摘要

输煤栈桥是煤炭企业地面运输系统的基础设施和重要通道。随着开采技术的进步和产能激增，输煤栈桥负载增大，持续运行周期延长，使得按原产能设计的栈桥KT型节点易发生疲劳破坏，由此引发的栈桥倒塌事故频频发生，已严重威胁煤矿生产安全。因此，研究长周期、高负载下输煤栈桥的动态响应规律，进而建立科学的疲劳性能评估方法对煤矿生产安全具有重要的理论意义和工程价值。本文以陕北某煤矿输煤栈桥为工程背景，采用理论分析、现场监测、数值模拟相结合的方法，对输煤栈桥桁架的动态响应、整体结构及KT型节点的疲劳性能开展研究，在此基础上进一步对其疲劳寿命进行预测。主要研究工作如下：

（1）综合考虑空载、满载情况下的线性加速、匀速、线性减速、静止等8种工况，提出了基于工作状态的栈桥结构竖向振动的动力荷载模型，在单质点弹簧体系上验证其可靠性，并对栈桥结构进行了有限元计算。结果表明栈桥的工作状态良好，竖向变形、应力计算值与实桥监测值较为吻合。栈桥在运行状态下的竖向振动不可忽略，托辊转动频率与结构一阶频率存在共振的可能，会产生较大幅度的动力响应；栈桥在服役期内存在着超越一般要求的循环次数(5×10⁴次)和速度响应(20mm/s)，有必要对构件进行疲劳验算。

（2）选取了5跨典型桁架结构，进行栈桥动态响应监测，得到了栈桥实际运行状态。监测数据表明，加速度和应力响应均表现出竖向最大的特征，相比于空载状态，满载运行时栈桥结构竖向加速度、应力响应显著增大，名义应力放大系数可达40倍。在栈桥动态响应研究的基础上，采用雨流法将构件应力时程曲线转换为结构应力谱，基于名义应力法对栈桥典型受力节点的疲劳性能进行了评估，分析得到最不利位置为第1监测段跨中上弦杆，其疲劳寿命为173.04年。

（3）选取输煤栈桥典型KT型节点，开展参数分析，分别考虑节点面内和面外弦杆弯矩、腹杆轴力、弦杆与腹杆轴力、腹杆弯矩四种基本荷载工况，研究了几何无量纲参数腹杆与弦杆角度、腹杆宽度与弦杆宽度之比、腹杆厚度与弦杆厚度之比对KT型节点应力集中系数的影响，并通过多元回归分析，提出输煤栈桥KT型节点应力集中系数参数计算公式，在此基础上，给出该节点应力集中系数最大值参数计算公式，可为输煤栈桥KT型节点疲劳评估中疲劳效应提供计算方法，并通过对有焊缝模型和无焊缝模型计算结果对比，分析了焊缝对有限元计算结果的影响。

（4）采用断裂力学法，开展了输煤栈桥KT型节点应力强度因子参数分析，研究了节点几何无量纲参数腹杆与弦杆角度、腹杆宽度与弦杆宽度之比、腹杆厚度与弦杆厚度之比，以及裂纹几何尺寸，裂纹几何参数包含半裂纹长度与裂纹深度之比、裂纹深度与弦杆厚度之比对KT型节点应力强度因子的影响，在此基础上，拟合得到几何修正系数Y的计算公式，并提出了输煤栈桥KT型节点应力强度因子计算公式，可为输煤栈桥KT型节点剩余疲劳寿命评估中疲劳效应提供计算方法。

（5）修正了输煤栈桥KT型节点构造细节热点应力幅S-N曲线，提出了输煤栈桥KT型节点疲劳评估热点应力法，采用空间杆系模型对输煤栈桥进行受力分析，对支点处最不利节点及其他典型受力节点进行疲劳性能评估，各节点均满足抗疲劳性能要求。给定输煤栈桥KT型节点疲劳裂纹扩展准则，提出了输煤栈桥KT型节点疲劳评估断裂力学法，建立了表面带裂纹的KT型节点有限元计算模型，对提出的计算方法进行验证，结果表明，计算得到的应力强度因子变化趋势基本相同，误差在7.2%以内。

（6）采用本文提出的热点应力评估方法，进行输煤栈桥KT型节点抗疲劳构造优化研究，分别对原方案、节点几何参数优化方案（变化腹杆和弦杆夹角、腹杆和弦杆厚度比）、矩形钢管节点、矩形钢管混凝土节点的疲劳性能和经济指标进行对比分析。结果表明，在原方案、节点几何参数优化方案总造价相同的情况下，通过节点几何参数优化可提高节点疲劳性能，提高材料利用率；矩形钢管节点性能优于前两种方案，实际工程中可适当减小矩形钢管的截面尺寸，在满足结构疲劳性能的同时降低结构的造价；由于矩形钢管混凝土节点内部填充了混凝土，造价略有提高，但其疲劳性能提升显著。

ABSTRACT

Coal transporting trestles are important infrastructures and channels of the ground transportation system of coal enterprises. With the advancement of mining technology and the increase of production capacity, the load of coal transporting trestles increases and the continuous operation cycle extends, which often result in the fatigue damage of KT-type joints designed according to the initial production capacity, and further lead to frequent collapses of coal transporting trestles, thereby seriously endangering the safe production of coal mines. Therefore, it is of great theoretical and engineering value to explore scientific fatigue performance evaluation methods of coal transporting trestles by studying its dynamic response law under high loads and long-term operation. Based on the engineering background of a coal conveying trestle in Northern Shaanxi, theoretical analysis, field monitoring and numerical simulation are combined to study the dynamic response of the coal conveying trestle truss, the fatigue performance of both the truss structure as a whole and KT-type joints, and its fatigue life is further predicted. The main research work is as follows:

(1) A dynamic load model of vertical vibration of trestle structure in working state is established by considering 8 working conditions of the trestle, namely uniform acceleration, constant velocity, uniform deceleration and stillness under no load and full load respectively. Its reliability was verified on the single mass spring system and the finite element calculation of the trestle structure was conducted. Results show that the trestle is in a good operating condition, and the vertical deformation and calculated stress values are in good agreement with the actual monitoring values. The vertical vibration of the trestle in operation cannot be neglected. There exists the possibility of resonance between the idler rotation frequency and the first-order frequency of the structure that can cause the occurrence of a large dynamic response. During the service period, both the cycle number (5×10⁴ times) and velocity response (20 mm/s) of the trestle exceed the general requirements. Therefore, it is necessary to check the component fatigue.

(2) 5 representative truss structures of the trestle are selected to monitor the dynamic response of the trestle and its actual operating state is obtained. Monitoring data demonstrate that the vertical one is the largest in terms of the acceleration and stress response. Compared with unloaded condition, the vertical acceleration and stress rise dramatically during the full load operation, with the nominal stress magnifying as much as 40 times. Based on the study of the dynamic response of the trestle, the rain flow method was adopted to convert the time history curve of the component stress into the stress spectra, and the trestle fatigue performance of the typical stress joints was evaluated based on the nominal stress method. It is found that the most unfavorable position is the upper chord of the first monitoring segment with a fatigue life of 173.04 years.

(3) A parameter analysis of the selected typical KT-type joints was carried out with considering in-plane and out-of-plane chord bending moment, web member axial force, chord and web member axial force, and web member bending moment. The effects of the geometric dimensionless parameters, such as the angle between the web and chord, the width ratio of the web and chord, and the thickness ratio of the web and chord, on the stress concentration coefficient of KT-type joints were investigated. The parametric formula for calculating the stress concentration coefficient of KT-type joints of the trestle is proposed through multiple regression analysis. On this basis, a calculation formula for the maximum stress concentration coefficient parameter of the joints is offered, providing a calculation method for the fatigue effect evaluation of KT-type joints in coal conveying trestles. The influence of welded seam on the finite element calculation results was analyzed by comparing the calculation results of the model with and without welded seam.

(4) By using the fracture mechanics method, the parametric analysis of the stress intensity factors of KT-type joints of the trestle was carried out, and the geometric dimensionless parameters of the joint were investigated, such as the angle of the web and chord, the width ratio of the web and chord, the  thickness ratio of the web and chord, and the geometric size of the crack, and the geometrical parameters of the crack include the ratio of the half-crack length and crack depth, and the ratio of the crack depth and chord thickness, which affects the stress intensity factors of KT-type joints. On this basis, a calculation formula for the geometric correction factor Y is fitted, and the calculation formula for stress intensity factors of KT-type joints of the trestle is proposed, which can provide a calculation method for the fatigue effect in the remaining fatigue life evaluation of KT-type joints of coal transporting trestles.

(5) The S-N curve of hot spot stress amplitude for the construction details of KT-type joints of the coal conveying trestle is modified, and the hot spot stress method for fatigue evaluation is proposed. A spatial rod system model was adopted to analyze the stress of the coal conveying trestle, and the fatigue performance of the most unfavorable joint at the support and other typical stress joints were evaluated. It is found that all joints meet the requirements for fatigue resistance. The fatigue crack propagation criteria for KT-type joints of coal conveying trestles are offered, a fracture mechanics method for fatigue evaluation is proposed, and an finite element calculation model for KT-type joints with surface cracks is established. The proposed calculation methods are validated and the results show that the calculated stress intensity factor has a similar trend, with an error of less than 7.2%.

(6) With the hot spot stress evaluation method proposed in this dissertation, a study was conducted on the optimization of the fatigue resistance structure of KT-type joints  of coal conveying trestles by making contrasts, in terms of the fatigue performance and economic indicators, among the original plan, the plan of optimizing geometric parameters of joints (changing the angle of the web and chord and the thickness ratio of the web and chord), the rectangular steel tubular joints, and the rectangular concrete-filled steel tubular joints. The results show that, with the same total cost of the original plan and the plan of optimizing geometric parameters of joints, the latter can improve the fatigue performance of joints and increase material utilization. The performance of rectangular steel tubular joints is superior to the first two plans. In practice, the cross-sectional size of rectangular steel tubular can be appropriately reduced to meet the fatigue performance of the structure with reducing the cost of the structure. The cost of rectangular concrete-filled steel tubular joints is slightly increased due to the filling of concrete structures, but there is a significant improvement in fatigue performance.

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