基于Hertz接触理论的涂层界面应力分析

应用大型有限元分析软件ANSYS 8．1，对接触载荷条件下涂层材料的应力场进行了数值模拟．通过比较有限元解与经典Hertz解析解验证了有限元模型的可信度；分析了不同涂层厚度、不同涂层／基体弹性模量比情况下，接触应力分布情况及接触宽度随着载荷的变化情况．数值模拟结果表明：涂层／基体界面剪应力峰值出现在略偏离界面中心位置；涂层／基体界面正应力峰值出现在界面中心位置；涂层／基体的弹性模量比在1～2．5之间取值时，对涂层／基体结合效果较为有利；涂层过薄容易导致界面剪应力过大，致使材料失效．模拟结果能够为涂层材料的力学研究及设计提供参者．     

金属基/陶瓷复合层受弯应力的有限元分析

利用ANSYS有限元分析软件对弯曲状态下金属基／陶瓷涂层的应力分布情况进行了理论建模，并基于此模型计算了不同涂层厚度和不同涂层弹性模量比情况下的应力分布情况。在弯曲中心处，涂层所受的拉应力随弹性模量的增加而增大，剪应力很小。在远离弯曲中心两侧处，剪应力值会达到峰值而拉应力减小，且剪应力最大值随着弹性模量和涂层厚度的增加而增大，且由此分析了由应力产生涂层失效的原因，其结果对陶瓷涂层的可靠性设计及应用具有一定指导作用。     

硬涂层半空间体的弹性场分析

运用Ｈａｎｋｅｌ积分变换详细推导了具有一个硬涂层的半空间体在Ｈｅｒｔｚ半椭圆接触应力作用下的轴对称弹性场。计算结果表明，涂层厚度对表层应力场有显著影响，在考虑表面粗糙度后，增加涂层厚度会使涂层底部出现较大的拉应力，导致涂层的断裂剥离，对滚动接触疲劳中陶瓷硬涂层的作用及破坏机理进行了较详尽的分析。     

Sensitivity Investigation and Optimization for Solar Irradiance Absolute Radiometer

弹性球压入单涂层半空间解析解

李一全,李晓舟,许金凯,于化东

（长春理工大学 机电工程学院,长春 130022）

中文摘要：

本文针对弹性球压入表面涂层半空间的接触问题,在单涂层半空间表面作用法向集中力的基本解基础上进行了理论分析。接触区域内压力分布采用Hertz假定,利用叠加原理构造了级数解。通过与有限元结果对比分析,可知解析解具有很快的收敛速度,而且应力和位移主要取决于级数解首项,即Hertz接触压力下均质弹性半空间的理论解。利用本文的解析方法,可以预测接触半径。

研究目的：

本文的主要研究目的是给出球体与涂层材料接触的理论解答,从而为相关应力分析提供理论方法,同时可进一步利用本文的方法和结果指导涂层材料的压痕实验。

研究方法：

本文为理论分析,主要采用镜像法和叠加法,同时利用有限元法对理论解进行对比验证。

结果：

弹性球压入表面涂层半空间的接触问题的理论解可通过构造无穷级数来实现。

结论：

理论解为显式级数表达式,且具有很快的收敛速度,而且应力和位移主要取决于首项,因此在实际应用时只取级数的前几项即可得到足够精确的结果。

关键词：基本解;镜像法;涂层半空间;球形压入;接触半径

     

用载荷系数曲线和应力系数曲线计算滚动轴承的新方法——圆锥滚子轴承计算

本文介绍了一种计算园锥滚子轴承的新方法.它是用有关的计算公式以及载荷系数曲线和应力系数曲线进行计算的,本文以Hertz的弹性接触问题的理论和Miner的累积疲劳损伤假说为基础,推导了这些公式和曲线.     

表面涂层裂纹的特性分析

采用有限元方法研究TiN涂层裂纹在弹性球循环挤压和滑动接触状态下的三维弹塑性特性,计算分析了涂层-基体的应力分布规律、涂层表面及界面裂纹的断裂强度。结果表明:在接触区边缘、涂层基体结合界面应力幅较大,容易萌生疲劳裂纹;裂纹强度J积分随载荷循环而呈周期性变化;涂层厚度、基体材料、裂纹形状、裂纹倾角等参数对涂层表面和界面裂纹的J积分有显著影响。     

重载齿轮涂层承载能力的仿真分析

为了将物理气相沉积(physical vapor deposition,PVD)涂层应用到高速重载齿轮传动装置中,运用有限元分析了涂层类型、涂层厚度、载荷大小对涂层应力分布的影响.考虑到齿轮轮齿工作面受力复杂,结合齿轮轮齿实际载荷,用非线性弹簧单元来模拟涂层-基体结构的界面结合层,建立了齿轮涂层接触力学计算模型.结合国内外其他学者所做的实验研究,计算结果表明:涂层表面的最大等效应力是涂层表面裂纹产生的主要因素,涂层厚度对等效应力分布有较大影响;涂层/基底界面的最大切应力是导致涂层剥落的主要因素,不同的涂层厚度对切应力点的分布有很明显的影响;载荷等级影响涂层的应力分布和失效形式.     

滚动轴承滚动体板单元模拟的边界元法

在三维弹性接触边界元法基础上,采用不同形状板单元描述中间滚动体,并置于内环上,从而将多物体接触问题简化成两物体接触问题。对于板单元的弹性变形,用Hertz接触公式,将其变形以等效间隙代入总体矩阵方程中,从而获得轧机滚动轴承负荷特性的三维分布。本方法具有计算模型直观,简单和较高的计算精度,因而成为设计和分析轧机滚动轴承负荷特性的有效数值方法。     

平面接触问题有限元计算

通过和实际结构相同的平面接触模型的光弹性试验与有限元计算应力分布的对比，验证了ＭＡＲＣ有限元计算程序在进行气门杆头部接触问题的应力分析时的可靠性；采用多级有限元计算法对具有分析解的典型接触问题接触区应力进行分析，证明经过多级网格逐级细化有限元计算可以精确分析接触面附近的应力分布，为应用有限元法分析接触问题提供了有效的途径     

基于Hertz接触的滚珠直线导轨副接触刚度建模与分析

为建立滚珠直线导轨副接触刚度模型,基于Hertz接触理论对滚珠和滚道的接触面进行了力学与变形分析.考虑了承载前后滚珠接触角的变化,得到了单个滚珠所受接触力与弹性变形之间的关系,在此基础上得到整个导轨所受外载荷同弹性变形的关系.以NSK滚珠直线导轨为研究对象,对所建立的模型进行仿真分析.计算了导轨在不同预紧力情况下的临界载荷,分析了外载荷在临界载荷前后导轨刚度变化情况,通过对比NSK官网相关资料验证了所建模型及理论分析的合理性.     

Effects of thickness and elastic modulus on stress condition of fatigue-resistant coating under rolling contact

The distribution and magnitude of surface and subsurface stresses of the single-layer sprayed-coatings on monolithic substrates were investigated by finite element method (FEM). The models of coating configurations with different thicknesses and elastic modulus ratios of coating to substrate were introduced, and the effects of thickness and elastic modulus ratio on the stresses were addressed. The calculation results show that the coating/substrate interface shear stress obviously decreases with increasing coating thickness, due to the location of the maximum shear stress moving away from the coating/substrate interface. At the same time, the magnitude of von Mises stress also declines in the case of thicker coatings. However, the high elastic modulus ratio results in extremely high maximum shear stress and the severe discontinuity of the von Mises stress curves, which leads to the intensive stress concentration on the coating/substrate interface. So the coating configurations with the larger coating thickness and lower difference of elastic modulus between coating and substrate exhibit excellent resistant performance of rolling contact fatigue (RCF).     

Numerical analysis of elastic coated solids in line contact

A line contact model of elastic coated solids is presented based on the influence coefficients(ICs) of surface displacement and stresses of coating-substrate system and the traditional contact model. The ICs of displacement and stresses are obtained from their corresponding frequency response functions(FRF) by using a conversion method based on fast Fourier transformation(FFT). The contact pressure and the stress field in the subsurface are obtained by employing conjugate gradient method(CGM) and discrete convolution fast Fourier transformation(DC-FFT). Comparison of the contact pressure and subsurface stresses obtained by the numerical method with the exact analytical solutions for Hertz contact is conducted, and the results show that the numerical solution has a very high accuracy and verify the validity of the contact model. The effect of the stiffness and thickness of coatings is further numerically studied. The result shows that the effects on contact pressure and contact width are opposite for hard and soft coatings and are intensified with the increase of coating thickness; the locations of crack initiation and propagation are different for soft and hard coatings; the risk of cracks and delaminations of coatings can be brought down by improving the lubrication condition or optimizing the non-dimensional parameter h/bh. This research offers a tool to numerically analyze the problem of elastic coated solids in line contact and make the blindness and randomness of trial-type coating design less.     

Finite Element Analysis of Thermal Stresses in Ceramic/Metal Gradient Thermal Barrier Coatings

This paper studied the thermal stresses of ceramicl metal gradient thermal barrier coating which combines the conceptions of ceramic thermal barrier coating （TBC） and functionally gradient material （FGM）. Thermal stresses and residual thermal stresses were calculated by an ANSYS finite element analysis software. Negative thermal expansion coefficient method was proposed and element birth and death method was applied to analyze the residual thermal stresses which have non-uniform initial temperature field. The numerical results show a good agreement with the analytical results and the experimental results.     

Effect of magnesium and nickel coatings on the wetting behavior of alumina toughened zirconia by molten Al-Mg ahoy

The wettability of alumina toughened zirconia (ZTA) by Al-Mg alloy was investigated using the sessile drop technique.The effects of nickel coating,magnesium content,nitrogen atmosphere,and processing temperature on the contact angle between the molten alloy and the substrate were determined.Likewise,the effect of these factors on the wetting properties was studied.The results showed that the nickel coating on the ceramic substrate caused a significant reduction in solid/liquid surface energy and the contact angle decreased obviously.The presence of magnesium in the molten aluminum alloy in nitrogen atmosphere reduced the contact angle effectively.The presence of magnesium in the alloy must be at a minimum amount of 2wt％-3wt％.Moreover,it was suggested that some chemical reactions in the Al-Mg-N system led to the production of Mg3N2 and A1N compositions.These compositions improved the wetting properties of the systems by reducing the surface energy of the molten.It was shown that increasing the temperature is also an effective factor for the enhancement of wetting properties.     

Effect of magnesium and nickel coatings on the wetting behavior of alumina toughened zirconia by molten Al-Mg alloy

The wettability of alumina toughened zirconia (ZTA) by Al-Mg alloy was investigated using the sessile drop technique. The effects of nickel coating, magnesium content, nitrogen atmosphere, and processing temperature on the contact angle between the molten alloy and the substrate were determined. Likewise, the effect of these factors on the wetting properties was studied. The results showed that the nickel coating on the ceramic substrate caused a significant reduction in solid/liquid surface energy and the contact angle decreased obvi-ously. The presence of magnesium in the molten aluminum alloy in nitrogen atmosphere reduced the contact angle effectively. The presence of magnesium in the alloy must be at a minimum amount of 2wt%-3wt%. Moreover, it was suggested that some chemical reactions in the Al-Mg-N system led to the production of Mg3N2 and AlN compositions. These compositions improved the wetting properties of the systems by reducing the surface energy of the molten. It was shown that increasing the temperature is also an effective factor for the enhancement of wetting properties.     

镁合金表面热喷涂Al-Al2O3/TiO2梯度涂层研究

采用氧乙炔火焰喷涂法，在AZ91D镁合金表面制备Al-Al2O3/TiO2梯度涂层。利用扫描电镜和电子探针对涂层的组织形貌、成分进行了分析。采用热震法测试了涂层结合强度，并对涂层耐磨性进行了测试。实验结果表明：Al梯度层与基体及陶瓷涂层结合良好。涂层具有较高的硬度、耐磨性及抗热震性。     

Microstructure and corrosion resistance of modified AZ31 magnesium alloy using microarc oxidation combined with electrophoresis process

A top electrophoresis coating was deposited on the surface microarc oxidation (MAO) modified ceramic coating on AZ31 magnesium alloy. Microstructure and corrosion resistance of this composite coating were studied by SEM, electrochemical potentiodynamic polarization, and acid corrosion test. The results showed that the composite coating with a top electrophoresis coating on the surface of ceramic coating exhibited a better corrosion resistance compared with the coating formed by chemical conversion film combined with electrophoresis process. Corrosive ions could permeate into the substrate with corrosion time, and the composite coating was firstly destroyed around the scratch. The formation of composite coating with a higher adhesive force due to the porosity of the ceramic coating contributed to the improved corrosion resistance property.     

TiC陶瓷滤片的制备及其性能研究

在对TiC陶瓷的性能及其制备工艺进行分析研究的基础上,利用SHS/PHIP技术制备了致密的TiC-TiB2复相陶瓷材料,并对材料进行切割加工成型和清洗,得到和所需滤片形状相同的TiC-TiB2复相陶瓷片,然后再根据TiC和TiB2化学性能的差异,用王水的强腐蚀性溶解其中的TiB2陶瓷相从而得到孔隙大小均匀的、性能优异的TiC陶瓷滤片.用该方法制备的TiC陶瓷滤片,孔隙的直径范围在2~3μm,分布均匀,可以在任何性质的液体中使用,也可用于熔融金属液的过滤.