of large thick plate structural parts, the strain results and the corresponding initial load or equivalent stress field of the weld joint corresponding to each weld of the large thick plate structural parts are matched by accessing the database.
9. The rapid welding simulation method for large thick plate structural parts according to claim 1, characterized in that: After completing the virtual weld joint simulation calibration list in step 7), the key positions of the overall model of the large thick plate structural member are identified. According to the stress characteristics and assembly requirements of the structural member, the key positions with greater overall influence are refined, and the secondary positions are simplified by reducing the order.
10. The rapid welding simulation method for large thick plate structural parts according to claim 1, characterized in that: The specific operation of step 8) is as follows: (1) Identify each weld in a large thick plate structure, retrieve the best matching weld joint from the virtual weld joint mapping database, and read the corresponding initial load or stress field; (2) In the elastic calculation model of large thick plate structural parts, the matched initial load or stress field is applied to the corresponding welds in sequence, and the boundary conditions of the calculation model are strictly kept consistent with the actual structure to ensure the calculation accuracy; (3) Using the elastic structure calculation method, the calculation of each weld is performed in sequence according to the actual welding sequence, under the premise of ensuring that the initial load or stress field of each weld of the large thick plate structural member is correctly matched from the virtual weld joint mapping database.