自冲铆接头疲劳性能影响因素研究进展

由于近年来车身轻量化的需求,全铝车身结构及混合材料车身结构是车身设计制造的发展趋势,其结构连接问题也面临巨大的挑战。自冲铆接作为一种冷成型技术,通过铆钉和板料形成机械内锁结构进行板材连接,可以用来连接两层和多层金属及非金属板材。相对于传统连接技术,自冲铆接具有无需预先打孔、连接过程环境友好、可以连接异质板材及非金属板材等优点,同时所得到的接头具有较好的密封性及力学性能。自冲铆接作为轻量化结构的一种新型连接手段,近年来因具有独特的优势得到迅速发展。疲劳性能是接头工程应用的关键性能指标,自冲铆接头的疲劳性能研究主要针对铝合金及高强钢等车身材料展开,近年来研究者们对钛合金和纤维增强复合材料等新型材料自冲铆接头的疲劳性能进行了相关探索性研究。影响自冲铆接头疲劳性能的因素众多,提高自冲铆接头疲劳性能的方法及探究接头的疲劳失效机理一直是研究者们所关注的热点。影响自冲铆接头疲劳性能的因素主要包括铆接工艺、基板参数、铆钉分布形式、接头搭接形式、疲劳加载参数、试验温度和添加粘接剂等,其中大量研究主要针对铆接工艺、基板参数和铆钉分布形式展开。研究表明,采用高强度的板材作下板、增加板厚及使用硬度较高的圆头铆钉进行连接能够提高单搭自冲铆接头的疲劳性能;铆钉个数的增加可以显著提高接头的疲劳性能,采用不同铆钉分布形式及铆钉边距影响接头的疲劳性能。自冲铆接头存在残余应力,同时微动磨损是导致机械连接疲劳失效的主要原因,通过去应力退火可以提高接头在高疲劳载荷下的疲劳寿命,对基板添加润滑剂镀层也可以改善接头的疲劳性能。此外,粘铆复合接头目前在车身连接中得到广泛应用,粘接剂可以减弱接头的应力集中,从而改善其疲劳性能。疲劳试验耗时较多,试验成本较高。研究自冲铆接头疲劳性能的影响因素可以为后续研究及其工程应用提供相关参考。本文归纳了自冲铆接头疲劳性能影响因素的研究进展并总结了改善接头疲劳性能的方法,同时对自冲铆接的研究方向进行分析和展望。     

换流变阀侧套管振动模态及其法兰根部应力研究

套管法兰是换流变压器阀侧套管的薄弱部位,承受着换流变振动等复杂环境动力,易因长期机械载荷作用出现疲劳开裂,导致换流变压器停运。应力集中是导致结构疲劳开裂的主要因素,但现在少有针对法兰应力分布和疲劳的研究。为优化套管法兰根部结构、提高法兰疲劳强度,采用有限元仿真方法分析法兰应力分布,研究不同根部结构下法兰应力集中特征,并采用模态分析和响应谱分析研究振动载荷下法兰应力分布。研究发现:应力集中在法兰拐角位置并随法兰拐角曲率半径增加而降低;套筒上与法兰盘连接的加强筋能明显降低法兰拐角应力,降低幅度随加强筋宽度和高度增加而提升;三角形加强筋在靠近应力集中位置时能明显降低法兰拐角应力,降低幅度随加强筋安装角度增加而减小;连接的加强筋还对套管受竖直方向和轴向振动时法兰拐角最大应力有明显抑制作用。     

超声振动对5A06铝合金自冲铆接头静力学性能影响

自冲铆接工艺作为一种性能优异、绿色、高效的连接新技术,可实现同种、异种和多层轻合金薄板材料的连接,广泛应用于新能源汽车等领域,成为实现车身轻量化的关键技术之一。但由于自冲铆接头是典型的紧密连接构件,在交变应力或振动作用下,易发生微动损伤,致使接头提前疲劳失效。本文选用5A06铝合金薄板材料,分别进行自冲铆接和不同超声焊接工具头下的超声自冲铆复合连接试验,基于拉伸-剪切和电子显微镜测试,研究超声振动对5A06铝合金自冲铆接头静力学性能的影响。研究表明：超声振动可有效提高自冲铆接头的静力学性能;超声金属焊接与自冲铆接复合连接时会在板材之间形成固相焊接,这是提高复合接头力学性能的根本原因;超声金属焊接头的焊接面积影响自冲铆接头的力学性能,焊接面积较大时超声固相焊的程度较高;超声焊接会使铆钉温度升高,一定程度影响接头稳定性。     

加筋矩形薄板的平均声辐射效率

采取工程等效的方法研究了四边简支矩形加筋薄板的振动与声辐射,推导了点力激励下的平均辐射效率计算公式,并进行了数值仿真和实验验证。理论分析与实验的一致性表明:四边简支情况下矩形加筋薄板与匀质矩形薄板和圆薄板的平均辐射效率公式相似,可以采用模态辐射效率加权平均的方法等效。在中高频段,纵横双向加筋薄板的平均声辐射效率最高,单向加筋薄板次之,匀质平薄板最低;而在低频段及临界频率以上,三种结构平均声辐射效率相差不大。     

用解析法研究L型加筋板的自由阻尼振动

在薄板的弯曲振动方程和加强筋的弯曲/扭转振动基础上,本文应用拉普拉斯变换技术,同时考虑了加强艋和板的材料阻尼影响,得到了L型加筋板结构自由振动的频率方特号,并讨论了加强筋数目、粘性对L型加筋板固有频率和对数衰减率的影响。     

无限大单向加筋层合板隔声性能研究

基于经典层合板理论,计及加强筋弯曲及扭转运动影响,建立无限大单向加筋层合板在平面声波激励下的声透射理论模型;应用空间谐波展开与虚功原理,推导出单向加筋层合板传声损失公式,并与解析解及简化模型计算结果对比,验证所建模型的精度及有效性;系统研究特征参数对加筋层合板结构隔声性能影响。研究表明：增加层合板铺设角度对结构隔声性能不利,材料损耗因子只影响结构共振频率处隔声性能;增大加强筋间距,加筋层合板结构低频段隔声性能下降明显,但全频段隔声性能有所改善;声波入射角度对单向加筋层合板隔声性能影响显著,结构对垂直入射声波隔声效果最好。     

典型边界条件下加筋矩形板的横向振动特性分析

采用能量法研究典型边界条件下加筋矩形板的横向振动特性。将矩形板、加强筋沿交界面切开,分别采用薄板弯曲理论和欧拉梁理论建立其横向振动的总能量方程,利用第一类切比雪夫多项式构造矩形板的位移试函数,由Rayleigh-Ritz法得加筋矩形板的横向振动特征方程。数值计算结果表明,该方法收敛性好,与有限元软件ANSYS和已有文献的对比显示了高精度,并可以得到任意阶次的固有频率,具有计算简单的特点;最后分析了加强筋位置和加强筋高度对加筋方板无量纲自振频率的影响。     

基于板梁组合理论的正交加筋板声振特性分析

基于板梁组合理论,建立了正交加筋板声透射计算模型,并分析了正交加筋板的声振特性.将加强筋视为平板的动反力及动反力矩,引入到平板振动方程,得到了正交加筋板声振方程;利用空间谐波展开法及虚功原理,得到了正交加筋板透射损失和平均振动速度级表达式.在此基础上,首先研究了单向加筋板的隔声性能,理论结果与已有计算结果取得了很好的一致,验证了模型的有效性;并进一步研究了正交加筋的声振特性.研究表明,正交加筋板对垂直入射声波的隔声效果最好;增大加强筋惯性矩可提高其低频段透射损失;增大加强筋间距可提高正交加筋板的低频段振动响应,却降低了其低频透射损失,总体而言,增大加强筋间距可改善结构的整体隔声性能.     

双向正交加筋板声振响应解析方法研究

提出双向正交加筋板声振响应的一种解析计算方法。使用两种连续性条件,建立双向正交加筋板的耦合振动方程。利用二维傅里叶级数作为双向正交加筋板振动位移表达式,将双向正交加筋板振动微分方程化为线性方程组,求解获得双向正交加筋板的模态特性以及加筋板稳态声振响应,并通过了现有文献数据和有限元方法的验证。通过进一步的参数分析,研究加强筋在板上的排布方式对加筋板声振特性的影响。     

几种几何形状的筋对薄板振动和声辐射特性影响的研究

加筋板的研究由来已久,板上加筋(单向),并且使筋通过激励点,可以有效地提高板的固有频率,从而有效地降低板的声辐射.由于筋的几何形状种类繁多,究竟那一种几何形状的筋抗振、降噪和弯曲直力等综合指标最好是工程技术人员所关心的问题.以一薄板加不同截面形式的筋为研究对象,应用统计能量分析方法进行振动噪声计算分析,通过对薄板的表面速度振动级和垂直薄板上方1m处的声压级的预测,得出槽形筋在综合指标下较好,希望给工程实践提供一点有益的帮助.     

Fatigue of single- and double-rivet self-piercing riveted lap joints

The fatigue behaviour of single‐ and double‐rivet aluminum alloy 5754‐O self‐piercing riveted (SPR) lap joints has been investigated experimentally and analytically. With the single rivet, the experimental program involves a set of 27 cyclic tension tests on joints with 1‐, 2‐ or 3‐mm‐thick sheet coupons. In most cases (85%), fatigue cracks are found to initiate in the gross section on the faying surface of the upper sheet. With two rivets (installed in two rows), the experimental program consists of nine cyclic tension tests, three for each of the three combinations of riveting orientation possible, on SPR joints consisting of 2‐mm‐thick sheet specimens. The fatigue life of double‐rivet joints is found to be strongly dependent on the orientation combination of the rivets. Monotonic tests with the double‐rivet joints also reveal an influence of orientation combination. In addition to experiments, values of local stress and rivet‐sheet microslip in the single‐rivet joints have been evaluated through three‐dimensional elastic finite‐element analysis. The analyses are used to interpret experimental observations of fatigue crack initiation location, life and fretting damage severity.     

Two‐stage fatigue life evaluation of an aircraft fuselage panel with a bulging circumferential crack and a broken stringer

The article presents two‐stage fatigue life evaluation of a stiffened aluminium aircraft fuselage panel, subject to ground–air–ground pressure cycles, with a bulging circumferential crack and a broken stringer. As a worst‐case scenario, it is assumed that double cracks start at the edge of a rivet hole both in the skin and in the stringer simultaneously. In the first stage, fatigue crack growth analysis is performed until the stringer is completely broken with the crack on the fuselage skin propagating. After the stringer is completely broken, the effect of bulging crack on the fatigue life of the panel is investigated utilizing the stress intensity factors determined by the three‐dimensional finite element analyses of the fuselage panel with the broken stringer. It is concluded that bulging of the skin due to the internal pressure can have significant effect on the stress intensity factor, resulting in fast crack propagation after the stringer is completely broken.     

Fatigue behaviour of welded joints with cracks, repaired by hammer peening

Rehabilitation of a welded structure, which involves repair of cracked joints, is achieved when the local treatment for repair gives a fatigue strength in the joint equal or above the fatigue strength of the uncracked original detail. If the treatment is properly applied the rehabilitation of the detail is assured, and the nature of the weld toe improvement methods can produce a joint, after repair, with a fatigue strength and residual life greater than the initial detail. The paper presents the results obtained on a fatigue study on the rehabilitation of non‐load carrying fillet welded joints loaded in bending at the main plate and with fatigue cracking at the weld toes of the attachment in the main plate and though the plate thickness. Residual stresses were measured at the surface, with X‐ray diffraction. The residual stresses induced by hammer peening at the weld toe were found to be greater along the longitudinal direction of the plate than in the transverse direction. The peak residual stresses near the weld toe were found to be close to yield in compression, justifying the great benefit of hammer peening. Results of a derived gain factor, g, in fatigue life were obtained as a function of the crack depth repaired by hammer peening.     

冷弯薄壁型钢锁铆连接力学性能及其本构模型研究

为将锁铆连接引入冷弯薄壁型钢结构中构件的连接,对锁铆连接及自攻螺钉连接的试件进行了抗拉、抗剪性能试验,探讨了铆钉端距、基板厚度差、铆钉长度等参数对锁铆连接抗剪性能的影响;基于传染病传播动力学SIR模型建立了铆接本构模型,提出了锁铆连接抗剪承载力设计计算方法。研究结果表明:锁铆连接的主要破坏模式为延性破坏模式,表现为铆钉腿部剥离下层板材并伴随铆钉头部局部脱离上层板材,且刚度、强度和耗能性能均明显优于自攻螺钉连接;所建立的本构模型能够较精确反映锁铆连接荷载-变形曲线的变化趋势,且抗剪承载力的理论值和试验值误差较小;锁铆连接用于冷弯薄壁型钢板间连接时,其组合厚度不宜大于4 mm,厚板与薄板的厚度比不宜大于1.5,锁铆接头的端距应大于2倍铆钉直径。     

基于模态叠加法的焊接结构疲劳寿命预测方法研究

针对焊接结构疲劳寿命预测,从动力学的角度提出了一种基于模态叠加法的动态结构应计算方法,并验证了其可行性与正确性,该方法以时变载荷作用下焊接结构的动平衡为基础,考虑结构自身振动加速度对用于评价焊缝疲劳寿命的结构应力的影响,实现了动态载荷下焊接结构的动态结构应力计算,有效地拓宽了主S-N曲线疲劳预测方法的应用领域。     

具有初始应力加劲板的非线性动力学特性

针对工程结构中常用的加劲板,研究了其在初始应力作用下的非线性振动特性。将母板与加劲肋分开考虑,其中母板按薄板理论考虑,加劲肋按Euler-Bernoulli梁理论考虑,根据母板与加劲肋的应力与应变关系建立系统的应变能表达式,同时结合系统的动能表达式,并利用Lagrange方程建立系统的非线性动力微分方程。运用椭圆函数求得加劲板单模态的非线性频率,采用同伦分析方法求解加劲板的3∶1内共振。通过参数分析,重点讨论初始应力变化对系统非线性动力特性的影响,并得出初始应力的存在对加劲板非线性动力特性的影响规律。     

Schwingfestigkeitsbewertung von Nahtenden unter kombinierter Beanspruchung

In the present study, a local stress based concept for the fatigue assessment of weld ends in thin sheet structures under combined normal and shear loading is introduced. The notch stresses were calculated using the finite element method and submodel technique. An idealised weld end model was used in order to determine the stress state for such loading situations. Moreover, a numerical method was used to consider size effects, which combines both the geometrical and statistical size effects, to an integrated approach. Therewith and in connection with the cycles‐to‐failure from fatigue test results, a standardised S‐N curve was derived.     

Low‐cycle fatigue life of thin‐plate auxetic cellular structures made from aluminium alloy 7075‐T651

In the article, the low‐cycle fatigue life durability of thin‐plate auxetic cellular structures is compared with the thin‐plate specimens of standard shape. Both the re‐entrant auxetic cellular structures and the standard specimens were cut from a 2‐mm‐thick strip of aluminium alloy 7075‐T651. First, a fatigue life curve and a cyclic curve were determined for the standard specimens. A special antibuckling device was applied to prevent the bending of the specimens. The same experimental arrangement was then applied to determine the low‐cycle fatigue life of auxetic structures. In the continuation, the most appropriate method was selected to calculate the fatigue life on the basis of the measured fatigue life curves. Abaqus and SIMULIA fe‐safe software were applied for this purpose. The best predictions for the standard specimens were obtained with the Brown‐Miller method. Finally, the selected method was applied to predict the low‐cycle fatigue life of re‐entrant auxetic cellular specimens.     

Stress intensity factors for three‐dimensional weld toe cracks using weld toe magnification factors

In welded components, particularly those with complex geometrical shapes, evaluating stress intensity factors is a difficult task. To effectively calculate the stress intensity factors, a weld toe magnification factor is introduced that can be derived from data obtained in a parametric study performed by finite element method (FEM). Although solutions for the weld toe magnification factor have been presented, these are applicable only to non‐load‐carrying cruciform or T‐butt joints, due possibly to the requirement of very complicated calculations. In the majority of cases for various welded joints, the currently used weld toe magnification factors do not adequately describe the behaviour of weld toe cracks. In this study, the weld toe magnification factor solutions for the three types of welded joints such as cruciform, cover plate and longitudinal stiffener joints were provided through a parametric study using three‐dimensional finite elements. The solutions were formed with exponents and fractions that have polynomial functions in terms of a/c and a/t – that is, crack depths normalised by corresponding half crack lengths and specimen thickness. The proposed weld toe magnification factors were applied to evaluate the fatigue crack propagation life considering the propagation mechanisms of multiple‐surface cracks for all welded joints. It showed good agreement within a deviation factor of two between the experimental and calculated results for the fatigue crack propagation life.     

Vibrational analyses of glass-reinforced polyester composite plates reinforced by a minimum mass central stiffener

Thin plates are extensively used in many fields of engineering, from ship superstructures, to the high technology of the modern aerospace industries. Flat plates which are incorporated into certain types of these structures have to be stiffened when the breadth/thickness ratio of the plate exceeds certain limits. In some structures, the addition of stiffeners to the plate would introduce a weight penalty. Consequently, it would be advantageous to keep the total mass of the plate constant by taking a thin uniform layer of constant thickness from the plate and forming it into one or several stiffeners. This would result in a considerable increase in the natural frequencies of the plate structure and a reduction of its vibration amplitudes whilst retaining the same mass of the plate system. Top-hat and rectangular stiffeners with different cross-sectional configurations have been investigated in order to increase the structural dynamic efficiency of these plates. The variables of the cross-section of the stiffeners were width and thickness but the mass of these stiffeners was kept constant.