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CO、甲醛与甲醇燃烧综合动力学机理研究

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CO、甲醛与甲醇燃烧综合动力学机理研究( Methanol Mechanis m 2008071016)

摘要:

本文构建了适用于 CO、甲醛、甲醇燃烧的统一详细动力学模型,基于层级式方法更新 H₂/O₂子机理与热力学参数,通过加权最小二乘法优化关键反应速率常数。研究新增 850–950 K、1.5–6 atm 下甲醛氧化的流场实验数据,模型经激波管、层流火焰、流动反应器等多工况验证,温度 300–3000 K、压力 0.03–20 atm,与实验结果高度吻合。灵敏度分析表明 CO+OH、HCO 分解等反应对点火与火焰速度影响显著。该模型包含 84 步反应与 18 种组分,可直接用于 CHEMKIN,为含氧燃料燃烧仿真提供可靠机理。

A Comprehensive Kinetic Mechanis m for CO, CH2O, and CH3OH Combustion

JUAN LI, 1 ZHENWEI ZHAO, 1 ANDREI KAZAKOV, 1  MARCOS CHAOS, 1  FREDERICK L. DRYER, 1 JAMES J. SCIRE, JR.2

1 Department of Mechanical and Aerospace Engineering, Princeton University, Princeton, NJ 08544

2 Advanced Fuel Research, Inc. , East Hartford, CT 06108

Received 27 May 2006; revised 18 September 2006; accepted 3 October 2006

DOI 10.1002/kin.20218

Published online in Wiley InterScience (www.interscience.wiley.com).

ABSTRACT:  

New  experimental  profiles  of  stable  species  concentrations  are  reported  for formaldehyde oxidation in a variable pressure flow reactor at initial temperatures of 850–950 K and at constant pressures ranging from 1.5 to 6.0 atm. These data, along with other data pub- lished in the literature and a previous comprehensive chemical kinetic model for methanol oxi- dation, are used to hierarchically develop an updated mechanis m for CO/H2O/H2/O2, CH2O, and CH3OH oxidation. Important modifications include recent revisions for the hydrogen–oxygen submechanis m (Li et al., Int JChem Kinet 2004, 36, 565), an updated submechanis m for methanol reactions, and kinetic and thermochemical parameter modifications based upon recently pub- lished information. New rate constant correlations are recommended for CO+ OH = CO2 + H (R23) and HCO + M = H + CO + M (R24), motivated by a new identification of the tempera- tures over which these rate constants most affect laminar flame speed predictions (Zhao et al., Int J Chem Kinet 2005, 37, 282). The new weighted least-squares fit of literature experimental data for (R23) yields k23 = 2.23 × 105 T1.89 exp(583/T )cm3/mol/s and reflects significantly lower rate constant values at low and intermediate temperatures in comparison to another recently recommended correlation and theoretical predictions. The weighted least-squares fit of lit- erature results for (R24) yields k24 = 4.75 × 1011 T0.66 exp(_7485/T ) cm3/mol/s, which predicts values within uncertainties of both prior and new (Friedrichs et al., Phys Chem Chem Phys 2002, 4, 5778; DeSain et al., Chem Phys Lett 2001, 347, 79) measurements. Use of either of the data correlations reported in Friedrichs et al. (2002) and DeSain et al. (2001) for this reaction sig- nificantly degrades laminar flame speed predictions for oxygenated fuels as well as for other hydrocarbons. The present C1/O2  mechanis m compares favorably against a wide range of ex- perimental conditions for laminar premixed flame speed, shock tube ignition delay, and flow reactor species time history data at each level of hierarchical development. Very good agree- ment of the model predictions with all of the experimental measurements is demonstrated.

OC   2007 Wiley Periodicals, Inc. Int J Chem Kinet 39:  109–136, 2007

INTRODUCTION

The  hierarchical  nature  of  hydrocarbon   oxidation kinetics  and the  importance  of s mall molecule  and radical kinetics in controlling the oxidation of larger carbon number  species  are well-established notions [ 1,2].  The  hydrogen–oxygen  kinetic  submechanis m [2] controls the most reactive radical pool composition of H, OH, O, and HO2  that attack the primary fuel. Carbon monoxide is a major intermediate species, and its conversion to CO2  is responsible for a significant fraction  of the  exothermicity  accompanying  hydro- carbon oxidation. It has been shown (e.g., [2,3]) that nearly all carbon atoms bonded to one another, to hy- drogen atoms, or hydroxyl groups are converted to CO through formaldehyde (CH2 O) and/or formyl radicals (HCO). Formyl radicals are a major source of H atoms and HO2 radicals in larger carbon number hydrocarbon combustion.

Methanol (CH3 OH), the simplest alcohol, converts to  CO  through  CH2 O  reactions  and  introduces  ad- ditional species, particularly CH2 , CH3 , CH3 O, and CH2 OH [4]. Over almost all conditions of practical in- terest, methanol combustion produces CH3 in such mi- nor concentrations that no C2  hydrocarbon species are formed and, hence, no sooting occurs. The collection of kinetic phenomena involved in hydrogen/oxygen, car- bon monoxide, formaldehyde, and methanol is there- fore a representative of the s mall radical pool interac- tions that couple with methyl radical and higher carbon number species and radicals in hydrocarbon combus- tion systems.

Detailed  mechanis ms  for  H2 ,  CO,  CH2 O,  and CH3 OH combustion  are also individually of practi- cal importance. Hydrogen kinetic properties have long been of interest in terms of safety, given the major use of hydrogen in chemical synthesis and fuel refining. The proposed transition to a hydrogen energy economy further emphasizes the need to understand hydrogen safety issues [e.g., 5,6] as well as hydrogen combus- tion under mild combustion conditions and with very high-exhaust gas recirculation. Carbon monoxide and formaldehyde  are primary pollutant  species emitted from many combustion systems and are important in reforming chemistry to produce hydrogen from hydro- carbons, as well as in atmospheric chemistry, toxicity, and carcinogen assess ments and an alyses. Methanol is used as an oxygenate additive in gasoline and is also an attractive alternative to traditional transportation fu- els because of its nonsooting characteristics, its facile synthesis from a wide variety of feedstocks, and its possible interim role as a hydrogen carrier for fuel cell applications.

The  combustion  chemistry  of each  of the  above species has been extensively studied previously. Ex- perimental  data exist in the literature from laminar flame, shock tube, flow reactor, and static reactor ex- periments, collectively covering a wide range of ini- tial temperature, pressure, and equivalence ratio. Our group has had a long involvement in studying these s mall molecule kinetics in flow reactors (Yetter et al. [7,8]; Hochgreb and Dryer [9]; Kim et al. [ 10], Nor- ton and Dryer [ 11], Held and Dryer [4, 12], Mueller et al. [ 13– 17]). We have previously developed com- prehensive mechanis ms for CO  [8],  CH2 O  [9],  and CH3 OH [4], and our recent work on updating and de- veloping a comprehensive mechanis m for hydrogen– oxygen [ 18] that includes advances in chemical kinetic rate and thermochemical information as well as val- idation data  sources points to the need to  similarly revisit and update our prior work on carbon monox- ide, formaldehyde, and methanol kinetics. While the flow reactor data we have previously published for hy- drogen, carbon monoxide, and methanol systems, each covering a very wide range of pressures, our prior work on formaldehyde oxidation was limited to atmospheric pressure studies [9]. In that work, chemical an alyses were conducted using offline gas chromatography, an an alytical method with potentially higher uncertainties than can be achieved using the Fourier transform in- frared (FTIR) online an alytical methods available to- day. Formaldehyde oxidation obtained in a variable pressure flow reactor (VPFR) at initial temperatures of 850–950 K and constant pressures ranging from 1.5 to 6.0 atm to expand the range of validation con- ditions. Moreover, new experiments in other venues, especially for CH2 O oxidation, have appeared in the literature using shock tubes [ 19–22] and laminar pre- mixed flames [23]. In addition, there have been some elementary kinetic publications further addressing the important reactions involved in the C1 oxidation system (e.g., [ 19,24,25]).

Utilizing our recent work on hydrogen/oxygen ki- netics [ 18], and updating the CO/O2 , CH2 O/O2 , and CH3 OH/O2 mechanis ms with more recent kinetic and thermochemical information, a comprehensive mecha- nis m has been hierarchically developed [26] that satis- factorily reproduces new experimental targets as well as those utilized in the original mechanis m studies ap- pearing in [4,8,9]. This paper reports the key features of the updated mechanis m, summarizes the comparisons of predictions with experimental targets as performed in [26], and augments these earlier comparisons using the results with some additional, recently published, kinetic  measurements  and  experimental  validation data.


EXPERIMENTAL METHODS

The new experiments on formaldehyde oxidation re- ported here were conducted in the Princeton variable pressure flow reactor [27]. Detailed information on the VPFR instrumentation and experimental methodology can be found in other publications [28], and only a brief description is given here.

Carrier gas (N2  in this study) is heated by a pair of electrical resistance heaters and directed into a reactor duct. Oxygen is also introduced at the duct entrance. The carrier gas/oxygen mixture flows around a baffle plate into a gap serving asthe entrance toa diffuser. The vaporized fuel (trioxane with water in this study) flows into the center tube of a fuel injector and injects radi- ally outward into the gap where it rapidly mixes with the carrier gas and oxygen. The reacting mixture exits the diffuser into a constant area test section. Near the exit of the test section, a sampling probe is positioned on the reactor centerline to continuously extract and convectively quench a s mall percentage of the flow. At the same axial location, the local reaction gas temper- ature is measured with a type R thermocouple accurate to ±3 K.

The sample gas flows via heated Teflon lines to an- alytical equipment including a FTIR spectrometer, an electrochemical O2  ana lyzer, and a pair of nondisper- sive infrared a nalyzers for CO and CO2. Other sta- ble  species of interest  (e.g., CH2 O, H2 O)  are mea- sured continuously online using FTIR spectrometry. The measurement uncertainties for the data reported here are O2 :±2%, CO:±2%, CO2 :±2%, CH2 O:±3%, and H2 O:±6% of reading.

The distance between the point of fuel injection and the sampling position is varied by moving the fuel vapor injector probe (with attached mixer/diffuser as- sembly) relative to the fixed sampling location. Mean axial velocity measurements along the centerline of the reactor are used to correlate distance with residence time. By these means, profiles of stable species versus residence time can be determined experimentally. The uncertainty in the residence time is approximately 5%.

In the present experiments, formaldehyde monomer was  generated through the  decomposition  of  1,3,5- trioxane. Hochgreb and Dryer [9] also employed this technique  in  their  atmospheric  pressure  flow  reac- tor (APFR) experiments. Trioxane decomposition pro- ceeds by the concerted rupture of the three C   O bonds to form three formaldehyde molecules [9,29]. Using gas chromatography, it was experimentally verified that CH2 O is the only product of trioxane decomposition, and trioxane decomposition is much faster than the subsequent reaction of formaldehyde at flow reactor conditions. For modeling purposes,  1  mol  of triox-ane reactant could therefore be replaced by 3 mol of formaldehyde.

In earlier work, [9,29], trioxane was melted and de- livered as a liquid to the evaporator of a prior APFR. A similar methodology would have required a complex modification of the present reactor, and a different ap- proach to deliver trioxaneto thereactor was utilized. At 18◦ C, the solubility of trioxane in water is 17.2 g/100 mL [30]. Trioxane was dissolved in distilled water, and the unheated solution was volumetrically metered to a liquid vaporizer system located within the VPFR pres- sure shell and at the immediate entrance to the fuel vapor injector probe. The metered liquid flow was gas- blast atomized using heated nitrogen, and the nitrogen, water vapor, and trioxane vapor mixture was then in- jected into the reactor at the mixing location with hot carrier gas. It was verified that the decomposition rate of trioxane at the conditions of the reported experi- ments led to immediate formation of monomer during the injection and mixing process, well upstream of the radially uniform reaction region where the reported data were obtained. Due to heat addition limitations for the hot nitrogen used to vaporize the liquid reactant flow and the solubility limit of trioxane in water, the maximum initial CH2 O mole fraction investigated was limited to 500 ppm. Other than this limitation, the use of water to deliver the trioxane did not significantly affect the experiments, as the amount of water added was included in the kinetic modeling comparisons.

A series of moist formaldehyde oxidation experi- ments were conducted in the VPFR at initial tempera- tures of 850–950 K and in the pressure range of 1.5–6.0 atm. For all of the experiments, the total carbon and oxygen balances experimentally determined at each residence time were within 4% of the specified input. The nearly identical total carbon and oxygen concen- trations at each  sampling location not only provide verification of the experimental measurements but also imply that any other carbon- or oxygen-containing sta- ble species present were only in negligible quantities. Although formic acid has been observed using these same diagnostics in VPFR experiments on methanol [4] and dimethyl ether [31] oxidation, none was de- tected in the present experiments on formaldehyde ox- idation. This is most likely the result of the very low fuel concentrations studied here, and that formic acid would be expected to be below detection limits.


UPDATED KINETIC MECHANIS MS FOR CO, CH2 O, AND CH3 OH COMBUSTION

We used a slightly modified version of the methanol mechanis m  published  by  Held  and  Dryer  [4]  as  a  starting point in developing the present mechanis m.* In the course of the present work, a number of ther- mochemical parameters and rate constant correlations were modified to reflect more recent kinetic informa- tion. The revised H2/O2   submechanis m is discussed in detail and validated against a large set of hydro- gen/oxygen targets in a separate publication [ 18], and this submechanis m is absorbed without further mod- ifications in the present work. Revisions included the use of the heat of formation of OH recommended by Ruscicetal. [33], which isin very good agreement with recent experimental results [34]. For the current work, we utilized 3.0 kcal/mol as the standard heat of for- mation of HO2 at 298.15 K [35]. Very recently, Ruscic et al. [36] have updated this heat of formation to 2.94 ± 0.06 kcal/mol. This change makes no significant differ- ence in the level of comparison of computations with the targets utilized in the present work.

In addition to revising the components associated with the hydrogen–oxygen submechanis m, the follow- ing revisions were also adopted over the course of this work.

      Thermochemical Data for CH2 OH

The thermochemical properties of CH2 OH, including enthalpy of formation, standard entropy, and heat ca- pacity at different temperatures, were updated to those reported by Johnson and Hudgens [37]. The data of Johnson and Hudgens also agree well with another re- cent IUPAC evaluation by Ruscicetal. [38]. These ther- modynamic properties were fitted with a 14-coefficient polynomial [39].

      CO+ OH= CO2 + H (R23)

This well-studied reaction is of critical importance to combustion modeling because it is the main pathway to convert CO to CO2 , the oxidation of CO is responsi- ble for a major fraction of the energy release derived in oxidation of hydrocarbons, and CO2  dissociation im- portant in determining adiabatic flame temperatures as a function of pressure. The reaction proceeds through the formation of HOCO adducts and thus is pressure dependent, particularly at low temperatures  [25,40]. Under most practical combustion conditions, however, the reaction can be treated as pressure-independent.

*In verifying the published mechanis m, we found that the model reported in [4] resulted in calculated flame speeds that were much higher than those shown in the publication. Dr. Held [32] concurs that the flame speed calculations reported in the paper resulted from the slightly modified version of the reported mechanis m, used as a basis in the current work.

The rate of oxidation of H2/CO/O2  and moist CO mixtures is very sensitive to reaction (R23) [8]. More- over, laminar flame speed predictions of hydrocarbons are strongly influenced by this reaction [41,42]. It is not surprising that targets such as shock tube ignition delay data or flow reactor data would constrain model parameters only over the particular range of temper- ature covered by the work. However, the temperature range over which laminar flame speed predictions are most sensitive to a particular elementary reaction has typically not been considered.

Recently, Zhao et al. [43] introduced a methodology to  determine  the  temperature-dependent  sensitivity of premixed laminar flame speeds to elementary rate constant   and  transport  properties.  An alyses  were conducted by locally perturbing the parameter with a Gaussian function profile. The center of the Gaussian profile was moved with an assigned temperature mean, and the sensitivity of the predicted flame speed was determined as a function of the perturbation-assigned mean temperature.  The  a nalysis  leads to the  deter- mination  of  a  “temperature  window”  in  which  the predicted  laminar  flame  speed  is found to be most sensitive to perturbations in the particular parameter. The  temperature  sensitivity  of  laminar  flames  for hydrogen/carbon  monoxide  mixtures  with  respect to (R23) was used as an application demonstration. The predicted laminar flame speed was shown to be most  sensitive  to  the  specific  rate  of  (R23)  in  the temperature range 300–1900 K (Fig. 1).

Recently,  Yu   [44],  Troe   [45],  Zhu   et  al.  [46], and  Senosiain  et  al.  [25]  performed  detailed  Rice– Ramsperger–Kassel–Marcus (RRKM) calculations to model the temperature and pressure dependence of this reaction. Most of these correlations were primarily cal- ibrated against high-temperature shock tube data and predict higher rates than experimental measurements at low to intermediate temperatures, as shown in Fig. 2 (the only exception being the results of Zhu et al. [46] which underpredict the majority of experimental data at the temperatures of interest). These temperatures include  the temperature  sensitivity  window  for  CO laminar flame speed to this reaction. If one assumes that the theoretical fits misrepresent the specific rate of this reaction by comparison with the (presumably) more accurate experimental data at these temperatures, one would expect CO/H2  flame speeds to be overpre- dicted with the reaction models based on these rate parameters. Indeed, as shown in Fig. 3, GRI-Mech 3.0 [47], which uses the values of Yu [44], overpredicts the experimentally measured CO/H2/air laminar flame speeds of McLean et al. [48].

On the basis of the above considerations, we fit the entire body of experimentally measured rate constants

image.png

Figure   1    Sensitivity   spectrum    of   reactions   CO+ OH = CO2+ H,    (R23),   HCO+ M = H+ CO+ M,   (R24),    and HCO+ O2 = HO2+ CO, (R25), for a range of equivalence ratio predicted by the present C1/O2  kinetic  mechanis m. The figures are taken from Zhao et al. [43]. Figure (a) is the sensitivity spectrum of (R23) for ambient CO/H2/air flames of two initial fuel compositions (95% CO+ 5% H2  and 50% CO+ 50% H2); (b) is that of (R24) and (R25) for ambient CH3OH/air flames. Bars indicate the temperature range where the sensitivity is more than 10% of the maximum value, and lines represent the temperature span for the specific flame.

available in the literature [44,49–54] by the method of weighted least squares to obtain a more representative correlation of the experimental measurements of this rate constant. The sum of weighted squared errors

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is minimized by taking the rate constant, k, as

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In Eq. (1), kexp  is the rate constant measured experi- mentally at temperature Ti , and σi  is the absolute error of log kexp at Ti . Equation (2) was used as the rate con- stant of reaction (R23) in this study. The values shown  in parentheses in Eq. (2) are the 95% confidence inter- vals of the fitted parameters.

Figure 2 shows the comparison of this expression with literature results, including those of Lissianski et al.  [54] which in the current study were recalcu- lated based on the present thermochemical data and the rate constant of the reverse reaction of (R23) provided in the original paper  [54]. The new correlation pre- dicts specific rate constant values in close agreement with those obtained from the correlation of Yu et al.

[55]  (within  6%  at  800–3500 K) derived by  fitting their high-temperature experimental measurements in a  shock  tube.  In  the  temperature  window  of  800– 2000 K, predictions from the new expression agree well (within 10%) with those of Troe [45] at 1 atm, while they are about 20% lower than the theoretical predictions of Yu [44] and Senosiain et al. [25] at1atm.

Very recently, and since the thesis research on this work  [26], another theoretical treatment of reaction 

image.png

Figure 2    Rate constant of reaction CO+ OH → CO2 + H (R23).  Symbols  are  experimental  data  (except  for  atmo- spheric pressure theoretical results of Zhu et al. [46]). Lines are the recommendations of Yu [44], Troe [45], Yu et al. [55] at 1 atm, Senosiain et al. [25] at 1 atm, Joshi and Wang [56] at the low-pressure limit, and that used in the present C1 mechanis m (Eq. (2)).

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Figure 3    Laminar flame speed of CO/H2/air mixtures at 298 K and  1  atm. The fuel composition is 95% CO and 5% H2 . Symbols—experimental data of McLean et al. [48]; dotted line—predictions of GRI-Mech 3.0 [47]; solid line— predictions of GRI-Mech 3.0 modified by replacing the rate coefficients of reactions (R24) and (R25) with the recom- mendations of Friedrichs et al. [ 19] and DeSain et al. [24], respectively.


(R23) has appeared in the literature  [56]. Joshi and Wang [56] have pointed out that consideration of both cis- and trans-isomeric forms of HOCO adduct as well as hindered rotation connecting the two (ignored in prior theoretical studies) leads to significant changes in the predicted thermal rate constant for reaction (R23). The resulting expression recommended by these au- thors is also plotted in Fig. 2. As can be seen, their re- sult is significantly lower at the intermediate tempera- tures of interest than the earlier theoretical predictions. Joshi and Wang have also indicated that “the treatment of the title reaction (R23) remains semi-empirical as more than one different model can satisfactory repro- duce a wide range of data.” The present empirical fit (Eq. (2)) is approximately half-way between the the- oretical results of Senosiain et al.  [25] and the new results of Joshi and Wang [56].

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Both the unimolecular decomposition and abstraction reactions of formyl radicals are the main pathways to generate CO during the high-temperature combustion of hydrocarbons. Because the H atom in HCO is very weakly bound, the dissociation reaction (R24) com- petes strongly with the H-abstraction reactions from HCO by H, OH, and O2. Timonen et al. [57,58] di- rectly measured the rate constant of reactions (R24) and (R25) in a heated tubular reactor below 832 and 713 K, respectively. More recently, Friedrichs et al.

[ 19] detected HCO in a shock tube for the first time by using frequency-modulated spectroscopy. Based on a reaction mechanis m primarily derived from GRI-Mech 3.0 [47], the rate constant of reaction (R24) was esti- mated by fitting the experimental HCO profiles at 835– 1230 K [ 19]. The work of Friedrichs et al. [ 19] infers that the rate of (R24) is about two times lower than the measurements of Timonen et al. [57]. DeSain et al. [24] also studied reaction (R25) at 296–673 K experi- mentally and reported a temperature-independent rate constant, which is about two times lower than that of Timonen et al. [58] at 1000 K.

In a flow reactor study of CH2 O/NO/O2 , Glarborg et al. [59] adopted the expressions of Friedrichs et al.

[ 19] and DeSain et al.  [24] for reactions (R24) and (R25), respectively, in a revised kinetic mechanis m, which predicted their flow reactor measurements rea- sonably well. Incorporating these expressions within the present mechanis m also results in as good agree- ment  with  the  flow  reactor  experiments  of  [9]  as achieved using the recommendations of Timonen et al. [57,58]. Closer inspection, however, reveals that the ratio  k24/k25   for the  new  correlations  is  almost the same as that used previously, and that the CH2 O/O2 system predictions under flow reactor conditions are sensitive to this ratio, rather than to the absolute mag- nitudes of the individual specific rate constants  [9]. On the other hand, premixed laminar flame speeds of  hydrocarbons, particularly those of simple oxygenates such as formaldehyde and methanol, are very sensitive to the absolute rates of (R24) and (R25) (e.g.,  [4]). Using the recommendations of [ 19,24] yields substan- tially different flame speed predictions from those ob- tained with the correlations of Timonen et al. [57,58]. Attempting to compensate for these discrepancies by combinatorial modifications of other elementary rate constants degrades the quality of predictions against other experimental targets.

Figure 3 compares the experimental flame speeds of CO/H2/air mixtures  [48]  with model predictions of GRI-Mech-3.0 [47] and with the predictions of a “modified”  GRI-Mech-3.0 in which the rate coeffi- cient correlations for reactions (R24) and (R25) are replaced by the recommendations of Friedrichs et al. [ 19] and DeSain et al. [24], respectively. The overall uncertainty of the experimental flame speeds was re- ported to be ±3% [48]. Obviously, the predictions of the modified mechanis m are significantly degraded in comparison to those using the original mechanis m and depart substantially from the experiments, particularly at fuel rich equivalence ratios. Similar behavior was observed for the laminar flame speeds of other hydro- carbon/air mixtures, particularly those for CH3 OH/air and C2H5 OH/air mixtures. In further demonstration of the novel method of temperature-dependent sensitivity an alysis, Zhao et al. [43] showed that 1300–2000 and 1200–1900 K are the temperature windows where hy- drocarbon laminar flame speed predictions are most sensitive  to  reaction  (R24)  and  (R25),  respectively (Fig. 1). These temperature ranges are well above the range of conditions of both the recent measurements of [ 19,24], and the earlier measurements of Timonen et al. [57,58]. Extrapolation of the rate constant cor- relations recommended in [ 19,24] yields substantially lower values for the rate constants within these temper- ature ranges than extrapolation of those recommended in [57,58]. As a result of these an alyses, the correla- tions recommended previously by Timonen et al. [57] and those in [ 19,24] were not adopted in this study even though the reported rate measurements [ 19,24] appear to have s maller estimated uncertainties than the previ- ous measurements [57,58]. Instead, we again applied a weighted least-squares fitting to all experimental data available in the literature for k24  [ 19,20,57,60–73] to yield a new rate correlation,

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Figure 4 compares this new correlation with the litera- ture data and the previous correlations. In the range of

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Figure   4    Rate   constant   of   reaction   HCO+ M    →H+ CO+ M  (R24). Symbols and lines with  symbols are literature results: 田 Friedrichs et al. [ 19];   Hidaka et al. [20]:  o Timonen  et  al.  [57];   Pearson  et  al.  [60];  -8- Schecker et al. [61]; 8- Browne et al. [62];   Bowman [63]; ▲ Ahumada et al. [64];     Baldwin et al. [65];   Wang et al. [66]; v Westbrook et al. [67];  Campbell et al. [68]; v Hochnadel et al [69];  Cherian et al. [70];  Cribb et al. [71];   Krasnoperov et al. [72];   Hippler et al. [73]. The dotted line is the recommendation of Timonen et al. [57], the dashed line is the recommendation of Friedrichs et al. [ 19], and the solid line represents the values used in the present model (Eq. (3)).

1500–2000 K, the prediction of Eq. (3) agrees with the data correlation of Timonen et al. [57] within 30% and is about 2–3 times higher than the correlation recom- mended by Friedrichs et al. [ 19]. Over 500–1300 K, where the rate coefficient of (R24) was measured by Friedrichs et al. [ 19], Timonen et al. [57], Krasnoperov et al.  [72], and Hippler et al.  [73], the  current cor- relation predicts values  almost equidistant from the measurements reported by Timonen  et  al.  [57]  and Friedrichs et al. [ 19].

It  should be noted that the correlation  shown in Eq. (3) was obtained by fitting low-pressure limit data. Timonen et al. [57] concluded, based on resonance the- ory, that significant deviations from the low-pressure limit would occur at (high) pressures beyond the scope of practical combustion processes, and reaction (R24) may be regarded as being in the low-pressure limit for most combustion applications. Recently, the pressure dependence of the rate constant of reaction (R24) has been measured by Krasnoperov et al. [72] and Hip- pler et al. [73], and the data show a somewhat unusual pressure falloff behavior. Based on their measurements and an isolated resonance model with variable reso- nance lifetimes, Hippler et al. [73] challenged the con- clusions drawn by Timonen et al. [57] and indicated

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Figure 5    Pressure dependence of the rate constant of re-action (R24) as measured by Krasnoperov et al. [72] (     : 1 bar; ◇ : 10 bar;  : 30 bar; o : 100 bar) and Hippler et al. [73] ( x : 1 bar;  : 10 bar;  米 : 30 bar; + : 100 bar), the rate expression used in the present model (solid line) as well as the low pressure measurements of Friedrichs et al. [ 19] and Timonen et al. [57] (  and , respectively) are also shown for comparison.

that deviations from the low-pressure limit may occur even below atmospheric pressure; Krasnoperov [74], however, has questioned the experimental method and an alyses performed by Hippler et al.  [73] when ob- taining low-pressure data (see [74,75] for full details). Figure5plots the pressure-dependent measurements of Krasnoperov et al. [72] and Hippler et al. [73] and com- pares them against the low-pressure data of Friedrichs et al. [ 19] and Timonen et al. [57] as well as Eq. (3). It is clearly seen that, even though falloff behavior is ob- served, the deviation from the low-pressure limit data is only significant at temperatures below 580 K; the calculated values (using Eq. (3)) are within a factor of 2–3 of the measured high-pressure data below this temperature. At lower temperatures and in any applica- tions related to combustion, the reaction of HCO with HO2 will be far more important than (R24). Therefore for combustion modeling, the use of a low-pressure limit rate constant for reaction (R24) causes no signif- icant differences in model predictions. Regardless of this result, more studies of the falloff behavior of (R24) are warranted.

Because there are few  specific experimental rate constant measurements at high temperatures for (R25) (e.g., see NIST kinetics database; http://kinetics.nist. gov),  the  recommendation  of  Timonen  et  al.   [58] was retained  [93].  Given the fact that the new rate expression  for  (R24)   (Eq.   (3))  does  not  deviate considerably from the recommendation of Timonen et  al.  [57]  over  the  temperature  range  relevant  to flow  reactor  studies,  retaining  this  rate  coefficient does not significantly alter the k24/k25  ratio which, as mentioned above, is important for the CH2 O system at flow reactor conditions. More recently, Colberg and Friedrichs [76] published new measurements for the rate of reaction (R25) at both room temperature and in the temperature range of 739–1108 K. Implementing this newly proposed rate (k25  (295 K) = 3.55 × 1012 ; k25  (739–1108 K) = 3.70 × 1013 exp(_1563/T ) cm3/ mol/s) in the present mechanis m has little impact on the quality of its predictions against targets discussed in the sections below. Under flow reactor conditions, this  rate  differs  by  no  more  than  20%  from  the recommendation of Timonen et  al.  [58],  assuring  a reasonable k24/k25   ratio. At higher temperatures  (T > 1500 K), however, the new rate correlation yields values  approximately  twice  those  recommended  in [58] and results in some differences in the modeling of laminar flame speeds (see Fig.  1). Laminar flame speed predictions are changed by approximately 10%, slightly  more  than  typical  uncertainties  in  modern measurements reported in the literature. On the basis of these results and considering that the new expression of Colberg and Friedrichs [76] has not been validated at   higher  temperatures,   we   continue   to   use   the recommendation of [58] in the model reported here.

       CH2 O-Related Reactions

In addition to the modifications inspecificrate constant correlations  for  reactions  (R23),  (R24),  and  (R25), other  important  reactions  for  the  CH2 O/O2   system were reviewed and the rate constants were updated to those appearing in more recent publications. These reactions include

        CH2 O+ M = H+ HCO+ M(R34)

        CH2 O+ M = H2 + CO+ M(R35)

        CH2 O+ H = HCO+ H2(R36)

        CH2 O+ HO2 = HCO+ H2 O2(R40)

        CH2 OH+ HCO = CH2 O+ CH2 O(R60)

Formaldehyde oxidation is very sensitive to the ab- straction reactions (R36) and (R40) under flow reac- tor conditions, and to the unimolecular decomposition reactions (R34) and (R35) in shock tube studies, as demonstrated earlier [9]. Eiteneer et al. [21] studied the ignition of CH2 O/O2/Ar mixtures behind reflected shock waves and developed an expression for the rate constant of reaction (R40) by fitting their data and liter- ature results. This new expression yields rates in close agreement with those used by Hochgreb and Dryer [9]

at intermediate temperatures (within 7% at 1000 K), while the predicted rate constant is about two times higher at 500 and 2000 K. In the current study, the rate correlation for (R40) suggested by Eiteneer et al. [21] was adopted.

Irdam et al. [77] performed formaldehyde pyroly- sis experiments and transition state theory calculations for reaction (R36). The recommended rate coefficient, adopted in the present study, was later found to be in excellent agreement with the direct measurements of Friedrichs et al. [78]. In a shock tube study of CH2 O thermal decomposition, Friedrichs et al. [22] measured the species time history profiles of CH2 O andHCO and conducted RRKM calculations for reactions (R34) and (R35). The authors also presented a new value for the rate constant of reaction (R60), which becomes impor- tant for mixtures with high concentrations of CH2 O. The recommendations of Friedrichs et al. [22] for reac- tions (R34), (R35), and (R60) were used in the current mechanis m. In addition, the rate coefficient of reac- tion,

          CH2 OH+ HCO = CH3 OH+ CO           (R59)

which competes with reaction (R60), was modified to 1 × 1013  cm3/mol/s, thus keeping the branching ratio, k60/k59 , the same as in the original mechanis m [4].

Furthermore, in an effort to include in the present model the most up-to-date rate information for the sys- tems treated in this study, the very recent measurements of the addition of OH and O2  to formaldehyde (reac- tions (R38) and (R39), respectively) have been adopted from the studies of Vasudevan et al. [79,80]. The rec- ommended rate constants [79,80] are within a factor of 2 of those suggested by Tsang and Hampson [81].

CH3 OH-Related Reactions

As in the case of formaldehyde, themethanol oxidation system is very sensitive to fuel abstraction and decom- position reactions [4]. There are several publications on the kinetics of these reactions that have appeared after the work of Held and Dryer [4]. In GRI-Mech 3.0 [47], the decomposition reactions of methanol were investigated using the RRKM theory and results were then fitted to several sets of experimental data pub- lished from 1984 to 1994. The obtained rate constants were expressed in Troe form [82] for the temperature and pressure dependence of the decomposition reac- tions. Koike et al. [83] have estimated the rate constant of the major decomposition reaction of methanol,

      CH3 OH (+ M) = CH3 + OH (+ M)         (R72)

from shock tube experiments of CH3 OH pyrolysis at 0.4–0.82 atm and  1400–2500 K. Under these condi- tions, the estimated rate constant isin reasonable agree- ment (about 50%) with that provided in GRI-Mech 3.0. In a more recent study, Krasnoperov and Michael [84] have reported the experimental recombination rates of CH3 and OH at conditions close to high-pressure limit that are lower than the high-pressure reverse rate of (R72) used by GRI-Mech. While detailed multichan- nel simulations of this system that would attempt to reconcile these new data are clearly warranted for fu- ture studies, the GRI-Mech 3.0 [47] rate constants for methanol decomposition reactions were adopted in the current study. There are two pathways for methanol abstraction reactions due to the two distinct sites of H  atoms in CH3 OH molecules. Jimenez et  al.  [85] experimentally derived the total rate constants of the abstraction reaction

        CH3 OH+ OH → products

at 235–360 K. The total rate constants agree within 20% with those of Bott and Cohen [86], which were used in the original mechanis m [4] and retained in the present work.


RESULTS AND DISCUSSION

The revised C1/O2 mechanis m as described above con- sists of 84 reversible elementary reactions among 18 species and the thermochemical data listed in Tables I and II, respectively. Reverse rate constants are com- puted from the forward rate constants and the equilib- rium constants. The first 31 reactions listed in Table I can be used as the comprehensive kinetic model for CO combustion, and it predicts the same behavior of CO/H2/O2  systems as that found using the entire C1 oxidation  mechanis m.  The  absence  of potential  C2 submechanis m elements as well as CH2  (singlet and triplet states) reactions on CO, CH2 O, and CH3 OH oxidation predictions for the targets investigated here was tested by incorporating a C2HX  (X = 1–6) reac- tion subset primarily taken from Wang et al. [ 112] and comparing predictions with the original mechanis m. Negligible differences were found for all of the cases studied here. For example, the compiled C2 mechanis m predicts less than 1% higher CH3 OH/air flame speeds than the present C1  model.

The current C1/O2  mechanis m has been compared against a wide range of experimental results, includ- ing laminar flame speeds, shock tube ignition delay data, and  species profiles measured in flow reactor, shock tube, and burner-stabilized flame studies. 

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SENKIN code [ 113] was used to simulate experimen- tal conditions in shock tubes and flow reactors assum- ing adiabatic systems under constant volume and con- stant pressure, respectively. The PREMIX code [ 114] was used for flame calculations. We used the standard CHEMKIN transport package [ 115] with Soret effects and multicomponent diffusion included. To assure a fully converged flame speed prediction, a minimum of 1000 grid points was imposed in the PREMIX calcula- tions. Tables III–V list the experiments that the current CO/H2/O2 , CH2 O/O2 , and CH3 OH/O2 mechanis m has been compared against. Representative results for these comparisons are shown in Figs.6–26. The performance of each of the hierarchical submechanis ms involving carbon is discussed below.

CO/H2/O2  Mechanis m Predictions

Comparisons in Figs. 6 and 7 show that the predic- tions of the current CO oxidation mechanis m are in good agreement with thepremixed laminarflame speed measurements  for  CO/H2/O2/N2   mixtures  at  atmo-spheric pressure. Predictions also compare very well with shock tube ignition delay data, as demonstrated in Figs. 8 and 9. The predicted ignition delay times presented in these figures were defined as the time required for CO2  [ 116] or OH [ 117] concentration to reach aspecified value, similar to the criteria used in the experimental work. Figures 10 and 11 show the time history of major species under flow reactor conditions. Predictions using the current mechanis m agree very well with all of the experimental target information.

spheric pressure. Predictions also compare very well with shock tube ignition delay data, as demonstrated

in Figs. 8 and 9. The predicted ignition delay times presented in these figures were defined as the time required for CO2  [ 116] or OH [ 117] concentration to reach aspecified value, similar to the criteria used in the experimental work. Figures 10 and 11 show the time history of major species under flow reactor conditions. Predictions using the current mechanis m agree very well with all of the experimental target information. Sensitivity an alyses were performed based on the present CO oxidation mechanis m for three representa-tive cases: the laminar premixed flame speed at equiv-alence ratio of 5.0  [48], the mass fraction of CO in a VPFR case at 3.5 atm  [ 118], and the ignition de-lay  time  under  the  shock  tube  conditions  of  Dean et al. [ 116]. The most sensitive reactions along with their sensitivity coefficients are shown in Fig. 12. The normalized sensitivity coefficient of a reaction is de-fined as,  ∂ ln Y/∂ ln k ,  ∂ ln s/∂ ln k, and  ∂ lnτ/∂ ln k for the disappearance of a species Y in a flow reactor, for laminar flame speed, and for ignition delay time,

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Figure 6    Laminar flame speeds of CO/H2/air mixtures at 298 K and 1 atm for two fuel compositions (95% CO+ 5% H2  or 50%  CO+ 50% H2). Symbols represent the exper- imental data  [48], and lines are predictions of the present CO/H2/O2 mechanis m.

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Figure   7    Laminar   flame    speeds   for    stoichiometric CO/H2/air mixtures (top) and reformer gas/air mixtures (bot- tom) at 298 K and 1 atm. Composition of reformer gas is 28% H2, 25% CO, and 47% N2 . Symbols represent the ex- perimental data of McLean et al. [48] (top), and Huang et al. [23] (bottom). Lines are predictions of the present CO/H2/O2 mechanis m.


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FEMFAT对于电弧焊接的疲劳评估方法

DannbauerHelmut,HofwimmerKlaus,ZhangWenxuanMagnaPowertrainEngineeringCenterSteyrGmbH&CoKG,Austria麦格纳动力总成–斯太尔工程中心关键字–有限元,疲劳,焊缝,标准,S/N曲线摘要–基于有限元分析的疲劳评估在汽车工业中被广泛的应用。但是如何处理在车身和底盘等结构中的焊接问题任然是一个研究课题。这篇论文将给出一个总揽并且对焊缝疲劳评估的不同方法进行对比。.基于标准的焊缝疲劳评估(EUROCODE3,BS7608,DS1612):基于名义应力的细分类别将被用来与一条S/N曲线相关联;平均应力的影响将以不同的方法进行处理(MKJ-图,减少负载循环中的压缩受力部分)。.基于德国FKM标准的焊缝疲劳评估:针对S/N曲线的细分类别;所有3个应力分量将被分别分析;不同的Haigh-图将应用在不同的残余应力等级上。.基于来自于有限元分析的结构应力的焊缝疲劳评估:简单板壳单元提供的结构应力将被用于与凹槽参数数据库相结合,以获得凹槽应力。.基于来自于有限元分析的凹槽应力的焊缝疲劳评估:带有1mm或5mm凹槽半径的实体模型将被用来进行凹槽应力分析;凹槽应力将应用主S/N曲线进行评估。.基于来自于有限元分析的节点受力的焊缝疲劳评估:从沿着焊缝走向的节点受力可以获得线载荷,它们将结合分析理论方程对结构应力进行计算。凹槽应力将通过凹槽系数的分析评估被确定下来,一个主S/N曲线将用于损伤值分析。各种不同方法的规范将在理论上进行介绍并且提供一个应用案例用以说明它们在实践中的不同之处。1.简介车辆必须能够承受动态应力,它的部件包含不同的焊缝、焊点和凹槽。在加工过程中非常不同的工艺处理将被应用。这些对于使用中的疲劳寿命会产生正面的或是负面的影响。焊缝特性对于车辆板材部件的刚度和硬度也会产生不同的影响。焊接工艺、焊接类型和焊缝的位置以及焊点的数量和分布有着极大的在技术上的和经济上的影响。实践告诉我们在底盘的疲劳试验中超过90%的裂纹来自于连接部位(1)(2),原因是,相对比基础材料焊缝和焊点具有相对较低的动态强度值。大量的标准规范以及出版物提供了不同的方法以评估在一个构件寿命周期内的动态应力。一些方法是基于名义应力的。另外一些方法应用结构或是凹槽应力以及最新的方法应用节点的受力。这篇文章的目的是想展示一下焊缝结构疲劳分析中不同的评估方法,以及通过一个应用实例来讨论一下这些方法的优点和可行性。2.基于规范的焊缝疲劳评估除了在汽车工业中的应用,按照规范焊缝结构的疲劳评估被广泛应用到许多行业中。尤其是在铁路或是其它安全相关的行业,基于大量的实验结果,规范提供了一个传统的和安全的方法。在通常情况下对于大多数常用的焊接结构,一个所谓的细分类别(detailcategories),通过疲劳实验可以对垂直和平行于焊缝的法向应力以及对剪切应力的S/N曲线进行建立。为了评估一个焊接结构,每个焊缝连接必须在规范中为每个分应力指定一个细分类别。规范中的各个S/N曲线将与名义应力,或由分析近似、有限元分析或试验中得来的结构应力相协同使用。2.1Eurocode3(3),BritishStandard7608(4),IIW-Guideline(7)这三个焊缝疲劳评估规范是大家非常熟悉的。Eurocode3和IIW-Guideline的主要规定是依赖于一套S/N曲线束,它们是同等间距的,并依赖于一套被分类的结构详图。与Eurocode3不同,规范BS7608的S/N曲线并不是等间距的而且斜率也在m=3到3.5和4到8之间变动(见图1)。图1:法向应力的S/N曲线,EUROCODE3(左)和BritishStandard7608(右)2.2DV952和DVS1612规范在德国铁路交通工具规范DV952(5)和DVS1612(6)中给出了可允许的最大主应力或是剪切应力相对于应力比率R的图表。在每个图表中对于几种凹槽类别给出了不同的曲线。这样就可以从一个凹槽类别和平均应力(分别的R值)找到相应的疲劳强度。这些图表可以应用于如下材料的焊接:DV952:St37,St52-3,AlMg3,AlMgMn,AlMg4.5Mn,AlMgSi1,AlZnMg1DVS1612:S235,S355在焊缝中的σmax或τmax的最大应力应当被确定,这个最大值必须小于图表中可允许的数值。这意味着,应用这些规范,仅能够评估疲劳安全系数,而不能够研究疲劳寿命。2.3FKM标准德国FKM标准用于评估钢和铝材料的焊接和非焊接构件的疲劳问题。这个标准对于工程师来说是一个非常强大的工具,它同时考虑了大多数对构件强度(静态和动态)产生影响的参数。关于焊缝评估,这个标准的应用类似于规范EUROCODE3和IIW-Guideline的细分类别。每个应力分项(σ丄,σ||,τ)必须通过利用度(utilizationdegrees)a的构成来单独评估:应力角标的说明:a应力振幅丄方向垂直于焊缝adm…在S/N曲线中允许的应力值||方向平行于焊缝对于复合应力状态,一个等价利用度(equivalentutilizationdegree)aV必须被使用:在表1中提供了各标准最重要的特征:图1:不同标准的最重要的特征σ丄垂直于焊缝的法向应力ΔσR基础S/N曲线的应力范围τ丄垂直于焊缝的剪切应力ΔσR,t考虑壁厚的应力范围τ||……平行于焊缝的剪切应力σ1……最大主应力teff……壁厚效应n=0.1–0.3……厚度校正的指数tref……参考板材壁厚3.应用有限元分析的结构应力进行焊缝疲劳评估应用名义应力对一个复杂的构件进行焊缝评估是十分困难的并且在很多情况下仅能做粗略的评估。有限元方法(FEM)提供了一个对结构应力的快速和准确的评估可能,它运用简单的板壳模型并且不考虑焊缝的几何结构。如下的步骤需要被留意:.部件的FEM模型来重现全局刚度;.从焊缝中确定结构应力的一个固定位置(或是用一个建模指导方针来控制单元尺寸,或是用软件工具来降低网格尺寸的影响);.基于结构应力的凹槽应力近似值;.通过一条主S/N曲线的凹槽应力评估;主S/N曲线的确定和凹槽应力的近似将在如下的篇章中进行表述。3.1半径1mm的平均值/离散度概念(R1MS)Radaj,Koettgen,Olivier和Seeger开发了一个方法,它可以进行焊缝动态强度极限的平均值和离散宽度的预测(9)。在对不同的焊接类型、负载状况和应力关系的41次试验系列中(大约400次单独试验),构件的S/N曲线被确定下来。所有的试棒都是经过退火的。然后对每一个试验系列在横截面裂纹损伤处的相应凹槽应力用数学方法从新进行了计算。在这样做的时候,焊缝的根(root)和脚(toe)的几何结构被模拟成一个凹槽半径为r=1mm。所模拟的焊缝上升角(weldclimbangles),它在焊脚对凹槽应力有很大的影响,近似的与每次单独的试验系列相一致。Fig.2:存活率[%]相对于疲劳强度1mm。图2显示的由试验确定的构件强度计算得来的凹槽应力疲劳极限,并应用上述所描述的模型r=1mm。虽然焊缝类型是不同的,但是却得到了一个小离散的凹槽应力疲劳极限的唯一值。这个结论对恒量应力比率R=-1和R=0是同时有效的。在图1中所给出的数值已经被核实并且对于其它焊接类型通过DVS(10)的S/N曲线目录同样被证实。这样就可以规定,对于任何由法向应力加载的焊接结构,焊根和焊脚的疲劳强度可以通过上述的模型被预测。这意味着,我们已经获得了一条主S/N曲线,它可以用在任何的焊接类型和焊接结构中。3.2凹槽应力的确定通过局部焊缝坐标,焊缝的应力状态可以由位于焊缝单元的应力状况的有限元结果来确定。根据Radaj的1mm倒角理论,凹槽应力可以通过子模型技术被计算出来。图3:为计算凹槽应力的Radaj子模型为了避免为构件的每个焊缝建立子模型,仅需要一次性的为绝大多数常用的焊接类型和焊缝结构进行建立。对于非常重要的载荷类型(拉伸,弯曲以及在网格平面的受力流),凹槽系数被存储在一个数据库中。基于来自有限元分析的结构应力,这些凹槽系数被用来近似的得到凹槽应力。根据Koettgen,Olivier和Seeger(R1MS概念),凹槽应力(基于1mm凹槽半径)可以通过主S/N曲线来被评估。这个方法已经包含在商业疲劳软件FEMFAT®(11)中了。在FEMFAT®中对电弧焊接的疲劳评估包含如下的部分(总揽请见图4):●焊缝有限元模型建立指导方针;●凹槽系数的数据库、Haigh图、S/N曲线和板材厚度的影响;●自动识别、分配和评估整个构件的所有局部焊缝区域;●自动应力修正以降低有限元网格密度的影响。图4:FEMFAT®焊缝仿真方法3.3最小板壳单元尺寸的影响焊接构件的有限元模型,如乘用车卡车的车架、白车身结构、火车底盘等,大多数都是由薄板壳单元进行建立的。对于焊接的评估在通常情况下,那些临近于焊缝的单元将会被使用。在这种情况下所使用的应力非常依赖于单元的大小。图5展示的是对于四种不同的单元尺寸(10x10mm,5x5mm,2.5x2.5mm和1.25x1.25mm),垂直于搭接接头焊缝的法向应力分布。一方面在接头处的应力尖峰值依赖于单元尺寸,在另一方面在与接头有一定的距离处应力大小对于所有不同的网格密度几乎是近似的。图5:对于不同单元尺寸的搭接接头焊接的应力分布疲劳分析软件FEMFAT提供了一个对焊缝进行自动应力修正的功能。给用户提供了可能来定义距离焊缝的特定间距。在默认情况下,这个间距使用最小板材厚度,它是焊脚所处的位置,介于焊缝和高热影响区域。在实际中,疲劳裂纹总是开始于这个位置或是在焊根处,进行疲劳分析也同样是在这个位置。FEMFAT由周边的单元把所要评估的应力给内插出来(见图6)。在图6中标记有X的单元应力被用来进行当前焊缝单元的评估。加权平均值的应力分项用下面的公式进行计算:σj…当前焊缝单元评估的应力分项(横向的、纵向的和剪切分量)。σi,j…在评估点单元i的j应力分项(参照局部焊缝坐标系的横向、纵向和剪切分量)。di…单元i的单元中心到评估点的距离。n…用于评估当前焊缝单元的在评估点的单元数量。图6:FEMFATWELD的自动应力修正这个步骤可以工作于一次和二次的板壳单元。这样FEMFAT提供了可能来使用一个距焊缝恒定的评估距离(焊脚位置),而不依赖于单元尺寸的影响。另外一个减少单元尺寸影响的可能是应用一个依赖于节点受力的方法,将在后面的篇章中进行阐述。4.应用有限元分析的凹槽应力进行焊缝疲劳评估另外一种得到更准确应力结果的可能是通过精细网格划分来建立焊缝几何结构(焊缝上升角的平均值,焊根合并度等)。它使用1mm圆角半径的焊根和焊脚凹槽。对于薄板材(壁厚小于5mm)或非常尖锐的凹槽,一个0.05mm的圆角半径被认为能够减少主S/N曲线的离散带(见(12)和(13))。图7:精细的焊缝实体有限元网格图8:对于凹槽半径0.005mm(12)的主S/N曲线如果使用图8中的S/N曲线,就不再需要对凹槽支撑效应进行考虑了。因为它已经包含在S/N曲线中了。5.应用有限元分析的节点受力进行焊缝疲劳评估对于所有上面所描述的方法,有限元应力或名义应力被用来进行评估。通常情况下有限元分析的应力结果对网格的尺寸和质量是十分敏感的。另外如果应用板壳单元非常详细的焊缝形状也很难被考虑。克服这些困难的一个方法是根据Zhang(14),基于受力的焊缝评估方法。图9:基于受力的焊缝评估参照Zhang(14)这个方法需要与一个简单的板壳单元模型联合使用,它包含4个步骤:1.基于临近单元的节点受力,确定沿着焊缝的线受力。对有限元网格大小和质量的敏感度被大大的降低了。2.根据平面理论,把线受力转化为结构应力。在分析法方程的帮助下并考虑详细的焊缝结构(焊缝厚度、焊接上升角),把垂直于焊缝方向的线受力和扭矩转化为结构应力。3.运用分析方法在焊缝的危险点处,基于结构应力对凹槽应力进行评估。4.应用一个主S/N曲线对凹槽应力进行评估。6.应用实例:卡车刚性轴图10展示了一个刚性轴的实验装置。这个轴的一端被固定,在另一端承受一个(R=0)的44kN循环剪切弯曲受力。图10:一个卡车刚性轴的弯曲受力实验装置损坏发生在减震器支架的一个焊缝处。这个支架本身并不承受应力,仅仅是轴管在承受弯曲。最大法向应力也因此任然是垂直于焊缝,支架板材仅受到微小的应力负载。在实验中的疲劳寿命循环是112,200次(见图11)。图11:卡车刚性轴的循环实验6.1使用标准规范评估刚性轴使用名义应力和S/N曲线细分类别进行按照规范EUROCODE3,BS7608和IIW-Guideline的疲劳评估。剪切应力非常的低,所以忽略不计。这样垂直于焊缝的法向应力就被用来当做等价应力了。在危险区域的名义应力σn(大约距夹具60mm的距离):得到:σn=423N/mm2这个名义应力值代表了负载循环的上应力(upperstress)。下应力(lowerstress)为零(R=0),因此应力振幅和平均应力(σa,n和σm,n)为:σa,n=σm,n=σn/2=211.5N/mm2现在需要从标准中选择恰当的细分类别,并且板材厚度和平均应力的影响需要被检查。使用斜率m1和在拐点Nf处的疲劳强度σR,可以得到对应于名义应力振幅σa,n的寿命循环N:表2:按照不同标准的疲劳寿命表2展示了对于50%存活率和1.0安全系数,根据不同的标准进行的疲劳寿命的评估。EUROCODE3和IIW-Guideline的结果是十分接近的,BS7608显示了比较低的寿命结果,而FKM-Guideline最好的接近于实验结果。总的来说预测的疲劳寿命比实验结果低(3-5倍)。这个方法的优点是,它非常简单和快速而不需要有限元计算的帮助。因此对于简单的例子和一个传统的步骤,这个方法是十分有用的。6.2使用有限元分析的结构和凹槽应力来评估刚性轴一方面一个简单的板壳模型被用来进行结构应力的分析,它不包含关于焊缝形状的详细信息。另一方面对一个详细的焊缝实体模型(大约.1,000,000节点),包含一个在凹槽处圆角半径1mm,进行了详细的研究。应用商业疲劳软件FEMFAT(11)对这两个模型都进行了疲劳分析。图12:在粗略的板壳模型上的疲劳结果图13:在精细的实体模型上的疲劳结果在图中所示的横截面,一方面是做为实体模型凹槽应力分析的基础,另一方面是结合板壳模型做为在FEMFAT焊缝数据库中存储的凹槽系数的基础。在焊脚处的疲劳寿命,简单板壳模型所计算的结果远远的小于实体模型。这说明,采用板壳模型,损坏的位置(焊脚)被预测的更好。6.3使用有限元分析的节点受力来评估刚性轴使用有限元分析的节点受力,我们有能力对详细的焊缝结构进行考虑。焊缝的几何结构可以通过一些参数来进行确定(焊缝厚度、焊缝上升角和焊缝熔深率)。这些参数能够在FEMFAT疲劳软件中人机交互的进行改变。不同焊缝形状的影响研究能够快速和简便的实现,而不需要改变有限元模型或是应力和受力的分析。图14:在粗略的板壳模型上的基于受力的疲劳结果这种方法的实验相关性是最好的。但是危险区域(焊根)并没有正确的确定出来。这种方法的另外一个不足是它仅能够对四种焊缝类型的垂直于焊缝的法向应力进行评估,并且焊缝的尾端不能够被评估。7总结对于焊缝构件不同评估方法的主要原理在这里进行了简要的描述。这些方法的特点通过一个简单示例,一个受弯曲力的刚性轴,进行了研究。结果在下述的表3中进行了总结。基于表3的综述,一个FKM标准加有限元计算的结构应力的组合可以很好的满足疲劳分析结果的要求,并且达到简便灵活的效果。参考(1)Singh,S;Schmid,G;Gao,S.“LeichtbaudurchoptimierteFügetechnik”Proceedingspage239-255lectureandpaperontheoccasionoftheDVMMeeting“Bauteil91”1991(2)Singh,S.;Schmid,G.“DünnblechkonstruktionenundihreEigenschaften–PrüfverfahrenundihreAussagekraft”,Proceedingspage17-26,lectureandpaperatspecialmeetingoftheSLV-Munich“FügenvonAluminiumimDünnblechbereich”1993(3)EUROCODE3:Designofsteelstructures.Part1.1:Generalrulesandrulesforbuildings.ENV1993-1-1(4)BritishStandard7608,“Fatiguedesignandassessmentofsteelstructures”,1993(5)DS952“VorschriftfürdasSchweißenmetallischerWerkstoffeinPrivatwerken.AnhangII:RichtliniefürdieBerechnungderSchweißverbindungen.“,1977(6)GuidelineDVS1612“GestaltungundDauerfestigkeitsbewertungvonSchweißverbindungenimSchinenfahrzeugbau”,DeutscherVerbandfürSchweißenundverwandteVerfahren,2006(7)GuidelineIIW„Recommendationsforfatiguedesignofweldedjointsandcomponents“,IIWdocumentXIII-1965-03/XV-1127-03,2005(8)FKMGuideline“Analyticalstrengthassessment”VMAVerlag,2003(9)KoettgenV.B.,OlivierR.,SeegerT.„SchwingfestigkeitsnachweisfuerSchweissver-bindungenaufGrundörtlicherBeanspruchungen“,ForschungskuratoriumMaschinenbau,Forschungshefte,Heft143,1989(10)KoettgenV.B.,OlivierR.,SeegerT.„SchwingfestigkeitsnachweisfürSchweissver-bindungenaufGrundoertlicherBeanspruchungen“,DeutscherVerlagfürSchweisstechnik,DVS-Report133,pp.75-83,1991.(11)FEMFAT4.7UserManual“Lebensdauer–SimulationdynamischbeanspruchterBauteilefürFiniteElementeModelle”,EngineeringCenterSteyrGmbH,2007(12)EiblM.„BerechnungderSchwingfestigkeitlaserstrahlgeschweißterFeinblechemitlokalenKonzepten“,FraunhoferInst.fürBetriebsfestigkeit,ReportFB-224,2004(13)Morgenstern,C.„KerbgrundkonzeptefürdieschwingfesteAuslegungvonAluminiumschweißverbindungenamBeispieldernaturhartenLegierungenAlMg4,5Mn(AW-5083)undderwarmausgehärtetenLegierungAlMgSi1T6(AW-6082T6)“,MasterThesisTUDarmstadt,2006(14)Zhang,S.“StructuralStressesinSeamWelds”,DaimlerChryslerAG,ResearchReporGR/VMB-07-001,2007免责声明:本页面/内容部分素材来源于互联网公开信息,旨在传递更多信息,不代表本平台立场。版权归原作者或机构所有,如涉及侵权,请通过平台联系我们,我们将在核实后第一时间处理。本平台对转载内容的真实性、准确性不作任何保证,用户需自行判断并承担使用风险。

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