调质42CrMo钢的弯曲微动疲劳实验研究

针对循环软化材料调质42CrMo钢进行了常规弯曲疲劳实验和弯曲微动疲劳实验,分析了常规弯曲疲劳和弯曲微动疲劳之间的差异,并讨论了循环弯曲载荷对疲劳寿命的影响。通过分析不同弯曲载荷下弯曲微动疲劳试样断口的形貌和不同循环次数下微动损伤的情况,揭示调质42CrMo钢弯曲微动疲劳过程中的损伤特性。研究结果表明:同一循环载荷作用下,弯曲微动疲劳的寿命明显低于常规弯曲疲劳的寿命;随着循环弯曲载荷的增大,弯曲微动疲劳的寿命降低更明显;微动引起的局部接触疲劳和局部塑形变形促进了弯曲微动疲劳裂纹的萌生和进一步扩展。     

重载齿轮弯曲疲劳寿命测试方法研究现状

重载齿轮是大型机械装置(推土机、挖掘机、装甲车等)传动系统的核心部件,它的主要功能是按照规定的转速比传递运动和转矩。随着科学技术的发展和军事装备的更新换代,重载齿轮的研究除了在材料性能、齿形设计、承载能力等方面取得了新成就外,另一个突出的进步就是在齿轮性能测试技术方面获得了很多成果,使得一些过去难以定量研究的问题(如齿轮的疲劳强度、齿轮传动品质等)都有了比较实用的测量手段。而在重载齿轮疲劳性能研究中,相对于接触疲劳产生的齿面点蚀、胶合、磨损等微小破坏而引起齿轮传动效率降低,啮合不到位等现象,弯曲疲劳则会直接导致齿根产生裂纹甚至形成断齿现象,造成重大事故。因此,准确测试重载齿轮的弯曲疲劳寿命,分析弯曲疲劳性能,进而优化齿轮设计,提升齿轮性能,对监测因弯曲疲劳失效所引起设备故障以及避免服役过程中发生重大事故具有重要意义。重载齿轮弯曲疲劳寿命受多方面因素的影响,其中包括材料性能、加工尺寸、制备工艺以及测试手段等,因此对其弯曲疲劳寿命的定量测试一直是各国研究人员关注的热点话题。关于重载齿轮弯曲疲劳寿命的研究可以归纳为以下三方面:弯曲疲劳原理探究方面已发展到声发射信号检测、光学图像分形理论计算、计算机有限元数学模拟等多方面的实际应用;性能检测实验已有单齿/双齿脉冲加载、动态啮合式加载等多种试验方法;数据处理方面已发展出升降法、成组法、雨流法以及多种S-N曲线拟合的数据处理手段。这些分析方法以及测试手段的应用可以大大节省实验成本、提高分析效率、减少试验误差,进而提高重载齿轮弯曲疲劳寿命检测的准确性。本文从重载齿轮弯曲疲劳寿命的测试原理、试验方法以及测试数据处理三方面出发,根据国内外研究现状,对重载齿轮的弯曲疲劳性能进行机理性与实验性的探究,为测试重载齿轮的弯曲疲劳寿命提供有效的理论依据、具体的测试方法以及准确的数据处理手段。     

碳酸亚乙烯酯对锰酸锂电池寿命的改善及消耗研究

研究了不同碳酸亚乙烯酯(VC)含量对锰酸锂体系动力电池的高温寿命的影响以及VC在电池循环中的消耗行为,结果表明,VC含量为3%(质量分数)时电池60℃的高温循环性能最佳,电化学交流阻抗(EIS)分析结果表明,随着VC含量的增大,负极SEI阻抗增大,直至含量为3%时达到最大值;还发现5Ah动力电池在60℃循环过程中,随着VC含量的不同,电池在循环一定次数之后,电解液中的VC都会消耗完,说明VC主要参与首次充放电过程中的固体电解质膜(SEI)形成,并在循环的前期参与部分SEI膜的修复,由于VC完全消耗之后电池的寿命曲线并未出现突降,说明VC是否存在对电池后期寿命影响较小。     

基于损伤理论的沥青混合料抗疲劳性能试验

为系统研究沥青混合料在疲劳破坏过程中的路用性能衰减过程,在不同温度、应变、频率下开展了四点弯曲疲劳试验,基于损伤理论从劲度模量变化情况和耗散能变化情况两方面评价了沥青混合料抗疲劳性能,并通过损伤面积法、灰关联分析法讨论了试验因素对沥青混合料抗疲劳性能的影响程度。研究结果表明：沥青混合料的抗疲劳性能可以采用基于耗散能的损伤因子随加载次数的变化的双对数曲线进行描述,疲劳寿命应由初始损伤和损伤累积速率共同决定;从劲度模量方面分析,沥青混合料疲劳寿命随温度的升高而增大、随应变的增大而减小、随频率的增大而减小;劲度模量和耗散能两方面的分析结果均表明温度对疲劳寿命的影响程度大于应变,劲度模量分析显示频率对疲劳寿命影响最次,耗散能分析结果显示频率与疲劳寿命的相关性不显著。     

斜搭接连接件疲劳特性分析

为了研究搭接角度对斜搭接连接件疲劳特性影响的规律,对不同搭接角度的斜搭接连接件进行了疲劳试验,并利用有限元软件对紧固孔在拉伸状态时的应力场进行了分析,采用名义应力法对紧固孔的疲劳寿命进行了估算。结果表明:失效部位发生在第一排孔边处;疲劳寿命随着搭接角度的增加而增大;搭接角度与疲劳寿命近似曲线关系为lg N=6.047-1.020×0.6601α。     

残余压应力对45钢疲劳裂纹萌生寿命的影响

本文研究了４５钢不同缺口半径及经预压，喷丸处理后对试样弯曲疲劳裂纹萌生寿命的影响。研究结果表明：随着试样缺口根部半径的增大，试样的弯曲疲劳裂纹萌生寿命增加。     

3238A/EW250F复合材料的弯曲疲劳性能

运用三点弯曲加载方式对3238A/EW250F复合材料的弯曲疲劳性能进行了研究。结果表明:该复合材料弯曲疲劳寿命的分散性较小,所有试验点的疲劳寿命都满足90%置信度的中值寿命;所有试样均在有效部位发生破坏,且试样表面出现分层后,还有较长的一段寿命期;试验测得0°方向铺层3238A/EW250F复合材料的条件疲劳极限以动应力表示为σr=73.2 MPa。     

AZ31镁合金型材温热弯曲实验研究

采用自制弯曲装置进行了AZ31镁合金型材弯曲成形实验,研究了型材成形温度和型材弯曲角度对镁合金型材弯曲性能的影响.结果表明:采用温热弯曲工艺可以成形出AZ31镁合金型材弯曲件;弯曲后的型材外缘筋部厚度值减小,其余筋部厚度值均增大;在相同的弯曲角度和模具预热温度条件下,随着坯料温度的升高型材回弹角度减小.AZ31镁合金型...     

不锈钢晶间腐蚀弯曲评价方法的影响因素

用嵌含有GTN延性损伤模型的ABAQUS有限元法,模拟研究了不锈钢晶间腐蚀弯曲评价方法中材料力学性能、弯曲角度和压头直径对弯曲试样塑性应变分布、延性损伤和裂纹起裂的影响规律,分析了其对晶间腐蚀弯曲评价结果的影响。结果表明：随着试样弯曲角度的增大和弯曲压头直径的减小,试样拉伸面的塑性应变增加,试样越容易产生弯曲开裂;在晶间腐蚀弯曲评价标准中,当固定弯曲角度和压头直径时,对于塑性、韧性和抗断裂综合力学性能较低的不锈钢材料,在弯曲过程中材料本身会发生开裂;因此,需要考虑材料力学性能对晶间腐蚀弯曲评价结果的影响;对于该研究中的典型的奥氏体不锈钢材料,当其弯曲断裂应变低于0．51左右时,在弯曲过程中材料本身会发生开裂,不宜用弯曲方法来评价其晶间腐蚀敏感性。     

接触应力对车轴钢旋转弯曲微动疲劳寿命的影响

研究LZ50车轴钢不同过盈配合接触应力水平对旋转弯曲微动疲劳寿命的影响。分别利用光学显微镜、扫描电子显微镜对过盈配合表面的微动损伤表面和断口进行分析。结果表明,随着过盈量的增加,LZ50车轴钢旋转弯曲微动疲劳寿命呈现先降低而后升高的非线性特征,这是多轴复杂应力、配合面的接触应力、微动摩擦应力以及微动磨损交互作用的结果。     

Proposal of an alternating bending technique for evaluating low‐to‐high cycle fatigue of structural steels

This paper proposes an alternating bending technique for evaluating fatigue life in the low‐to‐high cycle fatigue regime. A method was developed for estimating the stress, elastic strain, and plastic strain ranges of a plastically deformed specimen subjected to alternating bending with consideration of stress and strain distributions. To evaluate its effectiveness, fatigue testing was conducted using a specimen made of a steel used for pressure vessels. The stress, elastic strain, and plastic strain ranges could be obtained during cyclic bending. The elastic strain amplitude life and plastic strain amplitude life curves were linear in a log–log plot in the low‐to‐high cycle fatigue regime. Hence, the fatigue life under alternating bending could be evaluated using the proposed strain‐based approach. However, these curves could not be predicted using equations with parameters obtained from tensile testing, such as the universal slope method, due to the strain gradient in the specimen.     

高阻隔AZO包装薄膜制备与性能研究

为满足类似饮料、果汁、啤酒及熟制即食食品的保鲜、保质需求,制备对O2,CO2和水蒸汽等有高阻隔性的包装材料,采用靶材Zn与Al质量比为1:19,在普通PET薄膜表面制备具有高阻隔性能的包装薄膜.通过XRO衍射,对薄膜的结构和形貌进行了表征.采用透氧测湿测试仪器对不同工艺参数进行研究分析,结果表明,制备的AZO薄膜晶体结构择优取向性好、结晶度高,ZnO的离化式C轴方向拉伸力会引起衍射峰呈C轴择优取向,在适宜的工艺条件下,可制备得高阻隔性的包装薄膜.     

Characterization of structural films using microelectromechanical resonators

Micromachined resonant fatigue characterization structures have been used by a variety of investigators to evaluate the stress‐life fatigue behaviour of thin films. This work will review the design, testing and analysis of these versatile thin‐film characterization structures. Subsequent discussion will illustrate how this material characterization approach has been used to evaluate the high‐cycle fatigue behaviour of silicon films commonly used in microelectromechanical systems (MEMS). This work demonstrates that properly designed resonators can be used to monitor extraordinarily low fatigue crack growth rates (i.e. ? 10^?10 m/cycle) relevant to these minute mechanical components.     

蓄电池塑料箱自动缠膜包装机设计

目的 针对蓄电池外壳塑料箱贮存、物流运输过程中出现的粉尘污染、破损等问题,在注塑成型后,需经覆膜处理。由于蓄电池外壳较薄,热缩工艺防护手段变形严重,对产品质量产生较大影响,迫切需要设计一种高效、便捷的蓄电池外壳防护包装工艺。方法 依据功能模块化设计理念提出托盘式塑料箱缠膜的解决方法,针对缠膜包装制定了集整形、缠膜、物料输送为一体的塑料箱自动缠膜工艺和各功能模块机械系统设计,并通过数字化手段验证工艺的合理性。结果 该设备实现了对多种规格的蓄电池外壳塑料箱的整形、缠膜、物料输送一体化生产,效率达到42s/件,相较于人工方式的效率提升了1.4倍。结论 该设备结构合理,在保证缠膜包装质量的前提下,提高了缠膜包装效率,推动了企业自动化进程,为塑料箱自动缠膜包装提供了解决方案。     

Effect of cyclic hardening on fatigue performance of slide burnished components made of low‐alloy medium carbon steel

The slide burnishing process causes cyclic loading of the surface being treated, which provokes cyclic hardening. Using a forced‐controlled indentation test, the sixth “loading‐unloading” cycle was stabilised. The effect of the number of passes and the cyclic loading coefficient (CLC) on the fatigue performance of slide burnished specimens was investigated. Rotating bending fatigue tests were conducted using nine groups of hourglass shaped specimens, which were slide burnished through a different number of passes and CLC values. A stabilised cycle of the surface layer achieved with six passes, lead to largest fatigue limit, whereas the CLC exerted negligible influence on the fatigue performance. The observed phenomenon was explained through different residual stress relaxation rates, due to the rotating bending load, as well as with the obtained surface layer microstructure. The residual stress relaxation was investigated through rotating bending fatigue tests, using cylindrical fatigue specimens, followed by X‐ray stress analysis.     

Predicting and determining the bending stiffness of thin films and laminates

Three different techniques for experimentally determining the bending stiffness of flexible films and laminates have been evaluated using a number of different packaging materials. The results showed that a cantilever test was the best, giving reliable data for all kinds of films and laminates. A three‐point bending test proved to be sensitive to misalignment, whereas a bending‐under‐own‐weight test was incapable of handling curled samples and generally gave lower stiffness values. A model for predicting the bending stiffness of multilayer laminates from the elastic modulus of the constituents was developed and used to examine the influence of layer position and composition on the overall bending stiffness. Model calculations showed that thin layers, such as adhesives, print and barrier coatings, can have a large influence on the bending stiffness and that the influence often goes against what would be intuitively expected. The calculations also showed that layer modulus often is less important than layer thickness and that the position of the layer in the laminate can have a major influence on the overall stiffness. Copyright © 2001 John Wiley & Sons, Ltd.     

Observations and analyses of secondary bending for riveted lap joints

The phenomenon of secondary bending in riveted lap joints of the configuration representative of connections of the aircraft fuselage sheets in the longitudinal direction is investigated experimentally and analytically. The experiments involved strain gauge measurements of secondary bending stresses carried out in close proximity to the fatigue critical section of the riveted lap joint and fatigue tests performed to study the effect of secondary bending on the riveted joint fatigue life. The strain gauge measurement results allowed validation of a simple analytical model proposed by Schijve to estimate secondary bending moments induced in mechanically fastened joints with eccentricities. Variables considered in the fatigue tests were several joint geometry related parameters known to influence the magnitude of secondary bending in the fatigue critical location. It was shown that the fatigue test data for joints of various geometries, which were considerably scattered if the fatigue lives were presented against the applied stress amplitude, could become consolidated within common scatter bands when the lives were plotted in terms of the combined tensile stress amplitude including the bending stress computed from the model by Schijve.     

18CrNiMo7-6合金钢的弯曲微动疲劳特性

对18CrNiMo7-6合金钢进行弯曲微动疲劳实验,建立弯曲微动疲劳S-N曲线,并对实验结果进行分析。结果表明:该合金钢的弯曲微动疲劳S-N曲线不同于中碳钢材料,也不同于常规弯曲疲劳,而是呈"ε"型曲线特征。随着弯曲疲劳应力的增加,微动运行区域由部分滑移区向混合区和滑移区转变,损伤区的磨损机制以剥层、磨粒磨损和氧化磨损为主。在混合区内,裂纹最易萌生和扩展,且裂纹均萌生于材料接触区次表面。受接触应力和弯曲疲劳应力影响,弯曲微动疲劳裂纹的萌生和扩展可分为三个阶段:初期,在接触应力控制下,裂纹萌生于次表面;随后,裂纹受接触应力和弯曲疲劳应力共同控制,转向更大角度方向扩展;最后,裂纹完全受弯曲疲劳应力控制而垂直于接触表面扩展,直至断裂失效。     

Influence of non‐proportional bending with torsion on fatigue life of 10HNAP steel within the range of crack initiation and propagation

The paper presents a precise analysis of the influence of non‐proportional loading of specimens on fatigue life during initiation and propagation of fatigue cracks. Simulation of the fatigue life of specimens was based on relations describing propagation rate of the fatigue cracks. The Paris and Forman relations were applied; they were integrated after previous introduction of relationships for the equivalent range of the stress intensity factor ΔK_eq and including the phase shift angle ? between amplitudes of the bending moment and the torsional moment. Under bending with torsion, range of the equivalent stress intensity factor ΔK_eq includes ranges of stress intensity factors for loading modes I and III, i.e. ΔK_I and Δ K_III. The performed tests of 10HNAP constructional steel under cyclic bending with torsion allowed us to determine the influence of the phase shift angle ? on the fatigue life. It has been proved that increase of the phase shift angle from ?= 0° to ?= 60° and the ratio of amplitude of the bending moment M_ag to amplitude of the torsional moment M_as equal to 1.33, 2 and 4 cause increase of the fatigue life of the tested specimens. The maximum increase of the fatigue life of specimens made of 10HNAP steel was 73% (M_ag/M_as= 2, ?= 45°).     

Fatigue and fracture assessment for reliability in electronics packaging

Modern electronics products relentlessly become more complex, higher in density and speed, and thinner and lighter for greater portability. The package of these products is therefore critical. The reliability of the interconnection of electronics packaging has become a critical issue. In this study, the novel testing methods for electronic packaging are introduced and failure mechanisms of electronic packaging are explained. Electronics packaging is subjected to mechanical vibration and thermal cyclic loads which lead to fatigue crack initiation, propagation and the ultimate fracture of the packaging. A small-sized electromagnetic-type bending cycling tester, a micro-mechanical testing machine, and thermal fatigue testing apparatus were specially developed for the reliability assessment of electronics packaging. The long-term reliability of an electronic component under cyclic bending induced high-cycle fatigue was assessed. The high-cycle bending-fatigue test was performed using an electromagnetic-type testing machine. The time to failure was determined by measuring the changes in resistance. Using the micro-mechanical tester, low cycle fatigues were performed and compared with the results of a finite element analysis to investigate the optimal shape of solder bumps in electronic packaging. Fatigue tests on various lead-free solder materials are discussed. To assess the resistance against thermal loads, pseudo-power cycling method is developed. Thermal fatigue tests of lead-containing and lead-free solder joints of electronic packaging were performed using the pseudo-power cycling tester. The results from the thermal fatigue tests are compared with the mechanical fatigue data in terms of the inelastic energy dissipation per cycle. It was found that the mechanical load has a longer fatigue life than the thermal load at the same inelastic energy dissipation per cycle.