连续退火炉炉壳表面热应力测试

在一定的温度场和热应力等物理量作用下，连续退火炉炉壳会产生一定程度的变形，利用高温应变测试分析了炉壳的变形情况。由于工作温度较高，所以需采用高温应变片来组成应变测量电桥。通过电桥把应变转化成为电压信号，这样就实现了应变的测量。本文通过试验获得了炉壳热应力分布情况，并在此基础上分析了炉壳的变形情况和煤气流量对炉壳应力的影响。本文主要涉及高温表面热应变的测试，关键是解决高温环境下应变测量技术。     

基于串联参考光纤光栅法实现应变(应力)测量的温度修正

采用串联参考光纤光栅法,根据交叉敏感产生机理,理论分析和实验验证了光栅周期接近但不相等、其它结构参数和性能基本相同的2个FBG传感器对应变(拉应力)的响应特性,在温度变化范围为30~45℃范围内,测试了拉应力和温度同时作用引起的布拉格波长移动量,当采用修正公式扣除温度影响时,结果证明可以完全消除温度的影响,提高了应变(拉应力)的测量精度,测量相对误差可达0.001%。     

可调谐F-P腔进行锥形光栅 反射带宽解调的应力测量方法

理论分析和实验验证了通过对锥形光栅反射谱进行带宽解调来获得环境应力/应变的可行性,提出了对锥形光栅反射谱采用可调谐F-P腔进行带宽解调的方法,通过应力加载实验对该带宽解调方法进行了验证,并取得了较好的反射带宽解调和应力测量效果。实验证明,该测量系统实现了对温度变化不敏感的应力测量,同时具有较高的灵敏度,应力测量精度为0.060 N。在进一步进行锥形光栅中心反射波长解调的基础上,该方案可实现温度和应力的同时测量。     

环芯法测量深度方向上的残余应力分布

叙述了环芯法采用逐层铣槽方式测量残科应力的应力应变关系，并讨论了积分法和应变增量法两种方法测量主应力的误差问题。     

基于光纤传感技术的三维地应力传感器

为了实现对地下岩层空间应力状态及其变化规律的有效监测,基于光纤光栅传感技术与平面应力状态测量原理,提出了一种平面应变花与光纤光栅传感技术相结合的监测方法。通过利用碳纤维层积复合材料对光纤光栅封装做成应变传感单元,九个应变传感单元分别组成两组直角应变花与一组等角应变花,三组应变花分别放置于三个圆柱形探头S1,S2,S3上,三个探头以一定的机械结构连接构成地层空间应力的监测的三维地应力传感装置。对光纤应变传感单元进行温度与应力的标定实验,在室内对整体传感装置进行了应力加载模拟实验。实验结果表明:光纤应变传感单元的应力分辨率为0.017 2 MPa;应力监测为0~60 MPa;探头S1最大主应力的监测平均误差为16.31%,探头S2最大主应力的监测平均误差为24.36%,S3探头的绝对误差为0.006 8 MPa;实际加载应力与传感器测量的应力空间角度误差平均值为1.24°。传感器的监测结果与实际加载应力的变化规律相一致,可满足对地下岩层空间应力状态连续监测的要求。     

一种具有温度补偿的“王”字形FBG应变传感器研制

针对铁轨温度与外载应力实时监测,设计了一种"王"字形FBG应变传感器。该传感器借助一组平行布置但彼此相连的带狭长矩形窗口的基片,将2根FBG悬空粘牢,通过基片的固连和紧贴实现具备温度补偿的应变测量,同时防止啁啾。采用有限元仿真分析传感器的应变和温度特性,并进行基于强度梁的传感器标定;最后,在高速铁路60轨道上进行了实测。仿真与实验结果表明,该传感器既可进行结构温度测量,又能实现铁轨温度补偿后的外载应变测量。     

GH4169合金不同热变形条件下的流变应力研究

在Gleeble－3500型热加工模拟试验机上进行了GH4169镍基合金的高温压缩试验,变形温度为980℃～1100℃、应变速率为0,01s^-1、0,1s^-1、1s^-1、10s^-1,变形程度为50％。通过绘制真应力一真应变曲线,研究了GH4169镍基高温合金高温下的流变应力行为。结果表明：GH4169是应变速率和变形温度敏感型材料,变形温度升高和应变速率减小使流变应力显著减小;在变形的初始阶段,流变应力迅速增加,在到达峰值后,随着应变的增加,流变应力逐渐下降,并趋于一稳定值。采用简化后的双曲正弦模型Arrhenius方程,建立了GH4169高温条件下的本构方程,运用该方程计算出的峰值应力与试验测量值相比,拟合度达到了95.95％。     

新型高强轴承钢的热压缩变形行为与热加工图

以自行开发的贝氏体轴承钢为研究对象，采用热模拟试验机在变形温度900～1 200℃、应变速率0.01～5 s^-1条件下进行单道次热压缩试验，研究了该钢的热压缩变形行为，基于真应力、真应变数据，建立热变形本构方程，并绘制热加工图。结果表明：当变形温度不低于1 000℃、应变速率低于0.1 s^-1时，试验钢在热压缩过程中的动态再结晶较明显。在相同应变速率下，变形温度越高，峰值应力越小，到达峰值应力的真应变也越小；在相同变形温度下，应变速率越大，峰值应力越大，达到峰值应力的真应变也越大。试验钢的变形激活能为479.119 kJ·mol^-1,明显大于传统GCr15马氏体轴承钢，说明在相同变形温度下试验钢更难以变形。试验钢适宜的热加工区间为变形温度900～1 100℃、应变速率1.4～2 s^-1。     

非对称荷载下U形波纹管的实验研究

对金属Ｕ形波壳在端弯矩作用下的应力，应变作了实际测量分析，得到了应力分布曲线。     

Ti-6Al-4V动态力学性能与本构关系研究

采用分离式霍普金森压杆装置(SHPB)对钛合金(Ti-6Al-4V)进行动态压缩试验，获得不同温度和应变率的真实应力—应变曲线，分析了钛合金在应变率2000/s～10000/s、温度20℃～800℃范围内的动态力学性能，通过试验数据拟合得到Johnson-Cook(J-C)本构方程。试验研究结果表明，常温(20℃)条件下Ti-6Al-4V具有明显的应变和应变率强化效应，同时应变和应变率强化效应逐渐减弱，800℃时几乎没有应变和应变率强化效应；随着温度的提高，不同应变率的应力均近似线性下降，表现出明显的热软化效应；在应变硬化和热软化耦合作用下，试样剪切区产生绝热剪切破坏；所得的J-C本构模型较好地拟合了真实应力应变值及变化趋势。     

提升高温应变计寿命及精度的结构优化方法研究

高温应变电测技术广泛应用于航空发动机热端部件应力状态测量,如何将高温应变计的各部分结构参数进行合理搭配,以提高应变计灵敏度及使用寿命,在工程中具有十分重要的价值。首先,针对影响高温应变计测量误差与疲劳寿命这两个目标,分别建立简支梁-测量误差模型与悬臂梁-疲劳寿命模型;然后,经有限元分析得到各个参数变化对应变计测量误差以及疲劳寿命的影响规律,进而筛选出待优化的参数;接着,采用遗传算法与响应面法相结合对高温应变计进行优化;最后,通过试验对最终优化结果进行验证。结果表明,单参数分析法能直观反映各个参数对应变计灵敏度与寿命的影响规律,基于响应面模型和多目标遗传算法的优化,可得出高温应变计栅丝直径、栅丝长度、栅丝间距、栅丝弯数、基底厚度5个参数的最佳参数组合;优化后的测量误差为0.255%,疲劳寿命达到2.384 6×10~7次循环;试验验证结果表明,多目标优化后测量误差降低了89.2%,疲劳寿命提升了10.14%。     

Turning induced residual stress prediction of AISI 4130 considering dynamic recrystallization

Machining-induced residual stress distribution is strongly influenced by the machining process condition, tool geometry and workpiece material mechanical properties. The high temperature, large strain and high strain rate environment will promote the material micro-structural attribute changes. The material micro-structural attribute changes could directly affect the material mechanical properties. An analytical model is proposed for the residual stress prediction in the orthogonal turning by considering the material dynamical recrystallization induced grain growth effect. The grain size effect on the material flow stress behavior is included by adding a grain size dependent term into the traditional Johnson–Cook model. The Johnson–Mehl–Avrami–Kolmogorov model calculates the recrystallized volume fraction and grain size as a function strain, strain rate and time. The average grain size is calculated with a rule of mixture by volume. Then the modified Johnson–Cook model is embedded into a classic residual stress prediction model for the machining induced residual stress profile prediction on the machined workpiece surface. Experimental tests are conducted for the model validation. The predicted residual stress shows good approximation with the measurement in both the trend and magnitude of the residual stress. Also, the effects of cutting speed and feed rate on the residual stress profile are investigated.     

基于桥梁结构的FBG传感器温度与应变交叉敏感问题的研究

对光纤布拉格光栅(FBG)传感器在桥梁结构健康监测中产生的温度与应变交叉敏感问题进行了研究。采用参考光纤光栅法在应变传感光纤光栅附近额外加入一个温度测量光纤光栅,对应变光栅实现温度补偿功能。设计了基于参考光纤光栅法的FBG传感器及FBG传感器封装的机械结构,并通过实验来验证FBG传感器的性能。实验数据表明,温度传感光纤光栅几乎不受应变的影响,应变传感光栅的中心波长变化与温度变化呈一阶线性关系,修正后的测量结果更加精确,达到了双参数同时测量的目的,应变与布拉格波长的线性关系非常好,相关系数达到0.99以上。参考光纤光栅法能够很好地解决FBG传感器温度与应变交叉敏感的问题。     

板材热轧热力耦合有限元模拟

建立了三维热力耦合问题弹塑性有限变形有限元方法,并对板材热轧过程进行了计算机模拟。材料流动应力模型中考虑了应变历史、应变速率和温度的影响,导出了与其相应的本构关系矩阵。应用该方法可以给出轧件变形过程中诸如温度场、应变场和应变速率场等各种热力结果。算例表明,该方法具有较好的精度。     

A modified micromechanical approach to determine flow stress of work materials experiencing complex deformation histories in manufacturing processes

Work materials experience a broad range of strains, strain rates, and temperatures in many manufacturing processes such as machining, forming, etc. Strain rate has an important effect on the yield and flow stress of work materials, especially metals, since at higher strain rates there is less time for thermally activated events; consequently, it is equivalent to a lowering of the temperature of the materials. On the other hand, it is also true that, for high strain rate deformations such as metal cutting, adiabatic plastic flow may produce significant temperature changes in the materials. Flow stress is significantly affected by the strain rate history; hence, mechanical behavior may not be fully described in terms of a mechanical equation of state relating the instantaneous stress, strain, strain rate, and temperature.Based on the concept of dislocation mechanics, a micromechanical approach with the new concept of temperature coefficient has been explored to overcome the model issues such as negative or constant flow stress above the critical temperatures. The flow stresses of aluminum 6061-T6 and titanium Ti-6Al-4V have been predicted, for the first time, using the modified micromechanical model based on the available baseline high strain rates test data. The constitutive model was further modified and extended to predict flow stress below as well as above the critical temperature. The corresponding model predictions were compared with the experimental data, attaining good agreement.     

温度对机械密封金属波纹管力学性能的影响

为了研究温度对机械密封金属波纹管力学性能的影响,建立高温泵用机械密封焊接金属波纹管计算模型,利用ANSYS软件计算波片的温度场,并通过间接耦合法计算不同介质温度下的热应力与热应变场,得到温度对波纹管力学性能的影响规律.计算结果表明:在高温工况下波纹管波片内产生了较大的热应力和热应变,增大了波纹管断裂、失弹等形式的失效的危险,在设计和使用过程中必须对此引起足够重视;在高温工况下波纹管波片等效热应力、热应变的最大值均出现在波片波谷处.     

An internal state variable plasticity-based approach to determine dynamic loading history effects on material property in manufacturing processes

Worked materials in large deformation processes such as forming and machining experience a broad range of strain, strain rate, and temperatures, which in turn affect the flow stress. However, the flow stress also highly depends on many other factors such as strain path, strain rate and temperature history. Only a model that includes all of these pertinent factors is capable of predicting complex stress state in material deformation. In this paper, the commonly used phenomenological plasticity models (Johnson–Cook, Usui, etc.) to characterize material behavior in forming and machining were critically reviewed. Although these models are easy to apply and can describe the general response of material deformation, these models lack the mechanisms to reflect static and dynamic recovery and the effects of load path and strain rate history in large deformation processes. These effects are essential to understand process mechanisms, especially surface integrity (residual stress, microhardness, and microstructure) of the manufactured products.As such a dislocation-based internal state variable (ISV) plasticity model was used, in which the evolution equations enable the prediction of strain rate history and temperature history effects. These effects can be quite large and cannot be modeled by the equation-of-state models that assume that stress is a unique function of the total strain, strain rate, and temperature, independent of the loading path. The temperature dependence of the hardening and recovery functions results in the prediction of thermal softening during adiabatic temperatures rises, which are common in metal forming and machining.The dynamic mechanical behaviors of three different benchmark work materials, titanium Ti-6Al-4V, AISI 52100 steel (62 HRc), and aluminum 6061-T6, were modeled using the ISV approach. The material constants were obtained by using a nonlinear regression-fitting algorithm in which the stress–strain curves from the model were correlated to the experiments at different (extreme) temperatures. Then the capabilities of the determined material constants were examined by comparing the predicted material flow stress with the test data at different temperatures, strains, and strain rate history. The comparison demonstrates that the internal state variable plasticity model can successfully recover dynamic material behavior at various deformation states including the loading path effect. In addition, thermal softening due to adiabatic deformation was also captured by this approach.     

热变形参数对LC4铝合金流变应力的影响

在Gleeble-1500热模拟试验机上,以不同应变、应变速率和变形温度对LC4铝合金进行了高温压缩流变试验,得出了真实应力曲线,并采用神经网络的方法建立了该合金高温变形抗力与应变、应变速率和变形温度对应关系的预测模型。结果表明：变形温度和应变速率的变化强烈地影响合金流变应力的大小,流变应力随变形温度的升高而降低,随应变速率的提高而增大;神经网络能够比较精确地预测材料的流变应力。     

TNTZ钛合金流变行为及物理基本构模型

借助Gleeble-3500热模拟机对Ti-29Nb-13Ta-4.5Zr(TNTZ)钛合金进行了变形温度为700~900 ℃、应变速率为0.001~1 s-1的等温恒应变速率压缩实验,分析了应变速率和变形温度对TNTZ钛合金流变应力的影响。根据实验数据,计算了不同变形条件下的温升值,分析了变形热产生的规律。综合考虑温度对材料自扩散系数和弹性模量的影响以及应变对合金流变应力的影响,通过多元线性回归拟合材料参数与应变之间的函数关系,构建了基于应变补偿的物理基本构模型。研究结果表明：TNTZ钛合金的流变应力随应变速率的增大而增大,随变形温度的升高而减小;变形热效应引起的温升与应变速率正相关,与变形温度负相关。通过应变补偿建立的物理基本构模型预测精度较高,模型相关系数R达0.964,平均相对误差为10.63%。