基于Ansys的重型包装钢架箱工程轻量化设计

目的以某重型装备的运输用框架结构为研究对象,提出工程轻量化的设计准则及设计方案,以解决重型装备过度包装的问题。方法利用Ansys软件对运输用钢架包装箱的起吊工况和堆码工况进行数值仿真分析,并基于分析结果对经验设计方案进行改进。结果优化后的钢架箱质量减少了942kg,质量减少比例达到了43%,起吊工况静强度安全系数为2.14,堆码工况静强度安全系数为1.94,稳定性安全系数有4.96倍。结论工程轻量化设计后的钢架箱满足屈服强度失效准则和稳定性失效准则规定的安全性能,提高了材料的使用效率,包装成本显著减少。     

基于多工况的汽车座椅骨架轻量化设计

安全带静态拉伸工况以及行李箱动态碰撞工况是汽车座椅安全法规中的2个重要工况。在满足安全法规要求的前提下,为实现汽车座椅的轻量化设计,提出了一种基于多工况的座椅骨架轻量化设计方法。以汽车座椅安全法规为设计准则,以座椅骨架质量最小为设计目标,综合考虑静、动态工况,对座椅骨架关键构件的尺寸进行优化设计。首先,建立座椅骨架的有限元模型,并以座椅骨架的质量为响应进行灵敏度分析,确定座椅骨架关键构件尺寸优化的设计变量;然后,建立座椅骨架关键构件尺寸优化的数学模型,实现座椅骨架的轻量化设计;最后,对优化后的座椅进行静、动态工况下的有限元仿真分析和试验研究,以验证优化结果的正确性。结果表明,相较于原座椅,优化后的座椅在满足安全法规要求的前提下减重7.89%,验证了所提出的轻量化设计方法的有效性。研究结果可为汽车座椅的安全性分析和轻量化设计提供参考,具有重要的工程实用价值。     

CFRP板加固含裂纹受拉钢板的疲劳性能研究

根据线弹性断裂力学理论,采用“三维块体-弹簧-板”有限元模型对裂纹尖端的应力强度因子幅值进行计算,并基于Paris-Erdogan裂纹扩展模型,提出了CFRP板加固含裂纹受拉钢板的疲劳寿命预测方法。然后对4个CFRP板加固含初始疲劳裂纹钢板的受拉疲劳性能进行了试验研究,考察了碳纤维板加固量、单面和双面加固方式对疲劳性能的影响。试验结果表明,CFRP板加固钢板的疲劳寿命比未加固钢板显著提高,疲劳裂纹扩展的试验结果与预测结果符合较好。     

内嵌钢板及边缘框架相互作用对带连梁低屈服点钢板剪力墙结构受力性能的影响

为满足快速发展的高层建筑结构对抗震性能及空间灵活性的要求,将高耗能能力、高延性的低屈服点钢材与带连梁钢板剪力墙组合成新型带连梁低屈服点钢板剪力墙结构体系。采用有限元软件ABAQUS建立带连梁钢板剪力墙结构模型,结合国内外已有的典型试验结果验证数值方法的有效性。在此基础上,设计5个不同耦合度的低屈服点钢板剪力墙结构模型进行单调和循环加载,对比分析其损伤机制、承载性能及滞回耗能能力,探讨内嵌钢板与边缘框架的相互作用对结构及构件受力性能的影响,给出设计建议。结果表明:带连梁低屈服点钢板剪力墙结构内嵌钢板与边缘框架相互作用能够有效提高整体结构承载力、承载效率以及耗能能力。综合考虑材料利用率、承载能力及耗能能力,建议连梁耦合度控制在0.45以内。随着连梁耦合度的提高,边缘框架分担剪力多至60%,内部框架柱的轴力显著减小,连梁转角不断减小。因此,在带连梁低屈服点钢板剪力墙结构设计过程中应充分考虑内嵌钢板与边缘框架的相互作用,适当减小内嵌钢板设计厚度及边缘框架截面尺寸,提高材料利用率及设计经济性。同时,与纯框架抗侧性能相比,内嵌钢板与边缘框架的相互作用有效提高了边缘框架的初始抗侧刚度及承载力。     

圆柜内机缓冲衬垫多目标优化设计

目的 基于有限元软件研究圆柜内机包装件静态载荷下的力学特性，并进行多目标优化设计。方法 利用CREO建立三维模型、ANSYS Workbench建立有限元模型，对圆柜内机包装件进行静力学分析。以上缓冲衬垫的5条筋条厚度和2侧壁厚作为设计变量，以上缓冲衬垫的质量、包装件的最大变形量和最大等效应力作为目标函数建立优化模型。基于OSF试验设计方法和Kriging模型，采用多目标遗传算法进行多目标优化设计。结果 优化前的包装件最大变形量为1.511 3 mm，最大等效应力为0.327 6 MPa。优化后包装件的筋条和侧壁厚度显著降低，上缓冲衬垫质量减少了27%，整体强度无显著降低。结论 建立的多目标优化设计方法合理且Kriging模型精度较高，在保证缓冲防护效果的基础上，实现了轻量化设计，降低了包装成本。     

Fatigue life prediction of cracked padded plates

The fatigue crack propagation analyses of padded plates are conducted to predict the crack growth behaviour under various loading conditions. The fatigue life of a padded plate with a single edge crack originating from the weld toe is calculated using the weight function approach. The fatigue strength of padded plates with different pad thickness under remote loading conditions was investigated and compared to the T-plate joint. The improvement of the fatigue strength of the pad design is verified.
  The thickness effect of the padded plate was investigated using the fracture mechanics approach. The geometrically similar model pairs with different initial crack sizes were investigated under remote loading conditions. It was shown that the thickness effect depends on both stress concentration and initial crack size.     

3D fracture mechanics investigation on surface fatigue crack propagation

Surface fatigue crack propagation is the typical failure mode of engineering structures. In this study, the experiment on surface fatigue crack propagation in 15MnVN steel plate is carried out, and the crack shape and propagation life are obtained. With the concept of ‘equivalent thickness’ brought into the latest three‐dimensional (3D) fracture mechanics theory, one closure model applicable to 3D fatigue crack is put forward. By using the above 3D crack‐closure model, the shape and propagation life of surface fatigue crack in 15MnVN plates are predicted. The simulative results show that the 3D fracture mechanics‐based closure model for 3D fatigue crack is effective.     

Cause of failure and optimization of a V-belt pulley considering fatigue life uncertainty in automotive applications

High accuracy of dimensions and strength in design requirements are required to produce reliable automotive components with consistent strength distribution. For example, a V-belt pulley is widely used to transmit power between rotational mechanical elements. However, due to defects from the manufacturing process and heterogeneity of materials, different kinds of failure damage may occur in pulleys of identical shape and material. Common applications in the automotive industry include crankshafts, water pumps, air-conditioner compressors and power steering pumps. Although the shape and the usage of pulleys are very simple, evaluating the pulley design is difficult because the loading conditions and installation environment are complicated. This paper focuses on the clutch pulley in the A/C compressor system of automotives and cause of failure was investigated. The applied stress distribution of the pulley under high-tension and torque was obtained by using finite element analysis (FEA) and based on theses results, the life of the pulley with variation in fatigue strength was estimated with a durability analysis simulator. The results for failure probabilities of 50% and 1% were compared with the fatigue life. Incidentally, the purpose of this study was to optimize the fatigue life of vehicle components from the stochastic point of view. The fatigue life was obtained by an approximation function, and the optimum design was verified by fatigue tests considering durability and validity. The design optimization of a V-belt pulley was performed using an approximation function, which improved the fatigue life. A new shape optimization procedure was presented to improve the fatigue life of the pulley in automotive applications and the shape control concept was introduced to reduce the shape design variables. Design of experiment (DOE) was employed to evaluate the design sensitivity of fatigue life with respect to shape design variables.     

Fatigue design of a cellular phone folder using regression model-based multi-objective optimization

In a folding cellular phone, the folding device is repeatedly opened and closed by the user, which eventually results in fatigue damage, particularly to the front of the folder. Hence, it is important to improve the safety and endurance of the folder while also reducing its weight. This article presents an optimal design for the folder front that maximizes its fatigue endurance while minimizing its thickness. Design data for analysis and optimization were obtained experimentally using a test jig. Multi-objective optimization was carried out using a nonlinear regression model. Three regression methods were employed: back-propagation neural networks, logistic regression and support vector machines. The AdaBoost ensemble technique was also used to improve the approximation. Two-objective Pareto-optimal solutions were identified using the non-dominated sorting genetic algorithm (NSGA-II). Finally, a numerically optimized solution was validated against experimental product data, in terms of both fatigue endurance and thickness index.     

基于Ansys Workbench的快装箱多目标优化设计

目的研究快装箱在压力作用下的静态特性,并对其结构进行多目标优化设计。方法通过Ansys Workbench建立快装箱的几何模型和有限元模型,对快装箱进行静态分析。以快装箱的各箱板厚度和各钢边厚度为设计变量,以快装箱的质量、最大变形量和最大等效应力为目标函数建立多目标优化的数学模型,对快装箱进行多目标优化设计,并且分析对比优化前后的结果。结果通过分析获得的优化前后快装箱的箱板厚度和钢边厚度都有所减小,在保证强度和刚度的条件下,使得总质量减少了9.018%。结论经分析快装箱的多目标优化设计是合理的,在满足使用要求的前提下,减少了总质量,节约了材料,降低了成本。     

汽车乘员舱多层吸声材料的多目标优化

建立了汽车的统计能量分析模型,进行仿真与实验的误差分析,验证了所建模型的有效性,然后选取四层吸声材料布置于乘员舱顶棚,采用优化拉丁方法,以其厚度为设计变量,为降低驾驶员耳旁噪声和满足汽车结构轻量化和低成本的要求,以驾驶员头部声腔A声级降低幅度、吸声材料重量、降噪效率、材料价格和性价比为优化目标,选取30个样本点进行试验设计并通过计算得到全部响应值,之后建立了Kriging近似模型,为验证该近似模型模拟精度,任选三个新的样本点分析近似模型和仿真结果间的误差,最后以近似模型为基础执行多目标优化,与吸声材料初始组合相比,A声级降低幅度反而减小了0.289dB,但重量降低了54.8%,降噪效率提高了85.6%,材料价格降低了21.1%,性价比提高了6.0%。     

Fatigue tests on steel plates with longitudinal weld attachment strengthened by ultra high modulus carbon fibre reinforced polymer plate

Welded steel connections of infrastructures are susceptible to fatigue failure. Advanced carbon fibre reinforced polymer (CFRP) has been demonstrated promising for fatigue strengthening of steel structures. Limited research was conducted on CFRP strengthening of welded connections. This paper focuses on the application of ultra high modulus (UHM) CFRP plates with a modulus of 460 GPa to strengthen steel plates with longitudinal fillet weld attachment using five CFRP strengthening configurations. A series of fatigue tension tests were carried out with constant amplitude fatigue loading. Beach marking technique was adopted to record the crack propagation process. Effects of CFRP bond length, bond width and bond locations on fatigue performance of welded steel joints were investigated. The experimental results showed that UHM CFRP plates could generally increase the fatigue life of the welded steel joints. It seems better to apply CFRP on the welding side of the specimen to achieve longer fatigue life. Then, the effects of weld and weld attachment on the CFRP strengthening efficiency was further studied by comparing experimental results of non‐welded steel plates with single side UHM CFRP plate strengthening. Finally, the classification method was adopted to assess the strengthening efficiency of the UHM CFRP plate to the steel plates with longitudinal weld attachment.     

基于模糊综合评价法的可控震源振动器平板疲劳可靠性分析与优化

平板作为可控震源振动器的核心部件,其焊接部位的疲劳可靠性直接影响其自身的使用寿命和地震信号的激发品质。为了准确得到振动器平板焊接部位的疲劳可靠性,基于模糊综合评价法对其进行可靠性分析。首先,确定振动器平板疲劳可靠性影响因素的集合,并通过多位专家打分评估的方式建立影响因素的权重矩阵和评价矩阵,进而得到平板疲劳可靠性的模糊综合评价矩阵。然后,根据模糊综合评价结果,确定基于S—N曲线法和断裂力学法的平板疲劳可靠性分析模型的权重系数,并建立平板疲劳可靠性模糊综合分析模型。以振动器的结构、载荷和材料参数以及疲劳裂纹扩展的影响因素为随机变量,开展平板的疲劳可靠性优化设计。结果表明,优化后平板的综合疲劳可靠性提高了1.8%。研究结果可为提高可控震源振动器平板的抗疲劳性能和使用寿命提供重要的理论依据。     

Deformation and life analysis of composite flywheel disk systems

In this study an attempt is made to put into perspective the problem of a rotating disk, be it a single disk or a number of concentric disks forming a unit. An analytical model capable of performing an elastic stress analysis for single/multiple, annular/solid, anisotropic/isotropic disk systems, subjected to pressure surface tractions, body forces (in the form of temperature-changes and rotation fields) and interfacial misfits is summarized. Results of an extensive parametric study are presented to clearly define the key design variables and their associated influence. In general the important parameters were identified as misfit, mean radius, thickness, material property and/or load gradation, and speed; all of which must be simultaneously optimized to achieve the ‘best’ and most reliable design. Also, the important issue of defining proper performance/merit indices (based on the specific stored energy), in the presence of multiaxiality and material anisotropy is addressed. These merit indices are then utilized to discuss the difference between flywheels made from PMC and TMC materials with either an annular or solid geometry.Finally two major aspects of failure analysis, that is the static and cyclic limit (burst) speeds are addressed. In the case of static limit loads, a lower (first fracture) bound for disks with constant thickness is presented. The results (interaction diagrams) are displayed graphically in designer friendly format. For the case of fatigue, a representative fatigue/life master curve is illustrated in which the normalized limit speed versus number of applied cycles is given for a cladded TMC disk application.     

交通信号支撑结构疲劳裂纹扩展有限元分析

为了解决交通信号支撑结构疲劳裂纹扩展的问题,利用ANSYS软件对已有的信号支撑结构静力和疲劳试验分别建模分析,并用有限元结果与试验结果进行对比。研究表明:静力加载模型中,圆钢管上最大Mises应力为413.7 MPa,有限元结果与试验结果较为接近;裂纹最深点△K_Ⅱ和△K_Ⅲ值较小,△K_eff与△K_Ⅰ几乎完全相等,裂纹扩展寿命主要受△K_Ⅰ值的影响;远离裂纹端点处各点的△K_Ⅰ值呈现出M形状;Bowness公式计算得到的裂纹最深点的△K_Ⅰ值比有限元结果大,利用该公式预测交通信号支撑结构端板与圆钢管焊接节点的疲劳寿命较为保守。     

Application of continuum damage mechanics model in terms of fatigue life assessment for low cycle and quasi static loadings

The aim of this study is to test the classical Lemaitre model based on continuum damage mechanics (CDM) approach in the range of low cycle and quasi‐static fatigue life. Study is carried out with the use of results of experimental tests for C45 steel (according to AISI: 1045 steel) carried out under variable‐amplitude loading. Loading programs are of two‐step character and include blocks of cycles of different lengths and R = ‐1 coefficients. Fatigue lives are calculated according to Lemaitre model from experimentally obtained stress and strain histories recorded during fatigue tests. The results are compared with experimental tests results and with fatigue lives calculated with the use of by traditional fatigue approach based on Palmgren‐Miner damage summation hypothesis. Experimental test of fatigue life calculation results for C45 steel reveals that continuum damage method, using the recorded stresses and strains, predicts fatigue life better as compared to the remaining methods. The study also contains many detailed analyses of experimental results.     

Influence of solder thickness on interfacial structures and fatigue properties of Cu/Sn/Cu joints

Abstract

Copper plates were soldered with tin foil of different thicknesses to examine the influence of the solder thickness on formation of secondary phases at the interface and fatigue properties. In the case of an initial solder thickness of 60 μm, the thickness of the η (Cu₆ Sn₅) phase and the ? (Cu₃ Sn) phase linearly increased with the square root of the bonding time. The fatigue strength was 3 MPa and the fatigue life decreased with increasing stress amplitude and had a low scatter. In the fatigue process, fine cracks appeared in the η phase and propagated in the solder layer. This process was different from the case of static shear fracture. In the case of a 5 μm solder thickness, the solder was replaced by secondary phases in a short time, and only the ? phase remained at the interface after a bonding time of more than 300 min. The fatigue strength was 13 MPa and was independent of the interfacial structure, but the fatigue life showed a large scatter. In the fatigue test, unstable fracture occurred along the interfaces, similar to that observed in static shear fracture. From these results, it was concluded that solder joints become brittle with decreasing solder thickness.     

基于目标应变分布的TC17合金双性能盘预成形形状优化设计

目的 研究TC17合金双性能盘目标应变分布下的预成形形状优化设计方法.方法 采用拉丁超立方试验设计方法对预成形形状设计变量抽样选取样本点,并通过Deform有限元数值模拟获得样本设计变量下的局部应变分布.以局部应变分布与目标应变分布之间的方差最小为目标函数,采用Kriging方程建立近似替代模型预测响应应变误差,并结合遗传算法,以锻件的充填率及材料利用率为约束条件,优化设计预成形形状.结果 近似替代模型预测的应变误差与基于有限元数值模拟计算获得的应变误差之间的最大相对误差和最小相对误差分别为10.8％和0.01％.结论 这表明Kriging近似替代模型在预测响应应变误差时的精度较高,具有较好的可靠性,采用优化后的预成形形状经多道次等温锻造后的等效应变分布满足目标应变分布的设计要求.     

伺服机械压力机机身结构优化设计分析

目的 针对当前伺服机械压力机机身质量与结构分配不合理、刚度不足的问题,以6 000 kN闭式伺服机械压力机机身为研究对象,对该闭式伺服机械压力机机身进行重新设计,以实现提高机身刚度和轻量化的目的。方法 首先进行机身静力学分析,确定拓扑优化空间,获得压力机机身优化分析边界条件;然后采用变密度法对压力机机身进行拓扑优化分析,选择合适的密度阈值,获得机身的拓扑优化结构。为了便于加工制造,减少制造成本,基于该优化结构并考虑可制造性重新设计机身结构。最后,通过有限元仿真分析和机身刚度测试试验,对比优化前后机身的刚度。结果 优化后的伺服机械压力机机身质量减轻了10.9%,一阶模态频率提高了3.74%,机身刚度提高了约28%。结论 通过对伺服机械压力机机身结构进行优化设计,解决了高刚度机身设计的工程问题,为伺服机械压力机生产制造提供了一定的理论和技术支撑。     

Improving the fatigue performance of airframe structures by combining geometrical modifications and laser heating

This study aimed to investigate an optimization method that can maximize fatigue crack retardation based on the concepts of crenellation and residual stress engineering. By applying both concepts, fatigue crack retardation was achieved by the systematic modulation of the panel thickness and by the superposition of a beneficial residual stress field induced by laser heating. To identify an optimized implementation of both concepts, an advanced finite element method‐genetic algorithm coupled approach was proposed, where each possible configuration in terms of the crenellation geometry and the positioning of the laser heating lines was encoded in a binary string. The inclusion of the residual stress field induced by the laser heating in the finite element method model was achieved by the inherent strain approach. It was found that the optimized configurations showed from 38% up to 77% fatigue life extensions, which were much larger than the linear superimposition of the fatigue life improvements by each individual technique.