DB43-T 2314-2022 特种设备焊接残余应力盲孔法测试方法

ICS

25.160.40CCS

43湖 南 省 地 方标 准DB43/T

2314—2022特种设备焊接残余应力盲孔法测试方法Test

method

for

welding

residual

stress

of

special

equipmentby

blind

hole

method2022

-

05

-

06

发布

2022

-

-

实施湖南省市场监督管理局

发

布DB43/T

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

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

12规范性引用文件······································································································13术语与符号············································································································14 工件准备···············································································································25应变花与仪器·········································································································35.1 应变花几何形状································································································

35.2 标准应变花······································································································35.3 安装及使用······································································································35.4仪器···············································································································46 试验和测量············································································································46.1 试验技术·········································································································46.2 应力测量·········································································································47 计算方法···············································································································57.1 计算步骤及过程································································································

58 孔边塑性变形的修正································································································

58.1 修正原理·········································································································58.2钻孔加工塑性应变修正法····················································································

58.3 钻孔应力集中塑性应变修正法

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

79.1 测试报告·········································································································7附录

A（资料性） 钻孔偏心的修正················································································8参考文献··················································································································

10DB43/T

2314— 本文件按照

GB/T

—2020《标准化工作导则 第

1

部分：标准化文件的结构和起草规则》的规定起草。请注意本文件的某些内容可能涉及专利。本文件的发布机构不承担识别专利的责任。本文件由湖南省市场监督管理局提出。本文件由湖南省特种设备标准化技术委员会归口。新力机械有限公司。李检保、邵支农、林稳、许福、陈俊、杨才千、张衡、向丽、曾凡小、袁朝阳、罗奇志、王观次、郭跃飞。IIIDB43/T

2314—1

步骤及计算方法。本文件适用于可消耗或小浅孔不影响使用的特种设备焊缝处进行平面应力梯度较小的焊接残余应力测定。2

规范性引用文件文件。SL

499 钻孔应变法测量残余应力的标准测试方法CB

3395 残余应力测试方法钻孔应变释放法3

术语与符号3.1术语与定义

and

definitions下述术语和定义适用于本文件。3.1.1特种设备焊接残余应力 Residual

welding

of

equipment特种设备在焊接过程中产生的局部残余应力。3.1.2特种设备焊接高残余应力

特种设备在焊接过程中产生大于焊接部位材料

1/2

屈服强度的局部残余应力。3.1.3应力标定常数

constant贴位置、孔的形状和大小有关。3.1.4释放应变 Release

strain对具有焊接残余应力场的特种设备结构件钻孔，其钻孔前后应变的变化量。3.1.5钻孔 Drill

hole成孔转速在每分钟数千转，尤其指手电钻的加工方式。σ

——标定时的外加应力，其数值从零到材料的屈服点，N/mm

；DB43/T

σ

——标定时的外加应力，其数值从零到材料的屈服点，N/mm

；3.2符号和说明

and

descriptions下述符号和说明适用于本文件。D ——测量圆直径；D ——钻孔直径；E ——杨氏模量；Ε ——均布应力释放应变；ν ——泊松比；σ ——x

向均布正应力；σ ——y

向均布正应力；h——钻孔深度；σ——残余应力初算值；κ ——残余应力初算值与试件屈服强度的比值。ε ——因钻削加工引起的塑性应变；ε ——纯弹性释放应变；ε ——由应力集中引起的塑性应变。Q、Q

——过渡系数；ε、ε

——x，y

方向应变花中的弹性释放应变。ε、ε

——实测应变中

x、y

方向的塑性应变分量；ε’、——单向标定应变中

x、y

方向的塑性应变分量；2ε ——标定材料的屈服应变。4

工件准备4.1

60

达到

Ra3.2～6.4，面积不小于应变花面积的四倍，且不应采用明显改变测试表面应力状况的刮磨或研磨。4.2 表面预处理应严格限制，不应使用明显改变表面残余应力状况的方法。详细测量过程见

SL

499。4.3 对特种设备受试工件，应在应变花中心处上钻一通孔，应变花见图

1。详细钻孔步骤见

SL

499。

图

1钻孔应变花DB43/T

2314—5

应变计与仪器5.1 应变花几何形状5.1.1 应变花应包含

3

3

对应变计，应变计的编码应遵循顺时针（CW）编码规则。5.1.2 应变计应阵列于圆形图样上，与应变花中心等距离。5.1.3

3

2

所示，“12

45°或

13532135.1.4 图

2

中应变计

l

的方向定义为测试方向的

x

轴，y

轴为

x

轴逆时针旋转

90°。5.1.5 应变花测量圆的中心应能清晰可辨。a）应变花布置b）应变计详图GLGW图

2典型

3

单元顺时针编码规则应变花几何尺寸5.2 标准应变花5.2.1

1

所示，其对应尺寸见表

1。5.2.2图

1

中

A

型应变花有几种不同的几何尺寸，为通用类型。5.2.3 图

1

中

B

型应变花的应变计都位于同一侧，适用于障碍物附近的测试。5.2.4图

1

中

C

型应变花为特殊用途应变花，适用于应变灵敏度和热稳定性要求较高的测试。5.3 安装及使用5.3.1 应变花应粘贴于离测试工件边沿至少

D

5.3.2

B

0.5D于障碍物切线的法线上。

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 操作应变计（粘贴、焊引线、防护涂层）时应严格按照出厂说明书操作，并在钻孔过程中保护好应变计。5.3.4应变计应保证永久性连接，应确认其安装稳定性。接地绝缘电阻应不小于

20000

。5.3.5 应变计安装完毕后应进行检查。表

1 应变花直径表

1 应变花直径电阻应变仪的精度应不低于±1×10

1×10

-6 -6

A

型和

B

型应变花应采用三线温度补偿电路，C

以指定的

ε，ε和

ε表示，操作步骤见

。6

试验和测量6.1 试验技术6.1.1不确定的钻孔测试技术操作规程易导致不精确的测试结果，详细钻孔步骤见

SL

499。6.1.2 在条件达到的情况下，应对盲孔法与其他技术进行验证，进行不确定性分析，以确定和量化其测量不确定度。6.1.3 小尺寸的应变花可测量近表面的残余应力值。6.2应力测量6.2.1将粘贴好电阻应变花的特种设备工件安装在试验机上，并将测量导线接至应变仪上调零。然后进行钻孔，待孔的直径和深度达到要求时，记录其应变读数。6.2.2 使用钻孔方法，在不产生明显的加工应力状况下，整个孔深范围内测定的残余应力偏差应不超过±10％。6.2.3保证测试环境稳定、读数精准、应变计完好。DB43/T

2314—6.2.4

6

单元的

C

型应变花，用于重要测量和低传导率材料的测量。7

计算方法7.1 计算步骤及过程详细计算步骤见

CB

3395，计算过程中对偏心孔残余应力的修正见附录

A。8

孔边塑性变形的修正8.1 修正原理8.1.1 特种设备因其材料、结构的特殊性，在焊接过程中易产生较高的焊接残余应力。在盲孔法测试和钻孔应力集中引起的塑性应变

ε和

ε的确定是提高测量精度的关键。在所测量的总应变

ε

中，包含如公式（1）所示的三部分应变：=d

e

p„„„„„„„„„„„„„„„„„„„„„（1）8.2 钻孔加工塑性应变修正法对无应力试样按本文件方法钻孔测定

ε，然后从测量的总应变

ε

中将其减去。8.3钻孔应力集中塑性应变修正法8.3.1 应变释放系数分级计算法8.3.1.1 A、B

系数分级的依据。当残余应力的方向已知时。用公式（2）和公式（3）计算残余应力。

4

y

Bx

y

Ax

y

4AB„„„„„„„„„„„„„„„（3）

A、B

变化，A、B

也将有一系列数值，公式（2）和公式（3）可改写为公式（4）和公式（5）。

x

2xp

yp

xp

yp2s

xp

yp

y

2xp

yp

xp

yp2s

xp

yp

2s

xp

yp„„„„„„„„（5）从公式（4）和公式（5）可以看出，测量误差的大小决定比值

m。 mxp

yp

xp

yp„„„„„„„„„„„„„„„„„（ 公式（6）中的分子项是实测时的释放应变量，分母项为标定时的释放应变量。当

m

时，实测的和标定时的塑性应变相等，在运算中塑性应变可以基本消除，计算的应力值即为残余应力的真实值。当

m＞1

、

果有一定的误差。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—当

m＜1

时，实测应变中的塑性应变小于

A、B

中的塑性应变，计算应力小于真实应力，测量结果具有一定的负偏差。对于

m＞1

和

m＜1

A、B

按应力水平分为若干等级使用，以降低实测中塑性应变的影响，提高测量精度。8.3.1.2 A、B

A、B

系数分四级。A、B

分级数值及其使用条件见表

2。8.3.1.2.1 对实测应变

ε、ε23

2

中与孔径相对应的第一级

A、B

计算，得出残余应力初算值。8.3.1.2.2

1

中对应的数值范围，换用与之相对应的

A、B

重新进行计算，第二次计算的结果，即为经过修正的残余应力值。8.3.1.2.3

σ、σ，其中任一个超过第一级

A、B

应用范围时，应换用与初算值相应的

A、B

值进行第二次计算，如果两个数值同时超过，则应根据绝对值最大值选用与之相对应的

A、B值进行第二次计算，所得结果即为修正后的实际应力值。8.3.1.2.4 A、B

应力值则可不进行第二次计算。表

表

2 A、B

系数分级荐用值及其使用条件DB43/T

2314—9

9.1测试报告测试报告应包括以下内容：a）

测试特种设备的描述；b）

材料机械性能；c）

应变花的型号，几何形状及粘贴位置；d）

钻孔方法及孔径、孔深；e）

释放应变值；f）

应变释放系数

A、B

g）

应力计算结果；h）

误差分析。DB43/T

2314—附

录 A（资料性）钻孔偏心的修正A

钻孔偏心的修正A.1 为了保证测量精度，要求应变花测量中心与钻孔中心完全重合。当钻孔中心与应变花中心的不重合度误差在±（0.004～）D，且不可重复测量时，可按本方法进行修正其近似值。A.2当测量残余应力采用直角应变花时，若钻孔有偏心，如图

A.1

所示，孔心与应变花心偏离为

e，则以孔心

O

为原点的坐标系

X、YO的坐标系为

X、Y、、变成

、、、

、A

B

值也因距离

的变化而变成

、，

A、，

、。图

A.1钻孔偏心的坐标系A.3 按中心钻孔法测量各应变花的释放应变，和。A.4 用刻度显微镜（最小读数为

0.01

mm）测量孔心到应变花中心距离在

X

轴、Y

轴方向上的分量

x值、y

值。 A.5 按公式（）～公式（）计算孔心到

3

个应变花中心的距离

、、 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）计算

3

个应变花的应变释放系数

、，

A、，

、：A1

3

2

„„„„„„„„„„„„„„„„„„„„（）B1

3

2

„„„„„„„„„„„„„„„„„„