考虑成形方向的航空铝合金修正本构模型的构建

为了能够准确地反映材料成形方向对其动态力学性能的影响,利用电子万能试验机及分离式霍普金森压杆（SHPB）装置,对航空铝合金7050-T7451板材沿不同成形方向（法向ND,横向TD,轧向RD）取样,并进行准静态加载试验和动态冲击剪切试验。结果表明：成形方向是影响材料准静态和动态力学性能的重要因素之一,在动态冲击剪切过程中,铝合金7050-T7451表现出一定的应变率敏感性和正应变率强化效应。基于材料的成形方向影响规律,构建包含应变率敏感函数项的修正的Johnson-Cook本构模型,并对比验证修正模型与试验数据的结果,证明了修正的、包含应变率函数项的材料本构模型更适用于描述不同成形方向下的材料动态力学性能,该模型能够为建立精确可靠的各向异性材料仿真模型提供数据支持。     

3D finite element analysis and experimental validation of constrained groove pressing–cross route as an SPD process for sheet form metals

A new modification of constrained groove pressing (CGP) process named as constrained groove pressing–cross route (CGP-CR) was suggested for severe plastic deformation (SPD) of sheet form metals with great potential for fabricating high strength nanostructured sheets. This process is based on the conventional CGP process including some modifications. One pass of this process includes eight stages (four corrugation and four flattening) and involves 90° cross-rotation between each two stages. As a result of each CGP-CR pass, a strain magnitude of ～2.32 is imparted to the sample. To simulate the process, finite element modeling (FEM) was carried out using three-dimensional finite element analysis ABAQUS/Explicit simulation. Strain and hardness distribution through the sheet after CGP-CR process at different stages were examined via FEM. Low-carbon steel sheet was utilized as the testing material and CGP-CR process imparted upon it up to two passes. Afterward, equivalent plastic strain was measured ～4.64. Results show that the magnitude and uniformity of strain were different along three main directions of sheets: rolling (RD), transverse (TD), and normal directions (ND), at different stages of process. In addition, the results indicate that, for the CGP-CR’d sheets up to two passes, the magnitude and uniformity of hardness simulated via FEM were consistent with the experimental data.     

Two-Body Abrasive Wear of the Outside Shell Surfaces of Mollusc <Emphasis Type="Italic">Lamprotula fibrosa</Emphasis> Heude, <Emphasis Type="Italic">Rapana venosa</Emphasis> Valenciennes and <Emphasis Type="Italic">Dosinia anus</Emphasis> Philippi

Natural biological surfaces and biomaterials have some distinguishing properties for adapting themselves to natural surroundings. The outside shell surfaces of mollusc species often undergo the abrasive wear action from the sand particles in water sand slurry in natural conditions. The two-body abrasive wear behavior of the outside shell surfaces of three mollusc species Lamprotula fibrosa Heude, Rapana venosa Valenciennes and Dosinia anus Philippi was examined. Abrasive material used for tests were quartz sand (96.5 wt.%) with three different size ranges and powdered bentonite (3.5 wt.%). The two-body abrasive wear tests were run on a rotary disc type abrasive wear testing machine. The results showed that the abrasion resistance of the outside shell surfaces of the three mollusc species was higher when the corrugations on the shell surfaces were perpendicular to the sliding direction of the abrasive material than that when the corrugations on the shell surfaces were parallel to the sliding direction of the abrasive material. Basically, the shell of Lamprotula fibrosa Heude possessed the highest abrasion resistance among the three species of shell; the abrasion resistance of the shell of Rapana venosa Valenciennes was the lowest; and the abraded depth of the three species of shell increased with an increased abrasive particle size and relative sliding velocity. The abraded surfaces were observed with scanning electron microscope.     

Numerical estimation and practical validation of Hooputra’s ductile damage parameters

Forming limit diagram (FLD) is a useful criterion for damage prediction, but not suitable for complex operations. Hooputra’s ductile damage (HDD) is a proper failure criterion which relies on three relatively difficult experimental tests for each material. In this paper, first, using the FLD criterion, the required difficult experimental tests of HDD criterion are simulated and the HDD parameters for St14 steel are numerically estimated. Then, to evaluate the obtained HDD parameters, damage behavior of the material in a number of benchmark tests is numerically predicted, employing the HDD criterion. Finally, the simulated results are compared with the practical observations and the identified HDD parameters are validated. Comparison of the results reveals the HDD parameters can be numerically and properly extracted, utilizing the FLD and avoiding the difficult experimental tests.     

Simple uniaxial pressure device for ac-susceptibility measurements suitable for closed cycle refrigerator system

A simple design of the uniaxial pressure device for the measurement of ac-susceptibility at low temperatures using closed cycle refrigerator system is presented for the first time. This device consists of disc micrometer, spring holder attachment, uniaxial pressure cell, and the ac-susceptibility coil wound on stycast bobbin. It can work under pressure till 0.5 GPa and at the temperature range of 30-300 K. The performance of the system at ambient pressure is tested and calibrated with standard paramagnetic salts [Gd(2)O(3), Er(2)O(3), and Fe(NH(4)SO(4))(2)6H(2)O], Fe(3)O(4), Gd metal, Dy metal, superconductor (YBa(2)Cu(3)O(7)), manganite (La(1.85)Ba(0.15)MnO(3)), and spin glass material (Pr(0.8)Sr(0.2)MnO(3)). The performance of the uniaxial pressure device is demonstrated by investigating the uniaxial pressure dependence of La(1.85)Ba(0.15)MnO(3) single crystal with P||c axis. The Curie temperature (T(c)) decreases as a function of pressure with P||c axis (dT(c)dP(||c axis)=-11.65 KGPa) up to 46 MPa. The design is simple, is user friendly, and does not require pressure calibration. Measurement can even be made on thin and small size oriented crystals. The failure of the coil is remote under uniaxial pressure. The present setup can be used as a multipurpose uniaxial pressure device for the measurement of Hall effect and thermoelectric power with a small modification in the pressure cell.     

Tensile behaviour of threaded steel fasteners at elevated rates of strain

The tensile behaviour of threaded steel fasteners was studied experimentally at elevated rates of strain. Two testing techniques were used to perform the tests at strain-rates in the range from 10⁻³ to 1.9×10³ s⁻¹. The tests at low and medium strain-rates were performed in a servo-hydraulic testing machine, while tests at high strain-rates were achieved using a split-Hopkinson tension bar. All tests were carried out using a purpose-made fixture to ensure uniform test conditions, and to control the location at which failure by thread shearing could occur. The material tests and the threaded assembly tests showed approximately the same trend of an increased strength with increasing strain-rate. Owing to the strength ratio between the purpose-made fixture and the threaded fastener, two of three possible failure modes occurred during the performed tests, i.e. bolt breaking and bolt thread stripping. The length of the thread engagement, the grip length and the strain-rate had an influence on the failure mode. In addition, these parameters had varying effect on the strength and ductility of the threaded assembly. A modification of the Alexander [4] model was proposed, to predict the maximum load and mode of failure of threaded steel fasteners at high strain-rates. The modified model was in good agreement with the experimental results.     

静轴肩FSW铝合金6061-T4板的T形接头组织特征及动静载特性研究

利用自主开发的静止轴肩焊接工具及工装,在不同的焊接参数下均获得到了外观成形良好、无焊接缺陷的T形接头,并对接头内部成形、显微组织、硬度、静载强度和疲劳性能及疲劳失效机制进行了研究。研究结果表明铝合金静止轴肩搅拌摩擦焊T性接头内部质量良好,无缺陷,接头表面存在表面超细晶区,且焊核区内部由于流动状态不同导致组织及硬度存在一定差异,T形接头底板及筋板硬度较母材有不同程度的降低,底板和筋板拉伸试验均断裂于接头热影响区,在优化的参数下底板和筋板方向的接头系数均高于0.7,在2×10⁶疲劳寿命下的特征疲劳强度可达101.0 MPa,远高于IIW建议的设计准则。焊接速度对接头疲劳性能及疲劳失效机制影响较大,疲劳裂纹萌生于T形接头底板和筋板过渡处,低焊速时断裂机制为穿晶断裂,高焊速时由于晶界稳定性差,断口呈现穿晶断裂和晶间断裂的混合形貌。完成了铝合金T形接头的无缺陷焊接及组织性能研究,为铝合金静止轴肩搅拌摩擦焊T形接头在新型轻量化航天器密封舱结构中的应用提供了技术支撑。     

Fatigue strength of a wire passing through a cannulated screw: implications for closure of the sternum following cardiac surgery

It has been proposed that the incidence of sternal dehiscence can be decreased by passing the wires used for sternotomy closure through cannulated screws. However, there is a potential risk of fatigue failure as a result of the wire moving against the screw, e.g. during coughing and sneezing. The system of cannulated screws and wire was subjected to static tensile testing to failure. Five tests were performed and failure occurred at 388 +/- 34 N (mean +/- SD). Ten cyclic tests were then performed. Sinusoidal loading was applied at 10 Hz with peak forces in the range 10-90 per cent of the static failure force, at a constant load ratio R = 10. The test with the lowest peak force reached run-out at 6 x 10(6) cycles. The others failed by the ends of the wire closures becoming untwisted (one test), the wire fracturing at the twist (three tests) or the wire fracturing at the screw (five tests). However, calculations based on these results suggest that fatigue failure is unlikely to occur as a result of regular breathing or continuous coughing or sneezing.     

Deformation behaviour of soft-brittle polycrystalline materials determined by nanoscratching with a sharp indenter

Polycrystalline zinc selenide (p-ZnSe) is a typical soft brittle material with important optical applications. In this work, single and repeated nanoscratching tests were performed using a Berkovich indenter along the face-forward (FF) and edge-forward (EF) directions. The morphological features of the scratched grooves and the subsurface microstructural changes in the material were characterised by scanning electron microscopy, Raman spectroscopy, and electron backscatter diffraction (EBSD). Material removal in the ductile mode was obtained in the EF scratching direction; this was accompanied by the slip lines, and the radial cracks generated along grain boundaries. In contrast, brittle fractures occurred in the FF scratching direction, resulting in radial and lateral cracks which are responsible for generating the peeling of the material. The EBSD results demonstrated that the {111} planes are the primary slip plane and secondary cleavage plane, whereas the {110} planes are the primary cleavage plane and secondary slip planes. Tensile residual stress was detected in the subsurface region of the grooves scratched along the FF direction, whereas compressive residual stress was detected in the EF scratching direction. Fishbone-like patterns were observed in the scratched grooves under all conditions, while no phase transformation was detected. This study provides insights into the fundamental material removal mechanisms of soft brittle crystals in various abrasive machining processes, such as grinding, lapping, and polishing.     

一种磁记忆检测定量分析的新方法

金属磁记忆检测技术是利用磁记忆效应对铁磁性材料的应力集中区进行无损检测的新方法.磁记忆效应的特征是应力集中部位表面的漏磁场的切向分量最大、法向分量存在过零现象.在目前的研究工作中,研究方法主要是以测量磁记忆法向信号过零点位置来判断应力集中,从而割裂了切向与法向之间内在的关系.探讨了采用法向切向联合检测的方法,利用一种新型的磁阻传感器HMC1002,设计组装了高精度的二维弱磁场测量传感器.通过对拉伸试件进行2种方法检测的对比实验,结果表明,此方法比单一的法向磁场分量过零值点的检测更有效,可望在磁记忆检测定量分析研究中有很好的实际应用价值.     

Initiation and propagation of surface cracks in rolling fatigue of high hardness steel

Surface cracks initiating flaking failure observed by Sugino in rolling fatigue were further studied.Surface crack initiation was influenced by either running or material conditions, affecting the residual tensile stress just below the rolling contact surface. The fatigue crack is thought to initiate very near the surface by the stress cycle of small tensile residual stress and large compressive contact stress. The amount and direction of the tensile residual stress due to rolling contact varies with the contact geometry, which probably determines the direction of the surface crack and the appearance of flaking. The transition from the surface crack to flaking failure or complete section fracture is material and running condition dependent and is explained by a fracture mechanics concept.     

面向小偏置碰的轮毂断裂模拟研究

为准确地模拟轮毂的碰撞断裂失效行为,开展了AlSi7（铸铝）材料的断裂力学试验,基于CrachFEM失效准则研究了材料特性参数拟合方法。根据轮毂的准静态和动态试验与仿真对比分析,提出了适用于轮毂断裂模拟的有限元建模规则和材料失效参数调整方法,使轮毂碰撞断裂模式的仿真结果更贴合试验结果。研究结果表明：利用所提建模规则与方法显著提高了碰撞模拟的失效预测精度,可为小偏置碰的安全性能开发提供有效的虚拟仿真评估手段。     

基于累积损伤的三维复合材料层合板疲劳寿命研究

基于渐进疲劳损伤模型,建立复合材料层合板的三维疲劳寿命预测模型,模型以单向板单轴疲劳试验数据为基础,结合正则化剩余刚度模型、正则化剩余强度模型和等寿命曲线,通过层合板三维应力分析、失效分析和材料性能退化的循环迭代进行疲劳寿命计算,在Ansys软件平台上利用APDL语言编写相应的计算程序,估算不同铺层参数层合板在单轴和多...     

High-speed milling of CFRP composites: a progressive damage model of cutting force

Three-dimensional Hashin failure criterion and material stiffness degradation model were compiled by VUMAT subroutine. The Abaqus/Explicit solver was performed to establish progressive damage model of cutting force for CFRP high-speed milling, and high-speed milling experiments with different cutting parameters were carried out. Further, the impact mechanism of fiber cutting angle and cutting parameters on cutting force, stress, and material failure during milling was explored, and the material removal mechanism in high-speed milling of CFRP was revealed. The results show that the error between the experimental and simulated of cutting forces is less than 5%, which indicates that the progressive damage model is feasible. The fiber cutting angle has significant influence on cutting force and stress in cutting process, and the cutting direction has a significant influence on cutting force. In addition, cutting parameters play a critical role in cutting force, and the feed per tooth is the most significant factor affecting the cutting force. Simultaneously, the progressive damage model predicts that the shear failure of materials mainly concentrates in the cutting area and extends along the feed direction. Finally, the material removal mechanism of CFRP in high-speed milling was revealed combining cutting force experiment.     

Calibration of hoop stress in ring tensile test with Zircaloy-4 tube

Since Zirconium (Zr) alloys have been widely used as cladding material in a nuclear fuel rod, material properties of Zr are essential in prediction of failure and undesirable deformation. This paper mainly concerns calibration procedure to obtain the hoop stress of Zircaloy-4 tube with a simple ring tensile (RTT) test linking with a Digital image correlation (DIC) technique since it is substantially difficult to obtain, directly, with specialized experiment such as burst test with internal pressure. The uniaxial tensile tests along the axial and RTT along the hoop directions were conducted with Zircaloy-4 tube in which anisotropic stains were analyzed with a DIC technique to validate appropriate deformation history. Anisotropic yield criterion based on the measured R-values (R _θ = 1.88 and R _z = 0.814) is able to capture the precise deformation mode in the ring tensile test. The flow curve along the hoop direction is calibrated by converting F, G, and H material parameters based on the R-values to the function of stress ratios.     

High-precision tracking differentiator via generalized discrete-time optimal control

An enhanced discrete-time tracking differentiator (TD) with high precision based on discrete-time optimal control (DTOC) law is proposed. This law takes the form of state feedback for a double-integral system that adopts the Isochronic Region approach. There, the control signal sequence is determined by a linearized criterion based on the position of the initial state point on the phase plane. The proposed control law can be easily extended to the TD design problem by combining the first-state variable of the double-integral system with the desired trajectory. To improve the precision of the discretization model, we introduced a zero-order hold on the control signal. We also discuss the general form of DTOC law by analysing the relationship between boundary transformations and boundary characteristic points. After comparing the simulation results from three different TDs, we determined that this new TD achieves better performance and higher precision in signal-tracking filtering and differentiation acquisition than do existing TDs. Also the comparisons of the computational complexities between the proposed DTOC law and normal one are demonstrated. For confirmation of its utility, we processed raw phasor measurement units data via the proposed TD. In the absence of complex power system modelling and historical data, it was verified that the proposed TD is suitable for applications of real-time synchrophasor estimations, especially when the states are corrupted by noise.     

Influence of processing parameters on wear resistance of nanostructured OFHC copper manufactured by large strain extrusion machining

The tribological behaviour of three ultra-fine grained oxygen-free high conductivity (OFHC) copper materials manufactured by large strain extrusion machining (LSEM), under variable shear strain, is studied under ball-on-flat reciprocating configuration and compared with that of conventional microstructured copper. The results are discussed as a function of microstructure and sliding direction. The lowest wear volume is obtained when the sliding takes place in the perpendicular direction to that of grain orientation. The highest wear resistance is observed for nanostructured copper material with an elongated grain structure in the extrusion direction. The wear resistance of this anisotropic material depends on the sliding direction. Wear mechanisms are discussed from scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) observations.     

Process responses and resultant joint properties of friction stir welding of dissimilar 5083 and 6061aluminum alloys

The effects of combinations of dissimilar aluminum alloys during Friction stir welding (FSW) on the process response and resultant joint properties are experimentally investigated using two dissimilar automotive structural aluminum alloys. Depending on the materials on the advancing and retreating sides of the tool travel direction during FSW, four different material combinations are considered. FSW joints without macroscopic defects are successfully fabricated for the four different material combinations. The optical microscopy results show that the macroscopic material mixing behaviors of the two dissimilar material combinations during FSW are somewhat different from each other, even though the process responses during joining are not much different. The results of the quasi-static tensile tests and EBSD analysis demonstrate that the mechanical behaviors and orientation changes of the joint during tensile deformation are affected by the material locations with respect to the tool travel direction during FSW.

     

Identifying the directions of a set of 2D contours for additive manufacturing process planning

Additive Manufacturing (AM) is a process in which material is added layer by layer to build a physical part. In AM process planning, a stack of 2D closed contours is obtained when a 3D stereolithography (STL) model is sliced. Each slice may have a set of closed contours or polygons, each of which needs to be classified (oriented) as internal (clockwise) or external (counterclockwise) to identify where material should be added. This is not a straightforward task as the STL format does not ensure correct surface orientation of the 3D model. This work describes two methods for identifying the direction of each contour in a set, i.e., for sorting them into internal and external contours. Three alternative tests to check whether a point is inside or outside a polygon were evaluated. The tests are based on the ray-tracing principle and the classical point-in-polygon test. The proposed algorithms were devised and implemented in an AM process planning system. The methods were validated using 3D models with a variety of geometries, and the computing time for the alternative tests was compared. The results showed that the method based on the point-in-polygon tests has some advantages.     

Detecting gear tooth fatigue cracks in advance of complete fracture

Some results from using vibration-based methods to detect gear tooth fatigue cracks are presented. An experimental test rig was used to fail a number of spur-gear specimens through bending fatigue. The gear tooth fatigue crack in each test was initiated through a small notch in the fillet area of a tooth on the gear. The primary purpose of these tests was to verify analytical predictions of fatigue crack propagation direction and rate as a function of gear rim thickness. The vibration signal from a total of three tests was monitored and recorded for gear fault detection research. The damage consisted of complete rim fracture on the two thin rim gears and single tooth fracture on the standard full rim test gear. Vibration-based fault detection methods were applied to the vibration signal both on-line and after the tests were completed. The objectives of this were to identify methods capable of detecting the fatigue crack, and determine how far in advance of total failure positive detection was given. Results showed that the fault detection methods failed to respond to the fatigue crack prior to complete rim fracture in the thin rim gear tests. In the standard full rim gear test all of the methods responded to the fatigue crack in advance of tooth fracture; however, only three of the methods responded to the fatigue crack in the early stages of crack propagation.