基于时变可靠度和疲劳效应的井架钢结构剩余寿命分析

为准确预测在役井架钢结构剩余服役年限的长短,建立了基于时变可靠度和疲劳效应的剩余寿命预测理论。推导了杆件等效截面积与损伤缺陷随时间变化的函数关系,建立了井架钢结构抗力时变模型;编制了井架钢结构的疲劳载荷谱,并应用S-N曲线法及雨流计数原理等相关理论,建立了基于疲劳效应的寿命预测理论。对JJ220/42-K型井架钢结构进行了剩余寿命预测,结果表明,综合考虑腐蚀与初弯曲影响时的寿命明显低于仅考虑腐蚀时的寿命,说明局部损伤对寿命影响较大;结构的可靠度寿命明显低于疲劳寿命。     

高速动车组电机吊架载荷及损伤特性EI北大核心CSCD

以某型高速动车组电机吊架为研究对象,利用载荷标定方法制作电机吊架板簧力传感器,通过线路实测获得电机吊架垂向载荷时间历程,结合车载陀螺仪信号和速度信号,将实测载荷分解为趋势载荷和动态载荷,分析了电机吊架在起动加速、高低速直线、曲线通过、制动减速等典型工况的载荷特性。在此基础上,编制了电机吊架在典型工况下的载荷谱,分析了各工况载荷幅值和频次的特点;依据疲劳损伤准则,分析了不同工况下疲劳损伤密度的变化规律以及各级载荷谱的损伤分布,对比了趋势载荷和动态载荷的损伤占比。结果表明,电机吊架载荷主要由振动引起的动态载荷和电机扭矩引起的趋势载荷组成。电机吊架二、四位比一、三位受电机输出扭矩影响大,尤其在起动和制动阶段。当列车速度从195 km/h增大到295 km/h时,载荷均方根值增大了62%。随着速度提高,电机吊架振动主频呈正比增长。相同里程下,直线工况下的损伤密度值最大、起动工况损伤密度最小。电机吊架损伤主要由动态载荷引起,其损伤占比为99.6%。中幅区载荷谱产生的损伤占总体93%以上。     

基于振动时域信号并行雨流处理的振动疲劳寿命预估

对振动时域信号进行雨流计数处理构建疲劳载荷谱是进行时域振动疲劳研究的关键.工程实际中的振动信号载荷历程普遍较长,时域样本规模较大,对此类时域信号进行传统雨流计数处理精度差、计算时间长,因此在传统雨流计数的基础上引入了并行雨流计数处理,适用于处理长时间历程的振动信号,特别是含低频信号的振动信号.构建信号的疲劳谱后再结合S-N曲线和损伤累积理论实现了时域振动疲劳寿命的计算.初始程序在Matlab平台上完成,通过执行文件转成Labview程序并编制操作页面,简化操作,实现结果可视化.以航空典型结构加筋板为例,对比疲劳试验结果,验证了所编程序计算的精确性.     

基于聚类分析和支持向量机的非等间隔应力谱编制方法

为保证根据实测应力-时间历程数据编制的应力谱最大程度反映载荷实际作用特性，提出了一种基于疲劳损伤的非等间隔应力谱编制方法。通过引入非等间隔自适应比值系数，根据损伤等效原则，建立应力谱分级数与疲劳损伤关系数学模型；考虑每个应力循环的属性特征，采用聚类分析对所有应力循环进行分类，结合支持向量机多分类进行判别，得到不同分级数下的准确率和预测图；综合考虑数学模型得到的损伤相对误差和支持向量机分类准确率，选取应力谱最佳分级数，编制了相应的非等间隔应力谱，并与目前常用的等间隔和非等间隔8级谱进行比较。分析结果表明：基于损伤等效原则，采用聚类分析和支持向量机进行应力谱分级，不仅考虑了所有应力循环的整体特征，很大程度保留了应力的局部信息和属性，且根据疲劳累积损伤理论得到的损伤与实际损伤结果差异明显降低，从而更能准确反映实测数据的应力特性和疲劳效应，可为其他实测载荷-时间历程数据进行非等间隔分级和载荷谱编制提供参考。     

直升机尾减速器机匣疲劳试验方法研究

根据减速器机匣疲劳损伤应力循环的动、静应力包罗线方法确定了疲劳试验加载方案;根据设计载荷谱或飞行实测,确定各载荷作用点的状态载荷并编制了疲劳试验谱;根据减速器机匣的受力形式,完成减速器机匣疲劳试验装置的设计。结果表明,该试验装置既可以考虑高频动载荷的影响,又能简化疲劳试验的加载程序,明显缩短了疲劳试验的周期。     

基于静动力的在役钻机井架承载性能研究

井架作为石油钻机的重要承载设备,其承载性能直接关系到整套钻机系统的安全运行。为了准确预测安全承载能力,综合考虑静动力学特性,提出了联合静动力的分层次模型修正方法。在灵敏度分析和工程经验的基础上,以反映结构性能参数的残差最小作为目标函数,构建优化修正模型,利用一阶搜索优化算法实现模型修正问题的求解。以某在役海洋钻井平台使用的井架为例进行分析,结果表明修正后的模型能全面、正确地反映结构的静动力特性,验证了该方法的可行性和必要性。基于此,利用修正后的模型动态模拟钻井加载工况、分析多遇地震响应以及进行偶遇极端工况下的双重非线性分析,从而预测了井架的失稳状态、破坏形式和极限承载能力。为在役钻机井架的安全承载能力预测和和抵抗突发恶劣工况的预报提供一个新思路,具有一定的实用价值。     

橡胶隔振器加速疲劳试验谱的编制方法研究

通过大量的橡胶动静刚度试验和疲劳试验,分别获取了某填充型天然橡胶材料在各试验条件下的动静比数据表和疲劳寿命数据表。以发动机悬置为例,在充分考虑橡胶材料动态特性的基础上,建立了道路载荷值与应变值的转换关系。对采集的道路载荷谱进行雨流计数,根据Miner线性损伤累积理论与损伤等效原则,编制得到最终的加速疲劳试验谱。用该加速疲劳试验谱对发动机悬置进行疲劳试验,试验结果表明：用该方法编制的加速疲劳试验谱可成功应用于悬置等橡胶隔振器零件的疲劳试验,并且较大程度地缩短了试验与产品开发周期。     

非线性渐变刚度钢板弹簧疲劳分析载荷谱编制方法

提出了一种适用于非线性渐变刚度钢板弹簧疲劳可靠性分析评价的载荷谱编制方法。在ANSYS中建立考虑非线性接触的钢板弹簧总成有限元模型并根据台架试验结果进行参数识别,获得了簧片上任意点应力与形变之间的非线性对应关系。在试验场采集获得钢板弹簧在强化路面下的加速度信号,通过处理,获得了板簧弧高随时间变化的信号。结合应力与弧高的对应关系以及弧高随时间变化的信号,精确获得了强化路面下钢板弹簧疲劳热点区域的应力载荷谱。采用雨流计数法对编制获得的载荷谱进行分级计数并依此为基础对疲劳热点进行可靠性分析,预测结果与道路试验相吻合。     

随机载荷作用下疲劳寿命分布预测模型

为了研究构件在随机载荷下的疲劳寿命分布,建立疲劳寿命分布预测模型.应用雨流计数法,将随机载荷-时间历程处理成以载荷幅值和均值为随机变量的二维联合概率密度函数,得到构件的二维疲劳载荷谱.从Miner累积损伤的定义出发,分析了累积损伤分散性的来源.以此为基础,通过建立等幅疲劳中值Sa-Sm-N曲面,提出了基于二维载荷谱的疲劳寿命分布预测模型,当累积损伤的概率分布已知时,可以估算出构件的疲劳寿命分布,进而得到零件在任一时刻的可靠度.最后,给出了一个具体应用实例.结果表明所提出的疲劳寿命分布预测方法具有较好的工程实用价值.     

基于WIM数据分析的上海长江大桥拉索疲劳应力谱研究

拉索是斜拉桥的关键承重构件,拉索的疲劳状态直接关系到斜拉桥的正常运营,交通载荷导致的索力变化是拉索疲劳损伤和寿命评估的关键因素.本文利用上海长江大桥动态称重系统采集到的车辆载荷相关数据,依据等效疲劳损伤原理,推导出代表实际运营车辆的等效载荷谱,将载荷谱加载到ANSYS模型中获得拉索应力历程,采用泄水法,建立拉索应力谱,为拉索疲劳损伤及寿命评估提供可靠的依据.     

采油井架钢结构非线性力学行为分析

本文对采油井架钢结构进行了非线性有限元分析。采用空间梁单元,通过包含单元几何刚度阵和变形刚度阵的增量切线刚度法考虑大变形问题;用杆端集中塑性法来简化材料非线性;采用弧长法迭代计算,最终可得到考虑几何和材料双重非线性情况下,井架钢结构的极限承载力。文中最后给出了A型采油井架的算例。     

A new frequency domain method for random fatigue life estimation in a wide‐band stationary Gaussian random process

A new frequency domain method for random fatigue life estimation in a wide‐band stationary Gaussian random process was proposed for application in fatigue analysis. Simulations of the power spectral densities of different types were firstly performed; the simulated results showed that the accuracy and applicability for the current frequency domain methods are not only related to the spectral type but also associated with the types of the analysed materials. Compared with the current methods, the proposed method, in which the rain‐flow amplitude obeys Nakagami distribution, has better universality and could significantly reduce the error for the random fatigue life estimation with simulated and actual spectra. Verified application in cast‐steel fatigue life analysis were performed between random fatigue life and constant amplitude fatigue life. It is shown that the fatigue life analysis under random load cannot be ignored and the proposed new method can serve as a recommended method.     

EURAXLES – A global approach for design,production and maintenance of railway axles: WP1 – Advances in fatigue load analysis and reliability assessment of railway axles

The work presented in this paper was led within the collaborative project “Euraxles” of the FP7 program of the European Commission. It aimed at developing processes and methods that contribute to the minimization of the risk of fatigue failure of railway axles in service. This paper focuses on the development of a method to assess the reliability of axles according to fatigue damage. The proposed approach is mainly based on the stress strength interference analysis (SSIA) and the fatigue‐equivalent‐load (FEL) methods. It aims at calculating the axles’ probability of fatigue failure, by characterizing the variability of real in‐service loads and the scatter of the axles fatigue strength, and at evaluating more accurately the actual design margins. First of all, the main lines of the stress strength interference analysis method are recalled. This method aims at evaluating the in‐service reliability of components for their design or their homologation. It is used in many industries for various applications (mechanical components or systems, electronic elements, etc.). In the second part, the fatigue load analysis method that is proposed for railway axles is described. It starts with a post‐processing of an axle load measurement: from a time signal of forces applied to both wheels fitted on the axle, fatigue cycles of bending moment applied to the axle are identified and transformed into a cyclic equivalent load, the M_eq, which is a measurement of the severity of the initial variable load. Then, virtual but realistic load spectra are generated, thanks to a classification operation followed by a random draw of elementary load data that considers the operation and maintenance conditions of the axle. All the spectra are then analysed thanks to the fatigue‐equivalent‐load method in order to build the distribution of in‐service load severities that gives a picture of the stress to which the axles are submitted. In the third and last part of the paper, the methods are applied to real data of “Société nationale des chemins de fer français” (SNCF), the French national railway operator. Sensitivity analyses are performed in order to quantify the effect on the M_eq of variations of parameters and to verify the convergence and robustness of the process. Finally, results obtained for a passenger coach are given. The comparison between the distribution of load severities and the normative load, defined as according to european standards EN13103, shows that, for the studied axle, the normative load is very conservative. Using the axles fatigue limits identified on full‐scale tests, a stress strength interference analysis is performed to calculate the probability of failure of the axle.     

Modal Analysis of Drilling Machine Derrick

In this paper,the finite element analysis software(ANSYS)is applied to the modal analysis of a ZJ30/1700CZs drilling machine derrick under a natural condition and a loaded condition,re-spectively.The preceding nine step natural frequencies and the corresponding mode shapes of the derrick are calculated.By means of the comparison of the natural frequency of the derrick with the design work frequency of the drilling machine and the analysis of the step mode shape of the derrick,the drilling machine derrick structure design is proved to be correct.     

抗冰平台的冰振疲劳分析

基于现场原型结构的观测,对渤海抗冰导管架平台冰激疲劳寿命估计的必要性进行了分析。结果表明,由于渤海特殊环境条件与油藏分布决定了在该海域设计的导管架平台属于典型的柔性抗冰结构,冰激振动不仅能激起较大的加速度响应,而且引起的交变应力也比较明显,在结构设计中进行疲劳寿命估计是必要的。目前,精确估计冰激疲劳寿命的方法还不成熟,其中冰激励荷载与海冰疲劳环境模型是两个关键问题。结合现场观测,对建立锥体疲劳冰荷载与冰环境参数的研究方法进行了论述,为详细疲劳分析提供了基础。     

机翼构件不同载荷谱下的寿命反推

对飞机机翼构件在不同截荷谱下的宏、微观断裂特征进行了观察与分析，并结合载荷谱中的应力变化特点，对A飞机和B飞机翼构件在不同载荷谱下的裂纹扩展寿命进行反推。结果表明，载荷谱中不同的应力变化在失效构件断口上反映出不同的宏、微观断裂特征，采用断口定量分析技术可反推构件的疲劳寿命，并依此反推构件疲劳裂纹形核的先后顺序。     

G105钻杆管体刺穿失效分析

某油田钻井公司使用的规格为φ101.6 mm×8.38 mm的G105钻杆先后发生两起管体刺穿失效事故,通过化学成分分析、力学性能测试、金相检验、X射线衍射等方法并结合钻杆的受力状态对钻杆刺穿原因进行了分析。结果表明:钻杆刺穿失效形式为腐蚀疲劳,在钻井液中腐蚀介质作用下,钻杆首先发生氧腐蚀和Cl~-加速腐蚀,使钻杆外表面产生许多腐蚀坑,并于腐蚀坑底部形成应力集中;随后在钻井过程的交变应力作用下,应力集中严重的腐蚀坑底部开始萌生裂纹,裂纹不断疲劳扩展直至穿透管壁;最终在钻杆内钻井液的冲刷作用下发生刺穿失效。     

基于模型局部修正的井架钢结构极限承载力分析

提出以井架钢结构主要承载杆件测试应力为指标、与应力有关设计参数作为修正对象的模型局部修正理论进行井架钢结构极限承载力分析的新方法。对实验室井架钢结构模型进行多级动载再现实验,通过仿真模拟实现了多级动载应力的拟合,误差在5%以内,验证了模型局部修正理论的正确可行性;以该理论为基础,现场逐级载荷实验数据为依据,建立了真实体现实际井架钢结构力学行为的仿真计算模型,运用线性屈曲法、几何非线性法和双重非线性法,对现场某型号在用井架钢结构进行了实际极限承载力预测,得出了该井架钢结构的极限承载力、破坏形式及危险部位。     

Failure analysis of drillstring in petroleum industry: A review

Understanding the failure analysis of drillstring and its components i.e., drill collar and drilling bit is one of the essential issues in the oil and gas industry for the high cost of oil well drilling. Different ways such as air drilling, percussion drilling and downhole hydraulic ultra-high pressure (UHP) jet assisted drilling have been often used to improve the rate of penetration (ROP), minimize the cost of drilling per foot and diminish well deviation. Nevertheless, these drilling ways aggravate the working conditions of the downhole drilling tools materials and hence their properties cannot meet the demands of these conditions and consequently causing a risk drillstring failure. The unfavorable geological conditions and the repeated impact for breaking the rock may also cause severe bit bouncing and violent vibration. Tooth loss, tooth fracture, tooth wear and microcracks in addition to drill pipe fatigue from bending stress caused by buckling load are realistic examples of failure modes which occurred in the drilling tools. This study comprehensively describes the reasons causing these failure modes in order to manage risks and achieve high performance of wells and borehole sections. The role of working parameters i.e., bottom hole temperature and solid content on the drilling tools' life time, and the role of predrill predictions of pore pressure or wellbore stability on the drilling process are presented.