渗碳淬火件残余应力场的有限元模拟

本文对渗碳淬火后的残余应力场的形成机理进行了详细阐述,基于实验得到的不同温度下材料的热传导系数、比热、对流系数以及相变温度、比焓值和热膨胀系数等参数,利用有限元分析软件ANSYS对包涵多个时变参数的渗碳过程进行了数值模拟,得到了渗碳过程中应力场形成的有关数据和渗碳结束后的残余应力场,讨论了渗碳深度等参数对残余应力场的影...     

20CrMnMo钢渗碳齿轮磨削裂纹成因分析

采用化学成分分析、金相分析、显微硬度测试以及残余应力测定等方法对某20CrMnMo钢渗碳齿轮磨削裂纹产生原因进行了分析。结果表明:该齿轮产生磨削裂纹主要是由于磨削过程中表面产生严重的二次淬火烧伤和回火烧伤,二次淬火烧伤的次表面及边缘回火烧伤区硬度大幅下降及表面受拉应力,两者共同作用下产生了磨削裂纹;另外,渗碳层中存在针状马氏体和大量残余奥氏体,增加了齿轮磨削开裂的敏感性,这是齿轮产生磨削裂纹的另一个重要原因。     

深冷处理消除7A04长条构件残余应力的建模与仿真

建立了7A04铝合金长条构件深冷处理过程瞬态应力场的有限元模型,在构件瞬态温度场数值模拟的基础上,采用热-力顺序耦合方法对该构件深冷处理过程各阶段的瞬态应力场及残余应力场进行了数值模拟.数值模拟结果表明,该长条构件经深冷处理后其最大残余应力(Mises应力)从淬火状态的314.8 MPa降至152.6 MPa,残余应力幅度Δσ减小37.5%.     

SHS-离心法制备陶瓷复合管道热应力的有限元分析

模拟分析了SHS-离心法制备陶瓷复合管道在冷却凝固过程中的温度分布和变化,从而为工艺参数的选择和管道界面结构分析提供了基础.利用ANSYS软件的瞬态热分析功能和热-结构耦合功能,数值上模拟复合管道的残余热应力,分析SHS层厚度对陶瓷复合管道性能的影响.数值分析结果表明,合理调整SHS层的厚度,可使界面残余热应力变小,从而提高陶瓷复合管道的安全可靠性.     

重载汽车主减速器盆形齿轮的致裂因素

重载汽车主减速器盆形齿轮通常都采用大模数齿轮,经渗碳淬火处理。由于齿轮毛坯经锻轧而成,齿轮在锻轧后的热处理、渗碳前的预热处理工艺和渗碳工艺参数以及淬火处理,对齿轮的成分、组织及应力都会产生重大影响。本文在对磨削加工时齿轮凹齿面出现的裂纹进行分析,通过不同工艺参数热处理后齿轮的金相组织检验,讨论了大模数重载汽车盆形齿轮热处理致裂的原因,并提出了预防措施和方法。     

带台阶厚壁管类工件水淬的计算机模拟

本文以金属淬火冷却过程的连续过冷沸腾换热理论为基础,利用热分析和热结构耦合分析的有限元算法,以有限元分析软件ANSYS为分析工具,对45钢带台阶厚壁管类工件水淬过程进了计算机模拟,得到瞬态温度场、瞬态应力场以及残余应力场分布,并对计算结果进行分析.     

直齿轮“渗碳-温挤”渗碳层厚度分布模型

采用“渗碳-温挤压”工艺成形直齿轮，可使齿轮性能大幅度地提高，但经渗碳处理后的坯料，在塑性成形齿轮时，由于渗碳层流动不均匀，使齿面上不同部位渗碳层厚度不同，而沿齿面的渗碳层厚度应依据从齿顶到齿根不同工作特性的要求合理分布。通过分析齿轮失效的主要原因，提出了齿面上不同部位渗碳层厚度的基本要求，建立了直齿轮渗碳层厚度分布模型，并根据该模型，提出了采用“渗碳-温挤压”工艺加工直齿轮时坯料所需碳层的计算方法。研究表明：所建立的直齿轮渗碳层厚度分布模型为新工艺的实施提供了完善的目标和简明的计算方法。     

热处理过程中SiCP/2024Al复合材料的热应力分析

为研究热处理过程中SiCP/2024Al复合材料的热应力的变化规律,及热处理工艺对SiCP/2024Al复合材料热残余应力的影响,利用Marc有限元软件对淬火和冷热循环热处理过程中的SiCP/2024Al复合材料的热应力进行了数值模拟.研究结果表明:热处理过程中,颗粒和基体的界面附近会产生很大的热应力场,并且在SiC颗粒的尖角处产生热应力集中;经淬火处理后的SiCP/2024Al复合材料的热残余应力与基体的屈服强度接近,但经过冷热循环处理后的SiCP/2024Al复合材料中的热残余应力明显降低.     

热循环条件下圆柱结构热障涂层系统应力场有限元分析

采用有限元模拟方法,在热循环务件下模拟计算了圆柱结构热障涂层系统应力场的演变情况,分析和讨论了热循环工作温度、陶瓷层厚度对应力场分布的影响.研究发现,在仅考虑热弹性变形的条件下,热循环工作温度和陶瓷层厚度主要影响涂层系统在保温阶段的应力场大小;在每次热循环冷却之后,系统中同一位置的残余应力值相等.对于圆柱体结构的热障涂层系统,由于材料参数不匹配而导致材料的环向应力远大于径向应力数值,因此在后续分析测试中建议重点关注其环向应力的演变.     

20CrMnTi钢齿轮渗碳质量的控制

采用理化测试手段,研究了渗碳工艺参数对20CrMnTi齿轮的微观组织、力学性能、显微硬度及残余应力的影响,分析了影响渗碳层质量的因素,提出了控制热处理工艺的方法。     

Stress field simulation of carburized specimens with different carbon content during quenching process

This study focuses on the numerical model simulation of stress and temperature fields of carburized specimens with different carbon content during the quenching process. In the models the coupling between thermal field, phase transformation field and stress field was considered. The changes of the thermomechanical parameters of the material, as a function of carbon content and thermal field, were considered in the stress simulations. The residual stress fields of 20CrMnTi specimens with different carbon content of 0.8% and 1.0% were measured using an X-ray stress analyzer. Finite element model (FEM) was built for simulating the residual stress field after quenching. Meanwhile, the temperature and stress fields during quenching were simulated. The measured and simulated results are in good agreement.     

渗碳淬火齿轮磨削变质层的检测与分析

应用金相法，显微硬度及Ｘ射线衍射法等手段对渗碳淬火齿轮磨削变质层进行了检测与分析，结果表明，磨削材料对磨削变质有直接影响。为正确评估，优化磨削工艺，提高齿轮产品质量提供技术依据。     

面齿轮磨削齿面力热耦合及残余应力研究

根据面齿轮磨削残余应力的产生机理和Prandtl-Reuss方法,建立磨削表层热弹塑性力学本构关系;基于面齿轮磨削方法和Gleason接触原理,得出碟形砂轮磨削点接触椭圆方程参数、磨削力和磨削热流量的数学模型。构建面齿轮磨削单齿3D有限元模型,采用小步距移动法模拟磨削载荷的移动,仿真磨削温度场,得到磨削瞬态最高温度位于...     

A prediction method for endurance of carburized components based on fatigue of corresponding material states with different carbon contents

Carburizing generates different material properties and residual stresses in the carburized layer. A material mechanics based model for endurance prediction of carburized steel components has been developed, in which thin walled tubes are used under cyclic internal and monotonic external pressures allow the determination of the material properties of the carburized layers. An unexpected independence of endurance and mean stress sensitivity from carbon content and hardness has been found, contrary to existing scientific knowledge. Component like specimens were tested to validate the endurance prediction model. The deviations of the predictions from the experiment are in the range of ±8 percent.     

航空齿轮钢16Cr3NiWMoVNbE的真空低压渗碳

对航空齿轮钢16Cr3NiWMoVNbE进行真空低压渗碳热处理,研究了真空渗碳、淬火、冰冷处理以及回火工艺对材料的组织和性能的影响。结果表明：实验钢经渗碳淬火处理后,从表面到心部的组织可分为碳化物区、碳化物与针状马氏体混合区、针状马氏体区和心部板条马氏体区。在碳化物区的晶界有大量的块状Cr碳化物析出,在析出位置Ni元素较少。在针状马氏体和板条马氏体基体中细小的析出物为Nb、V、Mo微合金元素的碳化物。从渗碳钢表面到心部,随着碳浓度的降低硬度曲线呈现先升高后降低的趋势,渗层深度为0.95 mm。冰冷处理使残余奥氏体进一步转化为马氏体,使实验钢的硬度大幅度提高。     

齿轮开裂失效分析

采用断口分析、化学成分分析、低倍检验、金相检验和硬度测试等方法对某批经渗碳、淬火热处理及磨齿加工后放置一段时间发生开裂的齿轮的失效原因进行分析。结果表明：齿轮渗碳层碳化物级别过高,加上淬火后齿轮齿部应力集中,磨齿时又产生磨削裂纹,齿轮在放置期间由于应力导致裂纹扩展而开裂。     

Material influence on mechanical properties of gears with alternative microstructures

Case hardening represents the most important heat treatment process to increase the load carrying capacity of gear components. Beside predominantly martensitic surface layers with low proportion of retained austenite, there were investigated material structures with differing properties in preceding research work.

In a previous publication, the results of three variants made of the material 20MnCr5, which is typically used for gears, were presented. The reference heat treatment was a conventional carburizing with subsequent case hardening. The second variant was also gas carburized, but with a high proportion of retained austenite. The last presented variant had a bainitic structure in the surface layer. The second and the third variant showed a similar tooth root bending strength compared to the reference. The numbers of the pitting resistance were significantly higher than for the reference variant.

This paper presents the results of further investigations on the influence of different microstructures on the gear load carrying capacity. For this purpose, gears made of 18CrNiMo7‑6 were tested with regard to their load carrying capacity. 18CrNiMo7‑6 is a case hardening steel like 20MnCr5, too, which is often applied in big gear components. The tooth root bending strength was approximately constant, whereas the pitting resistance decreased compared to the corresponding variants of the material 20MnCr5. In comparison to the carburized 20MnCr5 reference variant, only the 18CrNiMo7‑6 variant with a large proportion of retained austenite showed a higher pitting resistance.

The tooth root bending strength investigations took place in the cycle regime of limited life as well in the high cycle fatigue regime. The pitting resistance was only determined in the cycle regime of limited life.

     

变速箱六档齿轮断裂分析及解决措施

对频繁出现轮齿早期断裂的变速箱六档齿轮进行了分析。通过对齿轮断裂特征、显微组织、硬度等方面的综合分析,确定了其断裂形式为低应力高周疲劳断裂。由裂纹扩展过程判断齿轮轮辐设计强度不足是导致其大批量早期疲劳失效的根本原因。据此通过改进齿形、油孔等设计措施,降低齿根部的设计应力水平,解决了这一问题。