转炉托圈和扭力杆的设计理论分析
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摘要
大吨位转炉设备属于重型设备,体积大,重量大,空间结构形式复杂。转炉设备运行于高温和冲击重载环境,运行工况十分恶劣。现有的结构力学设计理论不能胜任转炉设备设计的应力分析和变形分析,需要进行全尺寸、三维、复杂荷载下的热-机耦合非线性有限元分析和计算,计算建模工作量大,计算周期长,专业性强,设计院的普通设计工程师难以胜任,严重制约了我国大型转炉的自主创新设计。本文针对转炉设备中最为关键的两个部件,也是设计理论最为缺乏的变截面扭力杆和单箱双室水冷托圈进行研究,发展适合于普通工程设计师使用的新的设计理论和方法。
本文采用初等弹性理论和梁杆振动理论,建立了变截面扭力杆的应力、变形和振动理论分析模型,推导了应力、变形和振动理论公式。与三维全尺寸扭力杆有限元模型数值解的比较表明,理论解精度较高,适合于扭力杆的强度、刚度和振动特性的设计分析。
基于闭口薄壁杆件的约束扭转理论,建立了单箱双室闭口薄壁的托圈机械应力和机械变形分析的理论模型,推导了托圈内力、空间应力和空间变形理论公式。与三维全尺寸托圈结构有限元模型数值解的比较表明,理论解正确反映了托圈应力的复杂变化规律,精度较高,适用于基于机械荷载的托圈结构设计与分析。
根据大体积转炉炉体热辐射的特征,针对水冷托圈外表面温度场的径向、轴向和周向分布,提出了“二向线性(分布)理论”,推导了托圈空间温度场理论公式。与三维全尺寸托圈结构有限元模型温度场数值解的比较表明,理论解正确反映了温度的复杂变化规律,计算精度符合工程设计要求。
采用热弹性理论和力法,建立了单箱双室水冷托圈热应力和热变形分析的理论模型,推导了托圈空间热应力和空间热变形的理论公式。与三维全尺寸托圈结构有限元模型热应力和热变形数值解的比较表明,理论解可以正确反映热应力和热变形的变化规律,计算精度符合工程设计要求。
基于机械应力、机械变形、热应力和热变形的理论分析,采用应力分量和变形分量直接叠加的方法,建立了单箱双室水冷托圈的热-机耦合应力和祸合变形的理论求解方法。与三维全尺寸托圈结构有限元模型热-机耦合应力和热-机耦合变形数值解的比较表明,理论解可以正确反映耦合应力和耦合变形的复杂变化规律,计算精度符合工程设计要求,尤其是热-机耦合变形的理论解,具有相当高的计算精度。
由于所提出的应力和变形理论分析公式,均可以用解析式表达,计算编程简单,分析方便,大大缩短了扭力杆和托圈的设计周期,适合于普通设计工程师使用,从而为大型转炉的复杂扭力杆和托圈结构在复杂的机械载荷和热载荷联合作用下的结构设计,提供了简便、高效、可靠的新的设计理论方法。
Modern converters are heavy equipments of large volume, large tonnage and complicated spatial structural shapes. They are running under impact heavy loading and in high temperature environment. The existing structural design theory is incapable of analyzing of the spatial stress and deformation of converters. The three-dimensional nonlinear finite element technique with full size and full-shape of converters is required to calculate the thermo-mechanical coupled stress and deformation, in which the computational modeling is heavy workload and long computing cycles by professional computing staff. It is too hard to an ordinary design engineer. Such a situation has severely restricted the independent innovation of large-scale converter design.
This dissertation presents new design theories for two key equipments of converter, the torque bar with variable cross-sections and the water-cooled trunnion ring with single box and dual-chamber cross-sections. They are suitable for ordinary design engineers.
A theoretical modeling of the torque bar with variable cross-sections is established on the basis of the elementary elasticity theory and the torsional vibration theory. The analytical expressions of stress, strain and vibration are derived. The comparisons with the numerical solutions obtained by the full-size three-dimensional finite element method illustrates that the theoretical solutions have relatively high accuracy and can be applied to the design calculation of bar strength, stiffness and vibration property.
A bending and twisting mechanical modeling of the water-cooled trunnion ring with a single box and dual-chamber cross-section is established based on the closed thin-walled bar constraint torsion theory. The analytical expressions of internal force, mechanical stress, axis deflection, rotation angle as well as torsion angle in any section of the trunnion ring are derived under different mechanical loads, such as concentrated force, distributed force, bending moment and torque. The comparisons with the numerical solutions obtained by the full-size three-dimensional finite element modeling illustrate that the theoretical solutions are the correct expression of the complex variation of the stress and deformation and have relatively high accuracy. It can be applied to structural design of the water-cooled trunnion ring based on the mechanical loading.
The double-linear theory is presented to obtain the theoretical three-dimensional temperature field of the water-cooled trunnion ring in radial, axial and circumferential directions according the heat radiation characteristics of the large volume converter on the relatively small trunnion ring. The analytical expressions of spatial temperature distribution are derived. The comparisons with the numerical solutions obtained by the full-size three-dimensional finite element modeling illustrate that the theoretical solutions have relatively high accuracy and are the correct expressions of the complex variation of spatial temperature.
A thermo-stress and thermo-deformation modeling of the water-cooled trunnion ring with a single box and dual-chamber cross-section is established based on thermoelsticity and the force method of structural analysis. The analytical expressions of spatial thermo-stress and thermo-deformation distribution are derived. The comparisons with the numerical solutions obtained by the full-size three-dimensional finite element modeling illustrate that the theoretical solutions have relatively high accuracy to meet engineering requirements and are the correct expressions of the complex variations of spatial thermo-stress and thermo-deformation.
By the applications of the bending and twisting mechanical modeling, the double-linear theory, and the thermo-stress and thermo-deformation modeling of the water-cooled trunnion ring with a single box and dual-chamber cross-section, the theoretical solution method of the thermo-mechanical coupled stress and deformation is established by the sum of the corresponding stress and deformation components of mechanical loadings and thermo-loadings. The comparisons of the theoretical solutions with the numerical solutions obtained by the full-size three-dimensional finite element modeling show that the theoretical solutions have relatively high accuracy to meet engineering requirements and are the correct expressions of the complex variations of spatial thermo-mechanical coupled stress and deformation. Kspecially, the theoretical distributions of spatial thermo-mechanical coupled deformation are in high calculation accuracy.
The stress and deformation expressions presented in the dissertation are all the analytical expressions. They are simply to calculate hy the designed computer programming, and easy to be applied by ordinary design engineers. Hence, the calculation and design cycles should been shorten greatly.
本文采用初等弹性理论和梁杆振动理论,建立了变截面扭力杆的应力、变形和振动理论分析模型,推导了应力、变形和振动理论公式。与三维全尺寸扭力杆有限元模型数值解的比较表明,理论解精度较高,适合于扭力杆的强度、刚度和振动特性的设计分析。
基于闭口薄壁杆件的约束扭转理论,建立了单箱双室闭口薄壁的托圈机械应力和机械变形分析的理论模型,推导了托圈内力、空间应力和空间变形理论公式。与三维全尺寸托圈结构有限元模型数值解的比较表明,理论解正确反映了托圈应力的复杂变化规律,精度较高,适用于基于机械荷载的托圈结构设计与分析。
根据大体积转炉炉体热辐射的特征,针对水冷托圈外表面温度场的径向、轴向和周向分布,提出了“二向线性(分布)理论”,推导了托圈空间温度场理论公式。与三维全尺寸托圈结构有限元模型温度场数值解的比较表明,理论解正确反映了温度的复杂变化规律,计算精度符合工程设计要求。
采用热弹性理论和力法,建立了单箱双室水冷托圈热应力和热变形分析的理论模型,推导了托圈空间热应力和空间热变形的理论公式。与三维全尺寸托圈结构有限元模型热应力和热变形数值解的比较表明,理论解可以正确反映热应力和热变形的变化规律,计算精度符合工程设计要求。
基于机械应力、机械变形、热应力和热变形的理论分析,采用应力分量和变形分量直接叠加的方法,建立了单箱双室水冷托圈的热-机耦合应力和祸合变形的理论求解方法。与三维全尺寸托圈结构有限元模型热-机耦合应力和热-机耦合变形数值解的比较表明,理论解可以正确反映耦合应力和耦合变形的复杂变化规律,计算精度符合工程设计要求,尤其是热-机耦合变形的理论解,具有相当高的计算精度。
由于所提出的应力和变形理论分析公式,均可以用解析式表达,计算编程简单,分析方便,大大缩短了扭力杆和托圈的设计周期,适合于普通设计工程师使用,从而为大型转炉的复杂扭力杆和托圈结构在复杂的机械载荷和热载荷联合作用下的结构设计,提供了简便、高效、可靠的新的设计理论方法。
Modern converters are heavy equipments of large volume, large tonnage and complicated spatial structural shapes. They are running under impact heavy loading and in high temperature environment. The existing structural design theory is incapable of analyzing of the spatial stress and deformation of converters. The three-dimensional nonlinear finite element technique with full size and full-shape of converters is required to calculate the thermo-mechanical coupled stress and deformation, in which the computational modeling is heavy workload and long computing cycles by professional computing staff. It is too hard to an ordinary design engineer. Such a situation has severely restricted the independent innovation of large-scale converter design.
This dissertation presents new design theories for two key equipments of converter, the torque bar with variable cross-sections and the water-cooled trunnion ring with single box and dual-chamber cross-sections. They are suitable for ordinary design engineers.
A theoretical modeling of the torque bar with variable cross-sections is established on the basis of the elementary elasticity theory and the torsional vibration theory. The analytical expressions of stress, strain and vibration are derived. The comparisons with the numerical solutions obtained by the full-size three-dimensional finite element method illustrates that the theoretical solutions have relatively high accuracy and can be applied to the design calculation of bar strength, stiffness and vibration property.
A bending and twisting mechanical modeling of the water-cooled trunnion ring with a single box and dual-chamber cross-section is established based on the closed thin-walled bar constraint torsion theory. The analytical expressions of internal force, mechanical stress, axis deflection, rotation angle as well as torsion angle in any section of the trunnion ring are derived under different mechanical loads, such as concentrated force, distributed force, bending moment and torque. The comparisons with the numerical solutions obtained by the full-size three-dimensional finite element modeling illustrate that the theoretical solutions are the correct expression of the complex variation of the stress and deformation and have relatively high accuracy. It can be applied to structural design of the water-cooled trunnion ring based on the mechanical loading.
The double-linear theory is presented to obtain the theoretical three-dimensional temperature field of the water-cooled trunnion ring in radial, axial and circumferential directions according the heat radiation characteristics of the large volume converter on the relatively small trunnion ring. The analytical expressions of spatial temperature distribution are derived. The comparisons with the numerical solutions obtained by the full-size three-dimensional finite element modeling illustrate that the theoretical solutions have relatively high accuracy and are the correct expressions of the complex variation of spatial temperature.
A thermo-stress and thermo-deformation modeling of the water-cooled trunnion ring with a single box and dual-chamber cross-section is established based on thermoelsticity and the force method of structural analysis. The analytical expressions of spatial thermo-stress and thermo-deformation distribution are derived. The comparisons with the numerical solutions obtained by the full-size three-dimensional finite element modeling illustrate that the theoretical solutions have relatively high accuracy to meet engineering requirements and are the correct expressions of the complex variations of spatial thermo-stress and thermo-deformation.
By the applications of the bending and twisting mechanical modeling, the double-linear theory, and the thermo-stress and thermo-deformation modeling of the water-cooled trunnion ring with a single box and dual-chamber cross-section, the theoretical solution method of the thermo-mechanical coupled stress and deformation is established by the sum of the corresponding stress and deformation components of mechanical loadings and thermo-loadings. The comparisons of the theoretical solutions with the numerical solutions obtained by the full-size three-dimensional finite element modeling show that the theoretical solutions have relatively high accuracy to meet engineering requirements and are the correct expressions of the complex variations of spatial thermo-mechanical coupled stress and deformation. Kspecially, the theoretical distributions of spatial thermo-mechanical coupled deformation are in high calculation accuracy.
The stress and deformation expressions presented in the dissertation are all the analytical expressions. They are simply to calculate hy the designed computer programming, and easy to be applied by ordinary design engineers. Hence, the calculation and design cycles should been shorten greatly.
引文
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