DB43-T 2314-2022 特種設(shè)備焊接殘余應(yīng)力盲孔法測(cè)試方法

ICS

25.160.40CCS

43湖 南 省 地 方標(biāo) 準(zhǔn)DB43/T

2314—2022特種設(shè)備焊接殘余應(yīng)力盲孔法測(cè)試方法Test

method

for

welding

residual

stress

of

special

equipmentby

blind

hole

method2022

-

05

-

06

發(fā)布

2022

-

-

實(shí)施湖南省市場(chǎng)監(jiān)督管理局

發(fā)

布DB43/T

2314— 前言························································································································

Ⅲ1·····················································································································

12規(guī)范性引用文件······································································································13術(shù)語(yǔ)與符號(hào)············································································································14 工件準(zhǔn)備···············································································································25應(yīng)變花與儀器·········································································································35.1 應(yīng)變花幾何形狀································································································

35.2 標(biāo)準(zhǔn)應(yīng)變花······································································································35.3 安裝及使用······································································································35.4儀器···············································································································46 試驗(yàn)和測(cè)量············································································································46.1 試驗(yàn)技術(shù)·········································································································46.2 應(yīng)力測(cè)量·········································································································47 計(jì)算方法···············································································································57.1 計(jì)算步驟及過(guò)程································································································

58 孔邊塑性變形的修正································································································

58.1 修正原理·········································································································58.2鉆孔加工塑性應(yīng)變修正法····················································································

58.3 鉆孔應(yīng)力集中塑性應(yīng)變修正法

··············································································59·····················································································································

79.1 測(cè)試報(bào)告·········································································································7附錄

A（資料性） 鉆孔偏心的修正················································································8參考文獻(xiàn)··················································································································

10DB43/T

2314— 本文件按照

GB/T

—2020《標(biāo)準(zhǔn)化工作導(dǎo)則 第

1

部分：標(biāo)準(zhǔn)化文件的結(jié)構(gòu)和起草規(guī)則》的規(guī)定起草。請(qǐng)注意本文件的某些內(nèi)容可能涉及專利。本文件的發(fā)布機(jī)構(gòu)不承擔(dān)識(shí)別專利的責(zé)任。本文件由湖南省市場(chǎng)監(jiān)督管理局提出。本文件由湖南省特種設(shè)備標(biāo)準(zhǔn)化技術(shù)委員會(huì)歸口。新力機(jī)械有限公司。李檢保、邵支農(nóng)、林穩(wěn)、許福、陳俊、楊才千、張衡、向麗、曾凡小、袁朝陽(yáng)、羅奇志、王觀次、郭躍飛。IIIDB43/T

2314—1

步驟及計(jì)算方法。本文件適用于可消耗或小淺孔不影響使用的特種設(shè)備焊縫處進(jìn)行平面應(yīng)力梯度較小的焊接殘余應(yīng)力測(cè)定。2

規(guī)范性引用文件文件。SL

499 鉆孔應(yīng)變法測(cè)量殘余應(yīng)力的標(biāo)準(zhǔn)測(cè)試方法CB

3395 殘余應(yīng)力測(cè)試方法鉆孔應(yīng)變釋放法3

術(shù)語(yǔ)與符號(hào)3.1術(shù)語(yǔ)與定義

and

definitions下述術(shù)語(yǔ)和定義適用于本文件。3.1.1特種設(shè)備焊接殘余應(yīng)力 Residual

welding

of

equipment特種設(shè)備在焊接過(guò)程中產(chǎn)生的局部殘余應(yīng)力。3.1.2特種設(shè)備焊接高殘余應(yīng)力

特種設(shè)備在焊接過(guò)程中產(chǎn)生大于焊接部位材料

1/2

屈服強(qiáng)度的局部殘余應(yīng)力。3.1.3應(yīng)力標(biāo)定常數(shù)

constant貼位置、孔的形狀和大小有關(guān)。3.1.4釋放應(yīng)變 Release

strain對(duì)具有焊接殘余應(yīng)力場(chǎng)的特種設(shè)備結(jié)構(gòu)件鉆孔，其鉆孔前后應(yīng)變的變化量。3.1.5鉆孔 Drill

hole成孔轉(zhuǎn)速在每分鐘數(shù)千轉(zhuǎn)，尤其指手電鉆的加工方式。σ

——標(biāo)定時(shí)的外加應(yīng)力，其數(shù)值從零到材料的屈服點(diǎn)，N/mm

；DB43/T

σ

——標(biāo)定時(shí)的外加應(yīng)力，其數(shù)值從零到材料的屈服點(diǎn)，N/mm

；3.2符號(hào)和說(shuō)明

and

descriptions下述符號(hào)和說(shuō)明適用于本文件。D ——測(cè)量圓直徑；D ——鉆孔直徑；E ——楊氏模量；Ε ——均布應(yīng)力釋放應(yīng)變；ν ——泊松比；σ ——x

向均布正應(yīng)力；σ ——y

向均布正應(yīng)力；h——鉆孔深度；σ——?dú)堄鄳?yīng)力初算值；κ ——?dú)堄鄳?yīng)力初算值與試件屈服強(qiáng)度的比值。ε ——因鉆削加工引起的塑性應(yīng)變；ε ——純彈性釋放應(yīng)變；ε ——由應(yīng)力集中引起的塑性應(yīng)變。Q、Q

——過(guò)渡系數(shù)；ε、ε

——x，y

方向應(yīng)變花中的彈性釋放應(yīng)變。ε、ε

——實(shí)測(cè)應(yīng)變中

x、y

方向的塑性應(yīng)變分量；ε’、——單向標(biāo)定應(yīng)變中

x、y

方向的塑性應(yīng)變分量；2ε ——標(biāo)定材料的屈服應(yīng)變。4

工件準(zhǔn)備4.1

60

達(dá)到

Ra3.2～6.4，面積不小于應(yīng)變花面積的四倍，且不應(yīng)采用明顯改變測(cè)試表面應(yīng)力狀況的刮磨或研磨。4.2 表面預(yù)處理應(yīng)嚴(yán)格限制，不應(yīng)使用明顯改變表面殘余應(yīng)力狀況的方法。詳細(xì)測(cè)量過(guò)程見(jiàn)

SL

499。4.3 對(duì)特種設(shè)備受試工件，應(yīng)在應(yīng)變花中心處上鉆一通孔，應(yīng)變花見(jiàn)圖

1。詳細(xì)鉆孔步驟見(jiàn)

SL

499。

圖

1鉆孔應(yīng)變花DB43/T

2314—5

應(yīng)變計(jì)與儀器5.1 應(yīng)變花幾何形狀5.1.1 應(yīng)變花應(yīng)包含

3

3

對(duì)應(yīng)變計(jì)，應(yīng)變計(jì)的編碼應(yīng)遵循順時(shí)針（CW）編碼規(guī)則。5.1.2 應(yīng)變計(jì)應(yīng)陣列于圓形圖樣上，與應(yīng)變花中心等距離。5.1.3

3

2

所示，“12

45°或

13532135.1.4 圖

2

中應(yīng)變計(jì)

l

的方向定義為測(cè)試方向的

x

軸，y

軸為

x

軸逆時(shí)針旋轉(zhuǎn)

90°。5.1.5 應(yīng)變花測(cè)量圓的中心應(yīng)能清晰可辨。a）應(yīng)變花布置b）應(yīng)變計(jì)詳圖GLGW圖

2典型

3

單元順時(shí)針編碼規(guī)則應(yīng)變花幾何尺寸5.2 標(biāo)準(zhǔn)應(yīng)變花5.2.1

1

所示，其對(duì)應(yīng)尺寸見(jiàn)表

1。5.2.2圖

1

中

A

型應(yīng)變花有幾種不同的幾何尺寸，為通用類型。5.2.3 圖

1

中

B

型應(yīng)變花的應(yīng)變計(jì)都位于同一側(cè)，適用于障礙物附近的測(cè)試。5.2.4圖

1

中

C

型應(yīng)變花為特殊用途應(yīng)變花，適用于應(yīng)變靈敏度和熱穩(wěn)定性要求較高的測(cè)試。5.3 安裝及使用5.3.1 應(yīng)變花應(yīng)粘貼于離測(cè)試工件邊沿至少

D

5.3.2

B

0.5D于障礙物切線的法線上。

0.309

0.309

0.3455

0.65450.79mm1/32in2.57

0.79

2.57

0.89

1.680.101

0.031

0.101

0.035

0.0661.59mm1/16in5.13

1.59

1.59

1.77

3.360.202

0.062

0.062

0.070

0.1323.18mm1/8in10.26

3.18

3.18

3.54

6.720.404

0.125

0.125

0.140

0.264

0.309

0.223

0.3455

0.65451.59mm1/16in5.13

1.59

1.14

1.17

3.360.202

0.062

0.045

0.070

0.132

0.176

30

0.412

0.5881.59mm1/16in4.32

0.76

30

1.78

2.450.170

0.030

30

0.070

0.100

DB43/T

2314—5.3.3 操作應(yīng)變計(jì)（粘貼、焊引線、防護(hù)涂層）時(shí)應(yīng)嚴(yán)格按照出廠說(shuō)明書(shū)操作，并在鉆孔過(guò)程中保護(hù)好應(yīng)變計(jì)。5.3.4應(yīng)變計(jì)應(yīng)保證永久性連接，應(yīng)確認(rèn)其安裝穩(wěn)定性。接地絕緣電阻應(yīng)不小于

20000

。5.3.5 應(yīng)變計(jì)安裝完畢后應(yīng)進(jìn)行檢查。表

1 應(yīng)變花直徑表

1 應(yīng)變花直徑電阻應(yīng)變儀的精度應(yīng)不低于±1×10

1×10

-6 -6

A

型和

B

型應(yīng)變花應(yīng)采用三線溫度補(bǔ)償電路，C

以指定的

ε，ε和

ε表示，操作步驟見(jiàn)

。6

試驗(yàn)和測(cè)量6.1 試驗(yàn)技術(shù)6.1.1不確定的鉆孔測(cè)試技術(shù)操作規(guī)程易導(dǎo)致不精確的測(cè)試結(jié)果，詳細(xì)鉆孔步驟見(jiàn)

SL

499。6.1.2 在條件達(dá)到的情況下，應(yīng)對(duì)盲孔法與其他技術(shù)進(jìn)行驗(yàn)證，進(jìn)行不確定性分析，以確定和量化其測(cè)量不確定度。6.1.3 小尺寸的應(yīng)變花可測(cè)量近表面的殘余應(yīng)力值。6.2應(yīng)力測(cè)量6.2.1將粘貼好電阻應(yīng)變花的特種設(shè)備工件安裝在試驗(yàn)機(jī)上，并將測(cè)量導(dǎo)線接至應(yīng)變儀上調(diào)零。然后進(jìn)行鉆孔，待孔的直徑和深度達(dá)到要求時(shí)，記錄其應(yīng)變讀數(shù)。6.2.2 使用鉆孔方法，在不產(chǎn)生明顯的加工應(yīng)力狀況下，整個(gè)孔深范圍內(nèi)測(cè)定的殘余應(yīng)力偏差應(yīng)不超過(guò)±10％。6.2.3保證測(cè)試環(huán)境穩(wěn)定、讀數(shù)精準(zhǔn)、應(yīng)變計(jì)完好。DB43/T

2314—6.2.4

6

單元的

C

型應(yīng)變花，用于重要測(cè)量和低傳導(dǎo)率材料的測(cè)量。7

計(jì)算方法7.1 計(jì)算步驟及過(guò)程詳細(xì)計(jì)算步驟見(jiàn)

CB

3395，計(jì)算過(guò)程中對(duì)偏心孔殘余應(yīng)力的修正見(jiàn)附錄

A。8

孔邊塑性變形的修正8.1 修正原理8.1.1 特種設(shè)備因其材料、結(jié)構(gòu)的特殊性，在焊接過(guò)程中易產(chǎn)生較高的焊接殘余應(yīng)力。在盲孔法測(cè)試和鉆孔應(yīng)力集中引起的塑性應(yīng)變

ε和

ε的確定是提高測(cè)量精度的關(guān)鍵。在所測(cè)量的總應(yīng)變

ε

中，包含如公式（1）所示的三部分應(yīng)變：=d

e

p?????????????????????（1）8.2 鉆孔加工塑性應(yīng)變修正法對(duì)無(wú)應(yīng)力試樣按本文件方法鉆孔測(cè)定

ε，然后從測(cè)量的總應(yīng)變

ε

中將其減去。8.3鉆孔應(yīng)力集中塑性應(yīng)變修正法8.3.1 應(yīng)變釋放系數(shù)分級(jí)計(jì)算法8.3.1.1 A、B

系數(shù)分級(jí)的依據(jù)。當(dāng)殘余應(yīng)力的方向已知時(shí)。用公式（2）和公式（3）計(jì)算殘余應(yīng)力。

4

y

Bx

y

Ax

y

4AB???????????????（3）

A、B

變化，A、B

也將有一系列數(shù)值，公式（2）和公式（3）可改寫(xiě)為公式（4）和公式（5）。

x

2xp

yp

xp

yp2s

xp

yp

y

2xp

yp

xp

yp2s

xp

yp

2s

xp

yp????????（5）從公式（4）和公式（5）可以看出，測(cè)量誤差的大小決定比值

m。 mxp

yp

xp

yp?????????????????（ 公式（6）中的分子項(xiàng)是實(shí)測(cè)時(shí)的釋放應(yīng)變量，分母項(xiàng)為標(biāo)定時(shí)的釋放應(yīng)變量。當(dāng)

m

時(shí)，實(shí)測(cè)的和標(biāo)定時(shí)的塑性應(yīng)變相等，在運(yùn)算中塑性應(yīng)變可以基本消除，計(jì)算的應(yīng)力值即為殘余應(yīng)力的真實(shí)值。當(dāng)

m＞1

、

果有一定的誤差。mmmmh/Dmmmm

210

210

1201.52.01.332.5

6-946.04

53180.2

44025.5

32465.2

2750.71

104.87

18.8296-1211.4

53171.7

43358.4

31818.2

2513.54

68.932

40.437351.31201.52.01.333.0

6-3854.5

511587

413468

37665.3

22207.1

296.96

31.6586-4298.8

512213

413660

37582.7

22152.9

287.86

53.577353.11201.52.01.335.0

6-768.64

51774.6

41512.8

3594.2

2107.78

7.8592

23.626-2178.8

55494.3

45524.7

32801.7

2740.48

93.984

48.70135

h/D1.15DB43/T

2314—當(dāng)

m＜1

時(shí)，實(shí)測(cè)應(yīng)變中的塑性應(yīng)變小于

A、B

中的塑性應(yīng)變，計(jì)算應(yīng)力小于真實(shí)應(yīng)力，測(cè)量結(jié)果具有一定的負(fù)偏差。對(duì)于

m＞1

和

m＜1

A、B

按應(yīng)力水平分為若干等級(jí)使用，以降低實(shí)測(cè)中塑性應(yīng)變的影響，提高測(cè)量精度。8.3.1.2 A、B

A、B

系數(shù)分四級(jí)。A、B

分級(jí)數(shù)值及其使用條件見(jiàn)表

2。8.3.1.2.1 對(duì)實(shí)測(cè)應(yīng)變

ε、ε23

2

中與孔徑相對(duì)應(yīng)的第一級(jí)

A、B

計(jì)算，得出殘余應(yīng)力初算值。8.3.1.2.2

1

中對(duì)應(yīng)的數(shù)值范圍，換用與之相對(duì)應(yīng)的

A、B

重新進(jìn)行計(jì)算，第二次計(jì)算的結(jié)果，即為經(jīng)過(guò)修正的殘余應(yīng)力值。8.3.1.2.3

σ、σ，其中任一個(gè)超過(guò)第一級(jí)

A、B

應(yīng)用范圍時(shí)，應(yīng)換用與初算值相應(yīng)的

A、B

值進(jìn)行第二次計(jì)算，如果兩個(gè)數(shù)值同時(shí)超過(guò)，則應(yīng)根據(jù)絕對(duì)值最大值選用與之相對(duì)應(yīng)的

A、B值進(jìn)行第二次計(jì)算，所得結(jié)果即為修正后的實(shí)際應(yīng)力值。8.3.1.2.4 A、B

應(yīng)力值則可不進(jìn)行第二次計(jì)算。表

表

2 A、B

系數(shù)分級(jí)薦用值及其使用條件DB43/T

2314—9

9.1測(cè)試報(bào)告測(cè)試報(bào)告應(yīng)包括以下內(nèi)容：a）

測(cè)試特種設(shè)備的描述；b）

材料機(jī)械性能；c）

應(yīng)變花的型號(hào)，幾何形狀及粘貼位置；d）

鉆孔方法及孔徑、孔深；e）

釋放應(yīng)變值；f）

應(yīng)變釋放系數(shù)

A、B

g）

應(yīng)力計(jì)算結(jié)果；h）

誤差分析。DB43/T

2314—附

錄 A（資料性）鉆孔偏心的修正A

鉆孔偏心的修正A.1 為了保證測(cè)量精度，要求應(yīng)變花測(cè)量中心與鉆孔中心完全重合。當(dāng)鉆孔中心與應(yīng)變花中心的不重合度誤差在±（0.004～）D，且不可重復(fù)測(cè)量時(shí)，可按本方法進(jìn)行修正其近似值。A.2當(dāng)測(cè)量殘余應(yīng)力采用直角應(yīng)變花時(shí)，若鉆孔有偏心，如圖

A.1

所示，孔心與應(yīng)變花心偏離為

e，則以孔心

O

為原點(diǎn)的坐標(biāo)系

X、YO的坐標(biāo)系為

X、Y、、變成

、、、

、A

B

值也因距離

的變化而變成

、，

A、，

、。圖

A.1鉆孔偏心的坐標(biāo)系A(chǔ).3 按中心鉆孔法測(cè)量各應(yīng)變花的釋放應(yīng)變，和。A.4 用刻度顯微鏡（最小讀數(shù)為

0.01

mm）測(cè)量孔心到應(yīng)變花中心距離在

X

軸、Y

軸方向上的分量

x值、y

值。 A.5 按公式（）～公式（）計(jì)算孔心到

3

個(gè)應(yīng)變花中心的距離

、、 R1=

R1

x

2

y2

???????????????????（A.1）0.707R20.707R2

y

????????????（）

0.707R2

x

2

2R3R3=

x2

R3

y

???????????????????（A.3）DB43/T

2314—A.6按公式（A.5）計(jì)算

3

個(gè)應(yīng)變花的應(yīng)變釋放系數(shù)

、，

A、，

、：A1

3

2

????????????????????（）B1

3

2

??????????????????