Dynamic wear process simulation prediction method and device for inter-structure long-period large wear loss and storage medium

Abstract

The invention discloses a dynamic wear process simulation prediction method and device for inter-structure long-period large wear loss and a storage medium, and relates to the technical field of nuclear reactor fretting wear. The method comprises the following steps: constructing a finite element model among a plurality of to-be-analyzed components based on initial morphology parameters of the plurality of to-be-analyzed components; according to a grid reconstruction condition, based on the finite element model and the wear model, executing a preset operation in a segmented manner to obtain a wear depth set and a morphology parameter of each segment; determining wear process distribution based on the wear depth set and the morphology parameter of each segment; the preset operation comprises the following steps: detecting that a grid reconstruction condition is met; and stopping calling the finite element model and the wear model of the current time period, determining a wear depth set and morphology parameters of the current time period, updating the morphology parameters of the finite element model, calling the updated finite element model and wear model, and determining a wear depth set and morphology parameters of the next time period.

Description

Technical Field

[0001] This application relates to the field of nuclear reactor fretting wear technology, and in particular to a method, device and storage medium for simulating and predicting dynamic wear processes with long-term and large-volume wear between structures. Background Technology

[0002] Currently, numerical simulation prediction methods based on finite element models have become an important tool for studying fretting wear. In these methods, the contact pressure and relative sliding displacement of the contact area are calculated using a finite element model with fixed parameters, thereby estimating the wear amount based on the wear model. However, these simulation methods can only effectively simulate short-term, shallow-wear conditions. When simulating long-term, high-wear processes (e.g., the long-term, high-wear processes that may occur during the decades-long service life of reactor components), the calculations fail to converge due to mesh distortion and the accumulation of virtual stress, making it impossible to complete a full-lifetime wear assessment. Summary of the Invention

[0003] This invention provides a method, apparatus, and storage medium for simulating and predicting dynamic wear processes with long-term, high-volume wear between structures, thereby at least solving the problem of low accuracy in simulating and predicting long-term, high-wear processes in related technologies. The technical solution of this invention is as follows: According to a first aspect of the present invention, a method for simulating and predicting wear processes is provided. The method includes: constructing a finite element model among multiple components to be analyzed based on initial morphological parameters of multiple components to be analyzed; performing preset operations segment by segment according to mesh reconstruction conditions, based on the finite element model and the wear model, to obtain the wear depth set and morphological parameters of each segment; the preset operations include: real-time detection that the current time period meets the mesh reconstruction conditions; stopping the invocation of the finite element model and the wear model for the current time period, determining the wear depth set and morphological parameters of the current time period, and performing mesh reconstruction on the deformed finite element model based on the morphological parameters at the final moment of the current time period; invoking the updated finite element model and the wear model to determine the wear depth set and morphological parameters of the next time period among the multiple components to be analyzed; and determining the wear process distribution among the multiple components to be analyzed based on the wear depth set and morphological parameters of each segment.

[0004] In one implementation, the preset operation further includes: detecting that the current time period does not meet the mesh reconstruction conditions, calling the finite element model and wear model of the current time period according to the preset frequency, determining the wear depth of each mesh node in each frequency and determining the node coordinates of each mesh node in each frequency; and determining the morphology parameters of the current time period based on the node coordinates of each mesh node in each frequency.

[0005] The preset frequency represents the number of times node coordinates are collected per unit time.

[0006] In another implementation, the preset operation further includes: calling the finite element model of the current time period and performing the following adaptive meshing operation in the full integral element mode: determining the pre-wear region of the current time period and dividing the pre-wear region of the current time period into multiple standard elements; selecting a preset number of integration points in each of the multiple standard elements; sampling and summing the relative displacements on the preset number of integration points in each standard element; and performing adaptive meshing on the multiple standard elements according to the displacement summation results to obtain the node set of the current time period; the node set includes multiple mesh nodes.

[0007] In another implementation, based on the finite element model and wear model, preset operations are executed in segments according to the mesh reconstruction conditions. These operations include: dividing the total wear simulation time into multiple time periods in sequence; where each time period corresponds to a preset duration; each time period is a segment; if the execution time of the finite element model and wear model in any time period reaches the preset duration corresponding to that time period, it is determined that the mesh reconstruction conditions are met, the execution of the finite element model and wear model in any time period is stopped, and the next time period of any time period is entered in sequence.

[0008] In another implementation, based on the finite element model and wear model, preset operations are performed in segments according to the mesh reconstruction conditions. These operations include: determining the preset wear depth and preset depth difference corresponding to the multiple segments divided in sequence; if the wear depth output by the wear model is detected at any detection time within any segment and is greater than or equal to the corresponding preset wear depth, or if the depth difference between the wear depth output by the wear model at any detection time within any segment and the wear depth output by the wear model at the initial detection time within any segment is greater than the preset depth difference, it is determined that the mesh reconstruction conditions are met, the execution of the finite element model and wear model for any time period is stopped, and the next time period is entered sequentially.

[0009] In another implementation, the wear model is based on the following formula:

[0010] Where W is the local wear depth; s is the sliding distance; K is the wear coefficient; p is the local contact pressure; t is the time; and x is the xth node.

[0011] In another implementation, the wear process distribution among multiple components to be analyzed is determined based on the wear depth set of each segment and the morphological parameters of each segment. This includes: performing data analysis and data fitting on the wear depth set of each segment according to the simulation time to obtain a first relationship graph of wear depth versus time; performing data analysis and data fitting on the morphological parameters of each segment according to the simulation time to obtain a second relationship graph of morphological parameters versus time; and establishing a third relationship graph of wear volume versus wear depth based on the wear depth set of each segment and the morphological parameters of each segment.

[0012] In another implementation, multiple components to be analyzed have contact surfaces with preset curvature characteristics; the multiple components to be analyzed include any one of the following: nuclear reactor fuel cladding and grid support, heat transfer tubes and support plates or vibration damping strips in the nuclear reactor, guide components and load-bearing surfaces of the control rod drive mechanism in the nuclear reactor, plate-shaped components and connecting or supporting components of in-core components, and main pipes and wave pipes of the control rod drive mechanism.

[0013] According to a second aspect of the present invention, a wear process simulation and prediction apparatus is provided, the wear process simulation and prediction apparatus comprising: a construction unit for constructing a finite element model between multiple components to be analyzed based on initial morphological parameters of multiple components to be analyzed; The segmented calculation unit is used to perform preset operations segment by segment according to the mesh reconstruction conditions, based on the finite element model and the wear model, to obtain the wear depth set and the morphology parameters of each segment. The preset operations include: real-time detection that the mesh reconstruction conditions are met in the current time period; stopping the invocation of the finite element model and the wear model in the current time period, determining the wear depth set and the morphology parameters in the current time period, updating the morphology parameters of the finite element model based on the morphology parameters in the current time period, invoking the updated finite element model and the wear model, and determining the wear depth set and the morphology parameters in the next time period for multiple components to be analyzed. The prediction unit is used to determine the wear process distribution among multiple components to be analyzed based on the wear depth set of each segment and the morphological parameters of each segment.

[0014] According to a third aspect of the present invention, a wear process simulation and prediction system is provided, the system being configured to perform a wear process simulation and prediction method as described in the first aspect and any possible implementation thereof.

[0015] According to a fourth aspect of the present invention, an electronic device is provided, comprising: a processor and a memory for storing processor-executable instructions; wherein the processor is configured to execute the executable instructions to implement a wear process simulation and prediction method as described in the first aspect and any possible implementation thereof.

[0016] According to a fifth aspect of the present invention, a computer-readable storage medium is provided, on which instructions are stored, such that when the instructions in the computer-readable storage medium are executed by a processor of an electronic device, the electronic device is enabled to perform a wear process simulation and prediction method as described in the first aspect and any possible implementation thereof.

[0017] According to a sixth aspect of the present invention, a computer program product is provided, the computer program product including computer instructions, which, when executed on an electronic device, cause the electronic device to perform the wear process simulation and prediction method of the first aspect and any possible implementation thereof.

[0018] The technical solution provided by this invention brings at least the following beneficial effects: In order to enable the finite element model to accurately simulate and predict the long-cycle wear process, the long-cycle wear trend analysis is divided into multiple short-term periods according to the mesh reconstruction conditions, and segmented prediction is performed. In the calculation of each hourly period, the current calculation is actively stopped before the mesh is about to become distorted but before it causes calculation divergence. Subsequently, a brand-new finite element model with a regular mesh is created based on the current morphology. The mesh of this new model is re-divided from the initial state without deformation, except that the geometric boundaries are the shape after wear in the previous calculation. This completely eliminates the mesh distortion accumulated in the previous calculation, providing an accurate starting point for the next period calculation, thereby ensuring the continuous stability of the calculation. The above-mentioned segmented simulation and prediction method breaks the long cycle into short periods, with small wear depth in each stage, avoiding severe mesh deformation. At the same time, by periodically resetting the finite element model, virtual stress is cleared, preventing accumulation that leads to divergence, and avoiding mesh distortion and stress accumulation caused by excessive wear depth, thereby ensuring the calculation stability and feasibility of the entire long-cycle simulation and prediction.

[0019] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit this disclosure. Attached Figure Description

[0020] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application, and do not constitute an undue limitation of this application.

[0021] Figure 1 This is a flowchart illustrating a wear process simulation and prediction method according to an exemplary embodiment; Figure 2 This is a schematic diagram of a geometric model of a component to be analyzed, according to an exemplary embodiment; Figure 3 This is a schematic diagram of a finite element model according to an exemplary embodiment; Figure 4 This is a schematic diagram illustrating an adaptive mesh setting according to an exemplary embodiment; Figure 5 This is a schematic diagram illustrating an external load that causes wear, according to an exemplary embodiment. Figure 6 This is a schematic diagram illustrating the wear surface morphology at different times according to an exemplary embodiment; Figure 7 This is a schematic diagram illustrating the change of fuel cladding wear depth over time according to an exemplary embodiment; Figure 8 This is a comparison chart of experimental results for a wear process simulation and prediction method according to an exemplary embodiment; Figure 9 This is a block diagram illustrating a wear process simulation and prediction device according to an exemplary embodiment; Figure 10 This is a schematic diagram of an electronic device according to an exemplary embodiment. Detailed Implementation

[0022] To enable those skilled in the art to better understand the technical solutions of this application, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings.

[0023] It should be noted that the terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0024] Before providing a detailed introduction to the wear process simulation and prediction method provided in the embodiments of this application, let's briefly introduce the application scenarios and implementation environment involved in the embodiments of this application.

[0025] First, a brief introduction to the application scenarios involved in this application will be given.

[0026] During normal reactor operation, the circulation of coolant causes micro-vibrations in the fuel assemblies. These vibrations result in relative displacement between the fuel rods and the grid support surfaces, leading to cladding wear and reduced service life. In severe cases, this can even cause cladding rupture and radioactive material leakage, resulting in unacceptable economic and safety consequences. Therefore, wear is a crucial issue that must be considered in fuel assembly design. However, due to limitations in the quantity and conditions of in-service inspections, current structural design and wear prediction still rely on analytical evaluation methods. Conducting research on the fretting wear of reactor fuel assemblies plays a vital role in reactor structural safety design, protecting the structural integrity of fuel assemblies, and preventing serious accidents.

[0027] Wear depth is often used as an evaluation index in nuclear engineering design. Current wear models (such as the ARCHARD model and FOUVRY model) provide a macroscopic relationship between structural wear volume and wear energy. However, understanding the relationship between wear volume and wear depth is necessary to apply these wear models to engineering design. Currently, only the volume-depth relationship of some typical supports has been revealed (such as circular hole supports and plate-type limiting supports). However, the continuous emergence of new structural and support designs necessitates further research into this issue.

[0028] There are two technical approaches to solving this problem: experimental methods are time- and resource-intensive, and their versatility and generalizability are limited due to the variety of support types; numerical methods, with the development of computing capabilities, have found wider application in wear research due to their advantages of cost-effectiveness, versatility, and portability. Some studies have established refined finite element models between the structure and its supports, using information such as contact loads and relative displacements obtained from flow-induced vibration response analysis to evaluate wear morphology, wear depth, and wear volume. These methods mainly include intrinsic strain methods and methods combining engineering software with user subroutines. However, the intrinsic strain method can only apply intrinsic strain to the elements on the surface of the worn area, failing to achieve coordinated deformation of deeper meshes. The adaptive mesh module of engineering software accumulates virtual stress when controlling surface deformation, leading to non-convergence issues when the calculated wear depth reaches a certain level. This makes it difficult to assess dynamic wear analysis with large wear volumes over long periods, leaving designers unable to evaluate the wear condition of critical structures throughout their entire lifespan and hindering effective guidance for structural design improvements.

[0029] In summary, during the process of implementing the inventive technical solutions in the embodiments of this application, the inventors of this application discovered that the prior art has at least the following technical problems.

[0030] While existing technologies can simulate the dynamic evolution of fretting wear morphology, they have limited simulation depth. When the calculated wear depth reaches a certain level, computational convergence issues arise due to virtual stress accumulation and mesh distortion, making it impossible to simulate long-term, high-volume wear problems. In reality, structures have long service lives, and the impact of large wear depths is of great concern; existing methods cannot accurately simulate these effects, posing a significant challenge to assessing wear damage over the service life of a building.

[0031] To address the aforementioned issues, this application proposes a wear process simulation and prediction method. By segmenting the calculation into short time periods, each with a small wear depth, severe mesh deformation is avoided. Simultaneously, by periodically resetting the finite element model, virtual stress is eliminated, preventing accumulation and divergence, and avoiding mesh distortion and stress accumulation caused by excessive wear depth. This ensures the computational stability and feasibility of the entire long-cycle simulation and prediction. This method enables accurate and effective finite element numerical analysis and automated analysis processes for simulating reactor structure wear problems under high wear volume and long-cycle conditions, resolving convergence issues in numerical simulations caused by drastic increases in wear depth. It provides a simple, accurate, and reliable analytical method for nonlinear wear dynamic evolution and structural wear damage safety analysis under long-term service.

[0032] For ease of understanding, the wear process simulation and prediction method provided in this application will be described in detail below with reference to the accompanying drawings.

[0033] Figure 1 This is a flowchart illustrating a wear process simulation and prediction method according to an exemplary embodiment, which is implemented based on the following steps.

[0034] S11, based on the initial morphological parameters of multiple components to be analyzed, construct a finite element model between the multiple components to be analyzed.

[0035] For example, such as Figure 2 As shown, the geometric models and dimensional parameters of multiple components to be analyzed (i.e., two worn components) can be two arc-shaped surfaces of different sizes in contact with each other.

[0036] In some embodiments, geometric modeling software is used to establish a geometric model based on the drawings of the structural parts being analyzed and simulated, and the geometric features of the contact area between the two components to be analyzed are refined. A mesh generation tool is used to perform finite element mesh generation on the geometric model, and local mesh refinement is performed in the contact area to establish a finite element model with localized contact refinement. The contact area refers to the location where the two components to be analyzed may come into physical contact under load; in this embodiment, it is the arc-shaped outer surface of the two components to be analyzed.

[0037] For referenceFigure 3 The finite element model diagram shown has a tangential mesh size of 0.005 mm in the surface of areas where contact and wear may occur, in order to ensure that the mesh size conditions for accurate calculation of contact pressure are met.

[0038] To save computational costs, improve computational efficiency, and reduce the total number of meshes, the mesh size is increased layer by layer in the radial direction away from the contact area, with a maximum mesh size of approximately 0.6 mm and a total mesh count of approximately 26,000.

[0039] Furthermore, contact pairs are set up for areas where contact may occur (the relative distance between the first node and the second node within the contact area is less than a preset distance, and they are set as contact pairs; the first node and the second node are either nodes of the two components to be analyzed in the contact area).

[0040] In this embodiment, the contact pair consists of the arc-shaped outer surfaces of two components to be analyzed. The side that is assumed not to wear (rigid surface) is designated as the master surface, and the side that wears (flexible surface) is designated as the slave surface. Corresponding normal and tangential contact attributes are set.

[0041] Furthermore, the mesh cells contained within the pre-wear zone are set as the wear region cell set to define the adaptive mesh region range. The pre-wear zone refers to the area on the side of the component to be analyzed where wear is expected to occur, based on physical realities and engineering experience, and after considering a certain degree of conservatism.

[0042] In this embodiment, the pre-wear area is as follows: Figure 4 The red area on the left is illustrated. The pre-wear area surface nodes are set as the wear surface node set to define the adaptive mesh constraint region. In this embodiment, for example... Figure 4 The red area on the right is for illustrative purposes. The adaptive grid control mode is set to user-defined.

[0043] like Figure 4 As shown, the adaptive mesh region and its boundary constraint region of the pre-wear zone that is about to be worn in the surface interaction region are set.

[0044] S12, according to the mesh reconstruction conditions, based on the finite element model and the wear model, the preset operation is performed segment by segment to obtain the wear depth set of each segment and the morphology parameters of each segment.

[0045] Each segment can represent a time period.

[0046] The wear depth set for each segment is the set of wear depths for each node on the contact surface of the finite element model.

[0047] The above-mentioned preset operation includes the following steps.

[0048] First, if the current time period meets the mesh reconstruction conditions, the finite element model and wear model for the current time period will be stopped from being called.

[0049] Secondly, determine the wear depth set and morphological parameters for the current time period, and update the morphological parameters of the finite element model based on the morphological parameters for the current time period.

[0050] Third, the updated finite element model and wear model are invoked to determine the wear depth set and morphological parameters for the next time period in multiple components to be analyzed.

[0051] In some implementations, the long analysis period is divided into multiple segments. Based on these segments, the aforementioned preset operations are executed cyclically. The specific cyclic process is as follows: In the first segment, a finite element model is invoked for finite element analysis and a wear model is used for wear prediction. Multiple wear depths are recorded according to a preset acquisition cycle to form a first wear depth set. When the second segment is reached, the morphology parameters of the first segment are obtained, the invocation of the finite element model and the wear model is stopped, and the finite element model is reconstructed and updated using the wear depth set and morphology parameters of the first segment. The updated finite element model and wear model are then invoked to acquire multiple wear depths within the second segment to form a second wear depth set. Upon reaching the third segment, the topographic parameters of the second segment are obtained, the finite element model and wear model are stopped, and the mesh of the finite element model is reconstructed and updated using the wear depth set and topographic parameters of the second segment. The updated finite element model and wear model are then called, and multiple wear depths within the third segment are collected to form the third wear depth set. This process is repeated until the Nth segment. The mesh of the finite element model is then reconstructed and updated using the wear depth set and topographic parameters of the (N-1)th segment, and the updated finite element model and wear model are then called.

[0052] Furthermore, within each segment, a small loop can be executed to update the morphology parameters: after each acquisition of wear depth, the morphology parameters of the finite element model are updated based on the acquired wear depth, and the finite element analysis is continued using the finite element model with updated morphology parameters.

[0053] S13. Based on the wear depth set of each segment and the morphology parameters of each segment, determine the wear process distribution among multiple components to be analyzed.

[0054] The wear depth set includes multiple wear depths corresponding to each segment.

[0055] During the segmented simulation and prediction process described above, if the mesh reconstruction condition is met, it indicates a high probability of poor mesh quality. To reduce the calculation error of the finite element model, the finite element model for the current time period is terminated. At the same time, the morphological parameters of multiple components to be analyzed at the current moment are redefined, and the morphological parameters of the finite element model are updated based on these morphological parameters. This ensures that the finite element model can calculate the input parameters required for the wear model based on more accurate morphological parameters, thereby ensuring that the wear depth obtained based on the wear model in the next time period is more accurate.

[0056] The adaptive mesh region is set to the set of elements that may experience contact and fretting wear, and the adaptive mesh control method is set to user-defined. A user subroutine is written to call the contact pressure and relative sliding displacement of the contact region, calculate the wear depth of the contact nodes using the Archard wear depth formula, and change the node coordinates using adaptive mesh technology before the start of the next wear cycle.

[0057] In some embodiments, the wear depth calculation module is integrated into the Abaqus user-defined adaptive mesh boundary constraint subroutine UMESHMOTION. UMESHMOTION calls the solution variables at each node during the calculation process, processes them, and inputs them into the wear depth calculation formula to calculate the node displacement caused by wear.

[0058] UMESHMOTION is invoked at the end of each increment step. Within UMESHMOTION, the displacement behavior of nodes in a specific direction can be controlled by assigning a ULOCAL value. UMESHMOTION can also call default variables from Abaqus' internal programs. During the analysis of wear problems, it is necessary to call the solution variables at each node during the calculation process: contact pressure (CSTRESS) and relative sliding displacement (CDISP), and write them to local storage files. The absolute value of the difference between the relative sliding displacement of the node at the current moment and the relative sliding displacement at the previous moment represents the increment of the relative sliding distance at that node in this time increment.

[0059] By substituting the contact pressure and relative sliding increment into the wear depth calculation formula, the nodal wear depth is calculated and written into ULOCAL. This allows the surface nodal coordinates to be changed and the surface morphology updated before the start of the next incremental step calculation. The wear depth calculation formula used in this embodiment is the Archard wear depth calculation formula as shown in formula (1) below.

[0060] As one implementation method, the wear model is based on the following formula (1).

[0061] Formula (1).

[0062] Where W is the local wear depth; s is the sliding distance; K is the wear coefficient; p is the local contact pressure; t is the time; and x is the xth node.

[0063] In some embodiments, the application of external loads causing wear is controlled in the Load module by applying displacement boundary conditions to control the movement of each part, simulating relative sliding caused by the external load; the application of force load conditions controls the squeezing interaction of each part, simulating contact surface squeezing caused by the external load. The external loads in the embodiments of this application, such as... Figure 5 The contact force time history curve is shown in (a), and the relative sliding displacement time history curve is shown in (b). Based on this, an Abaqus calculation inp file is generated, and the Abaqus calculation job associated with the user subroutine UMESHMOTION is run. After the calculation results are submitted, the Abaqus background process is monitored, and the long-cycle, high-wear-amount wear problem is decomposed based on judgment. The corresponding wear calculation result odb file is read, and a Python script is written to post-process the calculation results to obtain the wear morphology. The wear morphology and wear simulation duration at the final moment in the result file are extracted, and the deformed model is imported into a temporary new cae file to build a new model and generate a temporary inp format file containing the node numbers and coordinate information of the deformed part.

[0064] After completing a portion of the long-cycle wear simulation, an automated Matlab script was written to replace the node numbers and coordinates of the parts in the finite element model's .inp file used for wear calculation with the node numbers and coordinates of the model after a period of wear deformation in a temporary .inp file containing staged wear results. The newly generated .inp file for subsequent wear calculations was then linked with the UMESHMOTION subroutine for continued calculations.

[0065] The dynamic evolution process of surface wear morphology obtained by numerical simulation is as follows: Figure 6 As shown, the wear depth changes over time as follows: Figure 7 As shown in the figure. The numerical simulation results demonstrate that the method of this invention can perform long-cycle, high-amount wear numerical simulations of surfaces with general curvature characteristics. A comparison of the method used in this application with actual wear results is shown below. Figure 8 As shown, the simulation data and simulation results are very close. Therefore, this demonstrates that, while ensuring the authenticity and validity of the numerical simulation results, the method of this application can perform long-cycle, high-amount wear numerical simulations on surfaces with arbitrary morphologies. Furthermore, its modular integration with commercial finite element software provides better applicability and facilitates wider adoption.

[0066] Through the above implementation method, in order to enable the finite element model to accurately predict long-cycle wear processes, the long-cycle wear trend analysis is divided into multiple short-term periods according to mesh reconstruction conditions, and segmented predictions are performed. In each hourly calculation, the current calculation is actively stopped before the mesh is about to distort but before it causes computational divergence. Subsequently, a completely new finite element model with a regular mesh is created based on the current topography. The mesh of this new model is re-divided from the undeformed initial state, except that the geometric boundaries are the shape after wear in the previous calculation. This completely eliminates the mesh distortion accumulated in the previous calculation, providing a precise starting point for the next period's calculation, thus ensuring the continuous stability of the calculation.

[0067] In the segmented simulation and prediction method described above, the long period is broken down into short time periods, with each stage having a small wear depth, thus avoiding severe mesh deformation. At the same time, by periodically resetting the finite element model, virtual stress is eliminated, preventing accumulation that could lead to divergence. This avoids mesh distortion and stress accumulation caused by excessive wear depth, thereby ensuring the computational stability and feasibility of the entire long-term simulation and prediction.

[0068] In one implementation, the preset operation further includes: detecting that the current time period does not meet the mesh reconstruction conditions, calling the finite element model and wear model of the current time period according to the preset frequency, determining the wear depth of each mesh node in each frequency and determining the node coordinates of each mesh node in each frequency; and determining the morphology parameters of the current time period based on the node coordinates of each mesh node in each frequency.

[0069] In the aforementioned preset frequencies, each frequency can be understood as an incremental step. Each incremental step is the most basic working unit in the entire simulation process. It is executed cyclically until a calculation segment ends. This invention integrates wear calculation and morphology updating within this most basic calculation unit, thereby achieving precise capture of the dynamic evolution of wear at a microscopic time scale.

[0070] Each increment step is essentially a time increment step. It is the unit for applying loads and boundary conditions; the unit for calculating contact pressure (p) and relative sliding displacement (s); the unit for calculating and accumulating wear depth (dW); and the unit for updating geometry.

[0071] As one implementation method, the preset operation further includes: calling the finite element model of the current time period and performing the following adaptive meshing operation in the full integral element mode: determining the pre-wear area of ​​the current time period and dividing the pre-wear area of ​​the current time period into multiple standard elements; selecting a preset number of integration points in each of the multiple standard elements; sampling and summing the relative displacements on the preset number of integration points in each standard element; and performing adaptive meshing on the multiple standard elements according to the displacement summation results to obtain the node set of the current time period; the node set includes multiple mesh nodes.

[0072] Adaptive meshing, also known as AMRAMR (Adaptive Mesh Refinement), is used to guide the movement of internal nodes based on stress and strain fields. While maintaining changes in boundary geometry (such as worn surfaces), it maximizes mesh quality and prevents excessive element distortion by rearranging internal nodes.

[0073] This implementation offers several advantages. First, fully integrated elements provide more integration points for collecting stress data. When AMRAMR technology needs to determine how to move internal nodes based on stress gradients, fully integrated elements offer richer and more continuous stress field information. This makes the mesh smoothing and rearrangement process more stable and reliable, and more effectively mitigates mesh distortion in stress concentration regions. Second, fully integrated elements inherently lack zero-energy modes. This inherent stability is crucial during the continuous mesh adjustment process of AMRAMR, ensuring that element deformation is a true physical response rather than numerical "noise," thus guaranteeing robust convergence of the entire simulation process.

[0074] As one implementation method, the segmented execution of the preset operation cycle process in step S12 above will be further explained.

[0075] First, the total wear simulation duration is divided into multiple time periods in sequence.

[0076] Each time period has a preset duration; each time period is a segment.

[0077] Secondly, if the execution time of the finite element model and wear model in any time period reaches the preset duration corresponding to that time period, it is determined that the mesh reconstruction condition is met; otherwise, it is determined that the mesh reconstruction condition is not met, the execution of the finite element model and wear model in any time period is stopped, and the next time period is entered in sequence.

[0078] Third, the simulation continues sequentially until the preset operation is completed in the last time slot, at which point the entire process stops.

[0079] As another implementation method, the segmented execution of the preset operation cycle process in step S12 above will be further explained.

[0080] First, determine the preset wear depth and preset depth difference corresponding to the multiple segments divided in sequence.

[0081] Secondly, if the wear depth output by the wear model is detected at any time within any segment and is greater than or equal to the corresponding preset wear depth, the mesh reconstruction condition is determined to be met; otherwise, the mesh reconstruction condition is determined not to be met.

[0082] Third, stop calling and executing the finite element model and wear model for any time period, and proceed to the next time period in sequence.

[0083] Fourth, the simulation continues in sequence until the preset wear depth reaches the total wear depth threshold or the total wear simulation time is reached, at which point the entire simulation prediction process stops.

[0084] As one implementation method, step S13 above is specifically implemented in the following manner.

[0085] Firstly, based on the simulated time, data analysis and data fitting are performed on the wear depth sets of each segment to obtain the first relationship graph of the maximum wear depth versus time.

[0086] Secondly, based on the simulation time, data analysis and data fitting were performed on the wear volume of each segment to obtain a second relationship graph of wear volume versus time.

[0087] Third, based on the wear depth set of each segment and the morphological parameters of each segment, a third relationship diagram of the relationship between wear volume and wear depth is established.

[0088] Based on this implementation method, the wear process distribution is visualized from three different wear parameter dimensions.

[0089] In one implementation, multiple components to be analyzed have contact surfaces with preset curvature characteristics.

[0090] Also known as general curvature features. Compared to non-general curvature (regular surface) features, general curvature (complex surface) features refer to surfaces with uneven and varied curvature. Examples include: wavy surfaces; grooves or protrusions of arbitrary shapes; contact surfaces between engine blades; and the morphology of a originally regular surface that becomes uneven after initial wear.

[0091] For example, the aforementioned components to be analyzed include, but are not limited to, the following in a nuclear reactor: fuel cladding and grid support, heat transfer tubes and support plates or vibration damping strips, guide components and load-bearing surfaces of control rod drive mechanisms, and plate-like components and connecting or supporting elements of in-core components.

[0092] As a specific implementation method, the above-mentioned wear process simulation and prediction method will be further explained in detail through the following steps.

[0093] First, the computational model mesh setup. A locally refined finite element model of the wear zone is established, and the geometric model and mesh information of the wear zone are imported or generated in the finite element simulation software. Local mesh refinement is performed near the contact surface area to achieve the mesh requirements for accurate calculation of contact pressure; that is, the solution for contact pressure at the contact area is independent of the mesh size. Note that the mesh type cannot be reduced integration elements; only fully integrated elements can be selected. Reduced integration elements cannot use AMR adaptive meshing technology to change the model geometry.

[0094] Secondly, the wear surface contact settings are configured. Contact pairs are set up for areas where contact may occur, with the side whose wear behavior will be simulated designated as the slave surface. The normal contact property is set to hard contact, allowing separation after contact. The tangential contact property is set to tangential friction, using the Coulomb friction model, and an appropriate friction coefficient is set for this contact pair.

[0095] Third, load and boundary settings. In the loading module, the movement of each part is controlled by setting the displacement boundary conditions of each assembly (Instance) to simulate the relative sliding caused by external loads during fretting wear; the squeezing interaction between each part is controlled by setting the normal force load conditions of each assembly to simulate the contact surface squeezing caused by external loads during fretting wear.

[0096] Fourth, AMR adaptive mesh settings. The region in the finite element model where contact and fretting wear may occur is called the pre-wear zone. The nodes on the surface of the pre-wear zone are pre-set as a node set, called the wear surface node set; the mesh elements contained within the pre-wear zone are also pre-set as a set, called the wear region element set. Note that at least every element containing nodes from the wear surface node set should be in this element set. In the adaptive mesh domain, the region is set to the previously preset wear region element set; in the adaptive mesh constraint, the region is set to the previously preset wear surface node set, and the motion mode is set to user-defined. Selecting this mode requires writing a user-defined adaptive mesh boundary constraint subroutine to implement customized control of node behavior.

[0097] Fifth, user subroutine writing. User subroutines are written to call the solution variables at each node during the calculation process: contact pressure and relative sliding displacement, and write them to a local storage file. The absolute value of the difference between the relative sliding displacement of the node at the current moment and the relative sliding displacement at the previous moment is the relative sliding distance increment at that node in this time increment. The contact pressure and relative sliding increment are then substituted into the Archard wear depth formula to calculate the node wear depth, which is written to the calculation file. This allows the surface node coordinates to be changed and the surface morphology updated before the start of the next incremental step.

[0098] Sixth, the wear calculation job file is generated and associated with the user subroutine for calculation. The established finite element model with local contact refinement is used to generate a command stream file for calculation. When submitting the job through the user interface or command line, the command stream file and user subroutine are associated to start the calculation.

[0099] Seventh, the deformation method for reading wear calculation results. After the wear calculation over a period of time is completed or terminated, a corresponding result file is generated. A script is written to post-process the result file after the calculation is completed to obtain the wear morphology. The simplified process of automated post-processing is as follows: extract the wear morphology and wear simulation duration at the final moment from the result file, import the deformed model into a temporary new simulation model file, build a new model, and generate a temporary calculation command stream file containing part name, part node number, and node coordinate information for this temporary new model.

[0100] Eighth, parameterization of wear calculation files and submission of associated subroutines. An automated script is written to read the previously established finite element model with refined contact localities and generate a command stream file for finite element software calculations. The node numbers and coordinates of the parts in this file are replaced with the deformed node numbers and coordinates from the temporary command stream file in the previous step, thus completing the inheritance of wear morphology between different wear segments. The finite element software console program is then invoked to associate the newly generated command stream file for continuous wear calculations with the user subroutine, and the continuous calculation begins.

[0101] Ninth, the criteria for splitting long-cycle, high-volume wear problems into segmentation methods and wear continuity calculation methods. There are two main criteria for splitting long-cycle wear problems into multiple short-term, low-depth fretting wear problems for continuity calculation: One is to monitor the background process of the finite element software calculation, and when the calculation diverges, automatically segment and execute the above-mentioned continuity calculation process; the other is to pre-set the calculation time for each wear segment based on engineering experience, and automatically stop segmentation and execute the above-mentioned continuity calculation process after each segment's calculation reaches the preset time.

[0102] To achieve the above functions, the wear process simulation and prediction device includes hardware structures and / or software modules corresponding to the execution of each function. Those skilled in the art will readily recognize that, based on the algorithmic steps of the examples described in conjunction with the embodiments disclosed herein, this application can be implemented in hardware or a combination of hardware and computer software. Whether a function is executed in hardware or by computer software driving hardware depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0103] This disclosure also provides an embodiment such as Figure 9 The wear process simulation and prediction device shown includes: a construction unit 91, a segmented calculation unit 92, and a prediction unit 93.

[0104] Building unit 91 is used to construct a finite element model between multiple parts to be analyzed based on the initial morphological parameters of multiple parts to be analyzed.

[0105] The segmented calculation unit 92 is used to perform preset operations segment by segment according to the mesh reconstruction conditions, based on the finite element model and the wear model, to obtain the wear depth set and the morphology parameters of each segment. The preset operations include: real-time detection that the mesh reconstruction conditions are met in the current time period; stopping the invocation of the finite element model and the wear model in the current time period, determining the wear depth set and the morphology parameters in the current time period, updating the morphology parameters of the finite element model based on the morphology parameters in the current time period, invoking the updated finite element model and the wear model, and determining the wear depth set and the morphology parameters in the next time period for multiple components to be analyzed.

[0106] The prediction unit 93 is used to determine the wear process distribution among multiple components to be analyzed based on the wear depth set of each segment and the morphology parameters of each segment.

[0107] In one implementation, the preset operation further includes: detecting that the current time period does not meet the mesh reconstruction conditions, calling the finite element model and wear model of the current time period according to the preset frequency, determining the wear depth of each mesh node in each frequency and determining the node coordinates of each mesh node in each frequency; and determining the morphology parameters of the current time period based on the node coordinates of each mesh node in each frequency.

[0108] In another implementation, the preset operation further includes: calling the finite element model of the current time period and performing the following adaptive meshing operation in the full integral element mode: determining the pre-wear region of the current time period and dividing the pre-wear region of the current time period into multiple standard elements; selecting a preset number of integration points in each of the multiple standard elements; sampling and summing the relative displacements on the preset number of integration points in each standard element; and performing adaptive meshing on the multiple standard elements according to the displacement summation result to obtain the node set of the current time period; the node set includes multiple mesh nodes.

[0109] In another implementation, the segmented calculation unit 92 is specifically used to: divide the total wear simulation time into multiple time periods in sequence; wherein each time period corresponds to a preset time period; each time period is a segment; if it is detected that the execution time of the finite element model and wear model in any time period reaches the preset time period corresponding to any time period, it is determined that the mesh reconstruction condition is met, the execution of the finite element model and wear model in any time period is stopped, and the next time period of any time period is entered in sequence.

[0110] In another implementation, the segmented calculation unit 92 is specifically used to: determine the preset wear depth and preset depth difference corresponding to the multiple segments divided in sequence; if the wear depth output by the wear model is detected at any detection time within any segment and is greater than or equal to the corresponding preset wear depth, or if the depth difference between the wear depth output by the wear model at any detection time within any segment and the wear depth output by the wear model at the initial detection time within any segment is greater than the preset depth difference, determine that the mesh reconstruction condition is met, stop calling and executing the finite element model and wear model for any time period, and sequentially enter the next time period of any time period.

[0111] In another implementation, the wear model is based on the following formula:

[0112] Where W is the local wear depth; s is the sliding distance; K is the wear coefficient; p is the local contact pressure; t is the time; and x is the xth node.

[0113] In another implementation, the prediction unit 93 is specifically used to: perform data analysis and data fitting on the wear depth set of each segment according to the simulation time to obtain a first relationship graph of wear depth versus time; perform data analysis and data fitting on the morphology parameters of each segment according to the simulation time to obtain a second relationship graph of morphology parameters versus time; and establish a third relationship graph of wear volume versus wear depth based on the wear depth set of each segment and the morphology parameters of each segment.

[0114] In another embodiment, the multiple components to be analyzed have contact surfaces with a preset curvature characteristic; the multiple components to be analyzed include any one of the following: nuclear reactor fuel cladding and grid support, heat transfer tubes and support plates or vibration damping strips in the nuclear reactor, guide components and load-bearing surfaces of the control rod drive mechanism in the nuclear reactor, plate-shaped components and connecting or supporting components of in-core components, and main pipes and wave pipes of the control rod drive mechanism.

[0115] Regarding the apparatus in the above embodiments, the specific manner in which each unit module performs its operations has been described in detail in the embodiments related to the method, and will not be elaborated upon here.

[0116] Figure 10 This is a schematic diagram of an electronic device provided in this application. (For example...) Figure 10 The electronic device 60 may include at least one processor 601 and a memory 603 for storing processor-executable instructions. The processor 601 is configured to execute the instructions in the memory 603 to implement the wear process simulation and prediction method in the following embodiments.

[0117] In addition, the electronic device 60 may also include a communication bus 602, at least one communication interface 604, an input device 606, and an output device 605.

[0118] The processor 601 may be a processor (central processing unit, CPU), a microprocessor unit, an ASIC, or one or more integrated circuits for controlling the execution of the program of the present application.

[0119] The communication bus 602 may include a path for transmitting information between the aforementioned components.

[0120] Communication interface 604 uses any transceiver-like device for communicating with other devices or communication networks, such as Ethernet, radio access network (RAN), wireless local area networks (WLAN), etc.

[0121] Input device 606 is used to receive input signals and output device 605 is used to output signals.

[0122] The memory 603 may be a read-only memory (ROM) or other type of static storage device capable of storing static information and instructions, random access memory (RAM) or other type of dynamic storage device capable of storing information and instructions, or electrically erasable programmable read-only memory (EEPROM), compact disc read-only memory (CD-ROM) or other optical disc storage, optical disc storage (including compressed discs, laser discs, optical discs, digital universal discs, Blu-ray discs, etc.), magnetic disk storage media or other magnetic storage devices, or any other medium capable of carrying or storing desired program code in the form of instructions or data structures and accessible by a computer, but not limited thereto. The memory may exist independently and be connected to the processing unit via a bus. The memory may also be integrated with the processing unit.

[0123] The memory 603 stores instructions for executing the scheme of this application, and the processor 601 controls the execution. The processor 601 executes the instructions stored in the memory 603 to realize the functions of the method of this application.

[0124] In a specific implementation, as one embodiment, the processor 601 may include one or more CPUs, for example... Figure 10CPU0 and CPU1 in the CPU.

[0125] In a specific implementation, as one example, the electronic device 60 may include multiple processors, such as... Figure 10 Processors 601 and 607 are described herein. Each of these processors may be a single-core (single-CPU) processor or a multi-core (multi-CPU) processor. A processor here may refer to one or more devices, circuits, and / or processing cores used to process data (such as computer program instructions).

[0126] The electronic device is as follows Figure 10 The diagram includes a processor 601 and a memory 603 for storing executable instructions of the processor 601; wherein the processor 601 is configured to execute executable instructions to implement the wear process simulation and prediction method as described in any of the possible embodiments above. And it can achieve the same technical effect, so to avoid repetition, it will not be described again here.

[0127] This application also provides a computer-readable storage medium, which, when executed by a processor of a wear process simulation and prediction device or electronic device, enables the wear process simulation and prediction device or electronic device to perform a wear process simulation and prediction method as described in any of the possible embodiments above. The same technical effects can be achieved, and to avoid repetition, further details are omitted here.

[0128] This application also provides a computer program product, including a computer program or instructions, which are executed by a processor as a wear process simulation and prediction method according to any of the possible implementations described above. It achieves the same technical effects, and to avoid repetition, will not be described again here.

[0129] Other embodiments of this application will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein. The specification and examples are to be considered exemplary only, and the true scope and spirit of this application are indicated by the following claims.

[0130] It should be understood that this application is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. A method for simulating and predicting dynamic wear processes with long-term, high-volume wear between structures, characterized in that, The method includes: Based on the initial morphological parameters of multiple components to be analyzed, a finite element model is constructed between the multiple components to be analyzed; According to the mesh reconstruction conditions, based on the finite element model and the wear model, preset operations are performed in segments to obtain the wear depth set of each segment and the morphology parameters of each segment. The preset operation includes: real-time detection that the current time period meets the mesh reconstruction condition; stopping the invocation of the finite element model and the wear model for the current time period, determining the wear depth set and the morphology parameters for the current time period, and performing mesh reconstruction on the finite element model based on the morphology parameters for the current time period; invoking the finite element model and the wear model after mesh reconstruction, and determining the wear depth set and the morphology parameters for the next time period for the multiple components to be analyzed. Based on the wear depth set of each segment and the morphological parameters of each segment, the wear process distribution among the multiple components to be analyzed is determined.

2. The method according to claim 1, characterized in that, The preset operation further includes: detecting that the current time period does not meet the mesh reconstruction conditions, calling the finite element model and the wear model of the current time period according to a preset frequency, determining the wear depth of each mesh node in each frequency and determining the node coordinates of each mesh node in each frequency; and determining the morphology parameters of the current time period based on the node coordinates of each mesh node in each frequency.

3. The method according to claim 1, characterized in that, The preset operation further includes: calling the finite element model of the current time period and performing the following adaptive meshing operation in the full integral element mode: determining the pre-wear region of the current time period and dividing the pre-wear region of the current time period into multiple standard elements; selecting a preset number of integration points in each of the multiple standard elements; sampling and summing the relative displacements on the preset number of integration points in each standard element; and performing adaptive meshing on the multiple standard elements according to the displacement summation result to obtain the node set of the current time period; the node set includes multiple mesh nodes.

4. The method according to claim 2, characterized in that, The step of performing preset operations in segments according to the mesh reconstruction conditions, based on the finite element model and the wear model, includes: The total wear simulation duration is divided into multiple time periods in sequence; each time period corresponds to a preset duration; each time period is a segment. If the execution time of the finite element model and the wear model in any time period is detected to reach the preset duration corresponding to that time period, then it is determined that the mesh reconstruction condition is met, the execution of the finite element model and the wear model in that time period is stopped, and the next time period is entered in sequence.

5. The method according to claim 2, characterized in that, The step of performing preset operations in segments according to the mesh reconstruction conditions, based on the finite element model and the wear model, includes: Determine the preset wear depth and preset depth difference corresponding to the multiple segments divided in sequence; If the wear depth output by the wear model is detected at any detection time within any segment and is greater than or equal to the corresponding preset wear depth, or if the depth difference between the wear depth output by the wear model and the wear depth output by the wear model at the initial detection time within any segment is greater than the preset depth difference, it is determined that the mesh reconstruction condition is met, the execution of the finite element model and the wear model in any time period is stopped, and the next time period of any time period is entered in sequence.

6. The method according to any one of claims 1 to 4, characterized in that, The wear model is based on the following formula: Where W is the local wear depth; s is the sliding distance; K is the wear coefficient; p is the local contact pressure; t is the time; and x is the xth node.

7. The method according to any one of claims 1 to 4, characterized in that, The determination of the wear process distribution among the multiple components to be analyzed, based on the wear depth set of each segment and the morphological parameters of each segment, includes: Based on the simulated time, data analysis and data fitting are performed on the wear depth sets of each segment to obtain the first relationship graph of wear depth versus time; Based on the simulation time, data analysis and data fitting are performed on the morphological parameters of each segment to obtain a second relationship graph between morphological parameters and time. Based on the wear depth set of each segment and the morphological parameters of each segment, a third relationship diagram is established to represent the relationship between wear volume and wear depth.

8. The method according to any one of claims 1 to 4, characterized in that, The plurality of components to be analyzed have contact surfaces with preset curvature characteristics; the plurality of components to be analyzed include any one of the following: nuclear reactor fuel cladding and grid support, heat transfer tubes and support plates or vibration damping strips in the nuclear reactor, guide components and load-bearing surfaces of the control rod drive mechanism in the nuclear reactor, plate-shaped components and connecting or supporting components of in-core components, and main pipes and wave pipes of the control rod drive mechanism.

9. A wear process simulation and prediction device, characterized in that, The device includes: The building unit is used to construct a finite element model between multiple parts to be analyzed based on the initial morphological parameters of multiple parts to be analyzed; The segmented calculation unit is used to perform preset operations segment by segment according to the mesh reconstruction conditions, based on the finite element model and the wear model, to obtain the wear depth set and morphology parameters of each segment. The preset operations include: real-time detection that the current time period meets the mesh reconstruction conditions; stopping the invocation of the finite element model and the wear model for the current time period; determining the wear depth set and morphology parameters for the current time period; updating the morphology parameters of the finite element model based on the morphology parameters for the current time period; invoking the updated finite element model and the wear model to determine the wear depth set and morphology parameters for the next time period in the multiple components to be analyzed. The prediction unit is used to determine the wear process distribution among the multiple components to be analyzed based on the wear depth set of each segment and the morphology parameters of each segment.

10. A computer-readable storage medium storing instructions thereon, characterized in that, When the instructions in the computer-readable storage medium are executed by the processor of the electronic device, the electronic device is able to perform the wear process simulation and prediction method as described in any one of claims 1-7.

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