表面粗糙度对表面应力集中系数和疲劳寿命影响分析

把平板的表面形貌简化为半椭圆形微缺口,采用有限元法对不同表面粗糙度下的应力场进行分析,得到不同表面粗糙度Rz时平板的表面应力集中系数,并预测不同表面粗糙度的平板在不同存活率下的疲劳寿命,讨论表面粗糙度对疲劳寿命的影响。采用回归方法建立表面应力集中系数与微缺口中心间距、表面粗糙度之间的经验公式。结果表明,在相同存活率下,表面粗糙度与平板的对数疲劳寿命呈二次曲线关系。     

表面微观形貌特征对二次挤压强化孔疲劳性能影响

建立了孔的二次挤压强化疲劳仿真模型,探究孔壁表面微观形貌特征对强化孔疲劳性能的影响。采用Abaqus有限元软件及MSC. Fatigue疲劳分析软件,对孔的二次挤压强化过程进行了模拟并计算了强化孔的疲劳寿命。选取孔壁微元,用半椭圆微观缺口代表零件表面微观轮廓,通过有效应力集中系数K_f修正材料S-N曲线,探究了表面微观轮廓对二次挤压强化孔疲劳性能的影响。结果表明,二次挤压强化后孔壁产生残余压应力层,试验件疲劳寿命得到提高;孔壁微观缺口数目增加可以有效缓解应力集中系数,应力集中系数K_t与深宽比b/a及间宽比d/(2a)成正相关;二次挤压强化可以降低孔壁表面粗糙度21%～49%,能有效缓解缺口应力集中现象,提高孔的疲劳性能。     

缺口应力集中对40Cr钢高周疲劳性能的影响

用超声疲劳试验方法测定了40Cr钢光滑试样和缺口试样在105-1010周次范围内的疲劳寿命(S-N)曲线,研究了缺口应力集中对疲劳性能的影响。结果表明:两种试样的S-N曲线呈现连续下降特征;缺口应力集中对材料疲劳性能的影响表现出阶段性特征,存在一个临界疲劳断裂循环数Nc,当疲劳断裂周次NfNc,Kf随Nf的增加而减小。在107以上超高周范围内,Kf和疲劳缺口敏感系数g与Nf具有线性关系。     

汽车用CNG钢瓶应力与疲劳寿命分析

通过有限元分析法,验证了计算选用的CNG钢瓶在热-固耦合作用下应力满足GB 150要求,在无表面划痕情况下疲劳寿命满足GB 17258要求。在此前提下,对表面存在划痕的钢瓶进行数值模拟研究,结果表明：缺口应力随缺口深度增加而明显增加,受缺口长度的影响并不显著;钢瓶的疲劳寿命随环向缺口的加深而递减,当缺口加深至1.0 mm后,疲劳寿命耗用系数仍小于1,满足疲劳寿命要求;钢瓶的疲劳寿命随纵向缺口加深而锐减,其影响程度远大于环向缺口,当缺口深度大于0.2 mm后,疲劳寿命耗用系数大于1,不再满足疲劳寿命要求。     

压力管道表面划痕对应力集中系数及安全性能影响的研究

利用三角形微型缺口表征压力管道表面的划痕,建立具有表面划痕特征的压力管道有限元模型,计算不同表面划痕深度的压力管道应力分布情况,揭示表面划痕深度对应力集中系数及安全系数的影响规律。研究表明:应力集中系数随着表面划痕深度增加而增大,且增大趋势越来越明显;安全系数随着表面划痕深度增大而减小,当表面划痕深度大于4 mm时,安全系数降低到1. 5以下,不满足设计要求,当表面划痕深度大于6 mm时,安全系数降低到1以下,若不采取措施,继续使用会导致严重安全事故。     

复杂曲面表面形貌的评定及其应力集中分析

为合理评定圆棒试样缺口底部复杂曲面的表面加工质量,提出小波变换并结合摄动法对其进行定量分析的方法。对测量的原始表面形貌进行小波变换提取出表面粗糙度信息,并进行表面粗糙度参数分析。采用摄动法对提取出的表面粗糙度信息进行应力集中分析,提出计算复杂曲面表面应力集中系数和表面相对应力梯度的方法。使用NPFLEX白光干涉仪测量平板试样和圆棒试样缺口底部复杂曲面的表面形貌。针对平板试样的表面形貌,使用所提方法对其表面形貌进行评定,验证该方法的准确性。对圆棒试样缺口底部复杂曲面的表面形貌进行评定及应力集中分析,为圆棒试样缺口底部复杂曲面表面加工质量的评定提供参考方法。     

冲击值与金属材料其他力学性能关系的研究

通过试验研究与理论分析,确定缺口应力集中系数,找出缺口应力集中系数和应力强化系数之间的关系;通过40CrMnSiMoA数字化冲击试验数据分析结果,找出冲击值与材料缺口敏感性的关系、冲击裂纹形成功与疲劳裂纹形成寿命之间的关系;从而得出结论:对于高强度和超高强度材料,冲击功值对缺口试样疲劳裂纹形成寿命影响更大,且冲击功值较高的材料比冲击功值较低的材料在等应力条件下疲劳寿命长。     

一种磨削表面微观形貌应力集中系数的计算方法

针对一种磨削表面微观形貌的应力集中问题提出了一种应力集中系数的精确计算方法。通过实验观察磨削工件表面微观形貌在进给方向具有沟壑状形貌特征,采用缺口模型分析计算磨削表面微观形貌应力集中系数;提出基于二维表面轮廓数据的缺口表征参数计算方法,建立无限大平面缺口模型并采用迭代法对模型进行修正,并用有限元方法进行对比验证。针对磨削表面微观形貌的应力集中系数与缺口模型特征参数-缺口的宽度、深度和谷底半径的定量关系,提供了对应的经验公式。研究工作为磨削表面微观形貌与应力集中系数关联规律研究提供一种定量计算方法,对分析磨削工件表面微观形貌的疲劳性能具有基础作用。     

中碳钢在低应力超长寿命范围内的疲劳性能

用20kHz超声疲劳试验技术测试40Cr钢、50车轴钢在105～1010周次范围内的疲劳性能.结果表明,两种钢并不存在传统意义上的所谓"疲劳极限".在超过107周次,甚至109周次的超长寿命范围内仍发生低应力疲劳断裂,其中40Cr钢的S-N曲线呈现"连续下降型"特征;50车轴钢呈现"阶梯下降型"特征.对两种钢缺口试样的疲劳性能测试表明,缺口应力集中对疲劳性能的影响呈现"阶段性特征",在106～107周次内存在一个临界疲劳断裂循环周次Nc当疲劳断裂循环数Nf＜Nc随Nf的增加,缺口应力集中对疲劳性能的影响程度呈上升趋势;当疲劳断裂循环数Nf＞Nc,随Nf的增加,缺口应力集中对疲劳性能的影响程度呈逐渐下降的趋势.     

构件不同部位粗糙度对疲劳性能影响差异分析

为验证构件不同部位粗糙度影响的差异性,以某型铝合金为研究对象,采用疲劳试验与理论分析相结合的方法分析不同部位粗糙度组合下构件疲劳性能的差异。试验设计中,为区分不同部位粗糙度造成的影响,着重对试样角部、面部和曲面部做不同的表面处理,同时设计棒试样及两类厚度的板试样以说明试验结果的普适性,并在试验结果处理中通过观测试样的断口形貌定义面断裂(曲面断裂)与角断裂两种断裂形式。为进一步定量分析不同部位粗糙度影响差异性的大小,采用有限元软件分析不同部位微缺口附近的应力分布特性,另外,针对本研究的特殊性提出一种适用于微尺寸缺口处应力计算的改进场强法,并采用此方法分别计算试样表面各类微缺口处的有效破坏应力及有效应力集中系数。通过试验结果与理论计算结果对比发现,对于同样表面粗糙度的试样,不同部位微缺口处的有效应力集中系数存在显著差异,即角部微缺口处集中系数明显高于面部,这一结论反映到宏观上表现为试样边角处的粗糙度对试样疲劳性能的影响明显高于试样面部粗糙度的影响,因此传统方法中将两者做等同处理缺乏一定的合理性。     

Experimental study of surface integrity and fatigue life in the face milling of inconel 718

The Inconel 718 alloy is widely used in the aerospace and power industries. The machining-induced surface integrity and fatigue life of this material are important factors for consideration due to high reliability and safety requirements. In this work, the milling of Inconel 718 was conducted at different cutting speeds and feed rates. Surface integrity and fatigue life were measured directly. The effects of cutting speed and feed rate on surface integrity and their further influences on fatigue life were analyzed. Within the chosen parameter range, the cutting speed barely affected the surface roughness, whereas the feed rate increased the surface roughness through the ideal residual height. The surface hardness increased as the cutting speed and feed rate increased. Tensile residual stress was observed on the machined surface, which showed improvement with the increasing feed rate. The cutting speed was not an influencing factor on fatigue life, but the feed rate affected fatigue life through the surface roughness. The high surface roughness resulting from the high feed rate could result in a high stress concentration factor and lead to a low fatigue life.     

Some considerations about fatigue failure in milled butt-welded joints affected by residual stress

Many factors are involved in determining the fatigue strength of welded joints. It is, however, very difficult to consider their relative importance. The aim of this paper is to isolate the effect of residual stress from other factors, establishing a relation between the amount of residual stress and fatigue life. A geometrical notch due to the weld bead is removed by milling the upper surface of the welded plates. Moreover, specimens are subjected to four-point bend loading. Before conducting the fatigue test, the magnitude of residual stress for each specimen is experimentally evaluated, and then linked to the number of cycles to failure. This relation is analyzed for three different plate thicknesses and for different stress amplitude levels in the high cycle regime. The results clearly show the significant influence of residual stress on fatigue behaviours when the load level is near the fatigue limit.     

基于支持矢量机的疲劳应力集中系数预测模型研究

疲劳应力集中系数作为材料疲劳抗力指标的疲劳极限,不仅反映了疲劳应力集中的程度,还反映了材料对缺口的敏感程度,将近年来飞速发展的支持矢量机(Support vector machine,SVM)应用于疲劳应力集中系数的研究。介绍支持矢量机的基本原理,利用LIBSVM,选择高斯型径向基函数(Radial basis function,RBF)作为核函数,建立以材料的抗拉强度、屈服强度、光棒疲劳强度、理论应力集中系数、缺口根部半径、试样尺寸及缺口疲劳极限作为输入值,疲劳应力集中系数为输出值的模型,从而对疲劳应力集中系数进行分析和预测。同时,SVM模型与经验公式Neuber式和Peterson式的计算值进行比较。结果表明,在小样本条件下,应用SVM技术构建的数学模型,模型的拟合相对误差小于7.4%,从而证明该SVM模型的准确性和适用性。     

Investigating the effect of clamping force on the fatigue life of bolted plates using volumetric approach

In this paper, the effects of bolt clamping force on the fatigue life for bolted plates made from Al7075-T6 have been studied on the values of notch strength reduction factor obtained by volumetric approach. To attain stress distribution around the notch (hole) which is required for volumetric approach, nonlinear finite element simulations were carried out. To estimate the fatigue life, the available smooth S-N curve of Al7075-T6 and the notch strength reduction factor obtained from volumetric method were used. The estimated fatigue life was compared with the available experimental test results. The investigation shows that there is a good agreement between the life predicted by the volumetric approach and the experimental results for various specimens with different amount of clamping forces. Volumetric approach and experimental results showed that the fatigue life of bolted plates improves because of the compressive stresses created around the plate hole due to clamping force.     

Fatigue cracks at notches

The failure of a component or specimen due to a fatigue crack growing from a notch is considered. Previous methods of analysis involving stress and strain concentration factors are shown to be inadequate. By defining equivalent cracks in notched and un-notched situations as cracks with equal growth rates, the concept of notch contribution to crack length is introduced. Theoretical notch contributions are obtained for a variety of central and edge elliptical notches via stress intensity factor solutions. These results when extended to a very wide range of general notch shapes can be reduced to a useful and simple design rule where e is the contribution to a crack of length l growing from a notch of depth D and root radius . This rule combines the size and shape effects long known to affect fatigue behaviour and defines the extent of the notch field as 0·13√(D).The fatigue crack propagation lives of a wide variety of notches were estimated by this rule and comparisons with experimental values revealed very small errors normally well within the scatter of fatigue lives.The design rule is extended to enable the conventional stress intensity factor method to be employed. A fatigue concentration factor is proposed which takes into account the presence of a fatigue crack which all previous methods have ignored.     

The stress and strain concentrations of out-of-plane bending plate containing a circular hole

The elastic stress and strain fields of a finite thickness plate containing a circular hole subjected to out-of-plane bending are systematically investigated using the finite element method. It is found that the stress and strain concentration factors of the finite thickness plate are different except at the notch root of the free surface even if the plate is in elasticity state. The through-thickness distributions of strain components are not linear with the distance from the mid-plane in the stress concentration region. The nonlinearity of these distributions is very severe near the free surface especially in thick plate. The Euler-Bernoulli hypothesis and Kane-Mindlin's plate theory may not be reasonable to be used in the stress concentration region especially near the free surface. The maximum stress and strain do not always occur on the free surface and their locations depend on the moment ratio and the plate thickness. The maximum stress and strain concentration factors occur on the free surface only in thin plates of small moment ratio. The differences between the maximum value and surface value of stress concentration factor increase with the plate thickness and the moment ratio. This relation of strain concentration factor is similar to the one of stress concentration factor. But the difference magnitude of stress concentration factor is larger than that of strain concentration factor in same plate.     

疲劳寿命影响因素的试验研究

考虑应力集中、表面加工及尺寸三方面影响因素设计10种疲劳试样,进行拉压疲劳试验,得到了不同形式试样的疲劳寿命。应用三参数Weibull分布描述了疲劳寿命分布的特性。试验结果分析表明:同时存在应力集中和表面加工影响的零件,应力集中对疲劳寿命的影响起主导作用;对于缺口试件,纯粹意义上的尺寸效应是不起作用的,危险点周围材料的应力梯度是造成尺寸效应的关键。     

大型组合机架的疲劳寿命分析

针对大型模锻压机机架的疲劳失效形式,在承受拉、压复合作用下,以等效应力作为裂纹寿命估算的依据,并采用有限元进行疲劳寿命数值分析。分别计算不同应力集中系数、过载荷、残余应力、表面粗糙度取值下的疲劳寿命,并进行相应的敏度分析。通过仿真分析,得到影响疲劳寿命的关键因素变化趋势,为改进疲劳寿命提供直接依据。