牙齿过盈配合的接触非线性数值模拟研究

以弹塑性理论为基础,基于非线性有限元软件ANSYS,建立了三牙轮钻头中单齿与牙轮的过盈配合的二维有限元力学模型;并在不同过盈量下,对牙齿动态地压入牙轮以及热胀冷缩作用的静态装配牙齿两种情况进行了仿真模拟.分析结果表明,静态装配中牙轮与牙齿的最大应力值小于动态装配;在动态压入装配过程中,压入载荷存在波动,而静态装配无载荷波动;动态压入装配成本较低,装配方便.     

涂层压入仪的研制及其应用

报道了涂层压入仪的研制背景、结构原理、主要技术特性及其应用举例,该仪器具有连续加载卸载功能并配有声发射和光学系统,能测量并记录连续的载荷与压入深度关系曲线,能用声发射系统对测试过程中涂层试样的开裂和剥落进行动态监测,并确定对应的载荷,用涂层压入仪作界面压入测得厚涂层与基体界面开裂的临界载荷pw可反映涂层的结合强度;也可正面压入考察薄膜与基体的结合,区分薄膜开裂和剥落并精确测定其对应的载荷值,用加载过程中发生初始剥落的载荷表征膜的结合强度,涂层压入仪还可用于膜韧性、膜和膜,基断裂韧性、离子氮化层脆性等的评价,测定块体材料硬度、塑性功、弹性功、弹塑性比等性能指标。     

弹性辊轧制过程的有限元仿真分析

为了得到轧制过程中轧辊及轧件的应力及变形情况分布,采用有限元软件Ls-dyna,通过三维弹塑性有限元方法,在工作辊与支撵辊均为弹性辊的情况下,对轧件精轧道次平辊轧制过程进行了仿真分析.详细介绍了有限元模型的建立,材料参数、边界条件及载荷的定义.仿真分析结果表明,轧制过程中接触弧内轧辊表面受到三向压应力作用;得出了工作辊的挠度曲线;支撑辊XY面剪应力呈现交变现象;同时分析了轧件的变形情况以及宽展曲线等.     

基于分子动力学的纳米压痕形变过程模拟

采用分子动力学方法模拟了金刚石压头压入Fe基体的纳米压痕全过程.研究了加载和卸载时基体的原子组态、载荷-位移曲线以及位错的发射和变化.分析了基体的塑性形变机理.发现压入深度为0.69 nm时出现位错.随压入深度的增加位错长大成环,基体塑性形变加剧.卸载过程中位错环不断减小,当压头恢复到起始位置后,基体中心残留有位错环,产生了永久塑性形变,位错环的存在是基体产生永久塑性形变的关键因素.      

热轧钢板矫直工艺的有限元分析

采用有限元软件ANSYS对热轧钢板矫直工艺进行模拟,研究了钢板同一初始状态下采用两种不同矫直工艺参数模拟后的结果,以及在同一矫直工艺参数下对钢板施加不同初应力载荷的模拟结果.探讨了钢板矫直过程中残余应力的变化情况以及矫直工艺参数与钢板残余应力的关系.模拟结果表明:在矫直过程中钢板表面都要经过拉一压-啦一压-拉的反复弯曲过程;对于纵向残余应力分布不均的通过模拟矫直能够达到明显的改善,并且在上矫直辊增加凸度值对消除横断面上的内应力分布不均是非常有效的.     

基于有限元的钎焊铝蜂窝芯平压变形过程分析

利用MSC.Marc建立了钎焊铝蜂窝芯的有限元模型并对其进行平压屈曲分析,得到蜂窝芯平压变形过程模式,并通过和已有实验结果的比较,讨论了有限元模型的合理性和可行性.     

7A60铝合金杯形件等温压扭关键工艺参数分析

以7A60铝合金杯形件为研究对象,通过工艺实验和有限元模拟研究了杯形件在等温压扭成形过程中关键工艺参数对其成形性能的影响。结果表明:坯料高径比对累积变形量的影响主要在镦粗变形阶段,下模扭转速度增大,成形载荷降低,扭矩增加;但当下模转速太大时,压扭件盘面过渡圆角区域损伤值将大于1,边缘易于产生破裂缺陷;成形温度的变化对成形载荷和扭矩的影响较为显著;成形过程中对压扭件施加小于1圈的扭转剪切变形,合金的连续性不会遭到破坏,且合金强度相比传统挤压件有所提高。     

复合板贴条应力的有限元分析

通过有限元弹性应力分析数值计算方法[1],在内压压力载荷作用下改变贴条厚度,分析贴条焊缝及贴条的应力,并对计算结果进行了应力分类对比分析。     

纳米TiO2轧制液对硅钢冷轧性能的影响

分别采用传统冷轧轧制液和纳米TiO₂的冷轧轧制液,对无取向硅钢板进行了四辊冷轧实验.重点研究两种冷轧轧制液的轧制润滑性能和对轧后硅钢薄带表面质量和耐蚀性能的影响.通过场发射电子显微镜和能谱仪对使用两种轧制液轧后得到的硅钢薄带表面形貌和成分进行了分析.给出了轧制液中TiO₂纳米粒子在轧制过程中的抗磨减摩机理.在轧制载荷较高时,纳米TiO₂轧制液具有优良的轧制润滑性能并能显著改善轧后硅钢薄带的表面质量.同时在高载荷作用下,TiO₂纳米粒子被压入硅钢薄带基体,形成一个滑动系来支撑载荷,从而使润滑膜的耐磨性提高.      

油泵齿轮轴精锻成形工艺研究及缺陷分析

针对油泵齿轮轴特殊形状设计了齿轮轴精锻模具.通过有限元仿真和精锻实验研究了齿轮轴成形过程和金属流动规律.分析了对油泵齿轮轴精锻工艺中产生齿形角隅填充不满缺陷的原因:角隅填充是成形终了时成形载荷陡增的主要原因之一,由于齿轮轴精锻模具结构的特殊性,其强度无法满足齿形角隅填充所需高成形载荷的需要.基于角隅填充状况,提出了齿形端面斜面分流和环形槽分流,并对传统精锻工艺和两种分流锻造工艺进行了有限元仿真.分析结果表明两种分流方法均能有效减小齿形角隅填充时金属流动阻力,保证齿形良好填充,降低成形载荷,并且斜面分流优于环形槽分流.锻造实验验证了有限元仿真的准确性.      

On the Constraint Factor and Tabor Coefficient Pertinent to Spherical Indentation

Measuring the uniaxial stress–strain response from indentation testing has been of great interest to the materials community ever since the seminal work on spherical indentation by David Tabor. In this regard, spherical indentation is the primary choice due to the ability to access a wide range of strains in a single test. While indentation testing is fairly simple to perform, the conversion factors required to calculate the uniaxial flow stress from hardness, which is commonly referred to as constraint factor and uniaxial strain from indentation contact radius and ball radius, which is called the Tabor coefficient, are not necessarily constant and most of the prior work involves assumptions about one of these conversion factors to calculate the other. In this work, we present a finite element analysis-based approach to independently determine the constraint factor and Tabor coefficient in the fully plastic indentation regime which is a pre-requisite for this analysis. The criteria to determine whether fully plastic indentation regime is satisfied has also been presented. The proposed approach has been validated by comparing the uniaxial stress–strain response from spherical indentation tests on OFHC copper and the data obtained by conventional uniaxial testing. Excellent agreement has been found between the two approaches which can be readily applied for measuring the uniaxial stress–strain response of coatings which is otherwise difficult to determine.     

Indentation creep behavior of a direct-filling silver alternative to amalgam

Amalgam creep has been identified as a key parameter associated with marginal breakdown and corrosion. The aim of this study was to evaluate the time-dependent deformation (creep) of a novel silver filling material as an alternative to amalgam. We made the silver specimens by pressing a precipitated powder at room temperature to a density that can be achieved in clinical hand consolidation. The surface of the silver was either polished or burnished. To examine local contact creep and the effect of surface finishing, we used an indentation creep method in which a Vickers indenter was loaded on the specimen surface at a load of 10 N with dwell times of 5 sec to 6x10(4) sec. We used a bonded-interface technique to examine subsurface creep mechanisms. The flexural strength (mean+/-SD; n = 10) was 86+/-20 MPa for amalgam, 180+/-21 MPa for polished silver, and 209+/-19 MPa for burnished silver-values which are significantly different from each other (family confidence coefficient = 0.95; Tukey's multiple-comparison test). Indentation creep manifested as hardness number decreasing with increased dwell time. With dwell time increasing from 5 sec to 6x10(4) sec, the hardness number of amalgam was reduced by approximately 80%; that of the polished silver and the burnished silver was reduced by only 40%. Subsurface creep in amalgam consisted of the shape change of the alloy particles from spherical to elongated shapes, and the separation of matrix grains from each other, possibly due to grain-boundary sliding. Creep of the polished silver occurred by densification reducing porosity and increasing hardness; that of the burnished silver occurred by the displacement of the burnished layer. These results suggest that, due to creep-induced subsurface work-hardening and densification, the consolidated silver exhibits a higher resistance to indentation creep than does amalgam. The hardness number of silver approaches that of amalgam after prolonged indentation loading.     

Improved relationship between Vickers hardness and yield stress for cold formed materials

Cold‐formed metal products are increasingly serving as high duty machine parts. Designers and users need to know their properties as accurately as possible. One such product property is the new yield strength, which can be approximated by the final flow stress of the workpiece material during forming. Vickers hardness measurements provide an easy and inexpensive method of evaluating the new local yield stress in cold‐formed workpieces. The well‐known available models given in literature to convert the measured hardness number into the corresponding yield stress have an error of up to 25 %. This is basically due to the facts that cold formed material experiences large plastic strains in the main forming stage, the hardening behaviour is anisotropic and, moreover, the material properties are inhomogeneous especially at the workpiece surface. The purpose of this study is to improve the accuracy of the well‐known available correlation models between Vickers hardness measurements and yield stress. This is achieved by utilizing finite element simulations of the indentation process. The models currently incorporate only the isotropic strain‐hardening behaviour of the work material. The new suggested model decreases the theoretical conversion error to less than 10 %. The improved model has been verified by experiments. The difficulty in verifying the models is realizing an experiment with a precisely known high plastic strain. In this study, the forward extrusion process was utilized for this purpose. In the forward extrusion process there is one location in the workpiece where the plastic equivalent strain and hence the yield stress is exactly known: the axis of the extrudate. By this method it is possible to obtain strain‐hardening states up to an equivalent plastic strain of 1.6 (!). Hence, making hardness measurements at the axis of extruded workpieces, it was possible to verify the improved relationship up to realistic strain values. The results have shown that the new relationship supplies conversions with a drastically reduced error as compared to the classical relations.     

粉末净成形压制工艺优化及三维复杂零件结构设计的数值模拟

基于粉末连续体，运用MSC.Marc有限元软件对粉末净成形压制工艺进行优化，并对减重齿轮的结构设计进行数值模拟。通过与实验数据对比分析，验证了材料模型及仿真模拟的可靠性，在此基础上利用有限元软件研究分析压制方式、压制速度、摩擦系数、压制温度、保压时间等五组因素对压坯密度分布的影响。结果表明，压制方式是最显著的影响因子，采用双向压制、温压成形、低压制速度、小摩擦系数及保压方式的组合压制工艺能有效地改善粉体的密度分布。利用有限元软件对减重齿轮的结构进行优化设计，研究圆环高径比与压坯相对密度的关系，并确定减重孔最佳尺寸。结果表明，采用强制摩擦压制方式代替浮动压制方式，可有效改善孔洞薄壁处密度。此外，结合Workbench有限元软件对减重齿轮进行结构力学模拟仿真，分析薄壁处的受力情况，以满足对齿轮强度的要求。     

不锈钢热压变形组织不均匀性的有限元分析与试验

 采用有限元方法对AISI 304钢经1100℃,0.1,1,10s-1的热压变形过程进行了数值模拟,分析了变形试样上等效应变的分布情况,确定了实际变形条件与试验设定条件之间的关系及合理的组织观察位置,研究了不均匀变形对奥氏体显微组织变化的影响。结果表明：不锈钢热压试样变形与组织不均匀性十分明显,心部的等效应变比实际设定值大40％左右,而端面值小于设定值的1/6,且应变速率对等效应变的分布情况影响不大;1100℃,1s-1,设定真应变为1（工程应变为63.2%）的试验条件下,变形试样心部组织发生完全动态再结晶,变形轴线端面位置组织与未变形组织形貌相似,且试样截面上硬度分布不均匀,沿变形轴线方向,硬度从端面到心部逐渐增大,端面硬度最小值为238HV,心部硬度最大值为251HV。     

Wall friction coefficient estimation through modelling of powder die pressing experiment

Abstract

Forming of PM components through powder pressing is a process, which is influenced by the friction between the powder and the tool walls. For good performance of the pressing process it is of great interest to understand and estimate the effects of powder–wall friction. However, quantification of the friction coefficient between the powder and the tool is a delicate task. Local contact conditions, such as contact stress, must be measured or otherwise estimated in order to evaluate the coefficient of friction. Here, the friction coefficient is estimated by combining an experiment with modelling of the experiment. Two methods for assessment of friction are presented, an optimisation approach using finite element analyses and an analytical approach. Experimental data are taken from the single action cold pressing of a cylinder shaped component.     

热轧定宽压力机板坯侧弯形成规律有限元仿真

某些现场热连轧生产线定宽压力机出口普遍存在板坯侧弯现象.采用有限元软件LS-DYNA建立了定宽压力机板坯定宽的有限元模型,对不同板坯中心线偏移量和锤头非对称倾斜角度下的板坯侧弯情况进行分析.造成减宽过程侧弯的原因是板坯中心线偏移,并给出其定量影响的关系式.      

Microindentation of aluminum

A simple model was developed to correlate the plastic energy dissipated in microindentation to the applied load and the average dislocation density underneath the indentation. The model predicted that the plastic energy dissipated in a loading-unloading cycle was proportional to the 3/2 power of the indentation load as well as to the 3/4 power of the average dislocation density underneath the indentation. The experimental results from the microindentation tests of the annealed Al and the equal channel angular extrusion (ECAE)-deformed Al supported the proposed model. A variation of the microhardness to the various sections of the ECAE-deformed Al was observed, suggesting that the Al rod was deformed to varying degrees of plastic deformation after only a single ECAE pass. The hardness of the most severely deformed sample showed the highest hardness, and the annealed sample showed the lowest hardness. Also, plastic recovery was observed in the indentation of the ECAE-deformed Al, which suggested a kind of Bauschinger effect took place.     

SP侧压过程板坯头部失宽的有限元分析

为了分析定宽过程中板坯头部失宽的变化规律,利用数值模拟的方法建立了板坯侧压的有限元模型。系统分析了在固定板坯宽度和不同侧压规程的前提下, 板坯头部失宽量的变化情况,得到了失宽量和侧压量的变化规律。并相应地进行了测试研究,对比模拟结果与现场实测值,两者吻合良好。表明建立的模型真实可靠,对控制侧压过程中板坯头部失宽有重要理论和参考价值。     

热压加工对含铬、镍块体纳米晶Fe_3Al组织和性能的影响研究

对通过铝热反应熔化制备的含10%(质量分数,下同)的铬和10%镍的块体纳米晶Fe3Al材料在不同温度、不同次数下进行了热压加工。利用XRD研究了热压加工前后纳米晶粒尺寸的变化,并测试了硬度变化和压缩率。结果显示:含10%铬的纳米晶Fe3Al在600℃表现出较好的塑性变形能力,材料在热压加工前后都是由无序bcc结构的Fe3Al相组成;含10%镍的纳米晶Fe3Al在800和1 000℃表现出较好的塑性变形能力,材料在热压加工前为无序bcc结构的Fe3Al相,在1 000℃热加工后,已转变为DO3有序结构;两种材料的压缩率都随着热压加工次数的增加逐渐增大。含10%铬的纳米晶Fe3Al在600℃和含10%镍的纳米晶Fe3Al在1 000℃随着热压加工次数的增加,晶粒尺寸都发生了增大,但材料硬度变化不大。