低周疲劳精密下料新工艺及试验研究

传统的金属棒料下料工艺存在着材料利用率低、能耗高、生产效率低以及下料断面质量差等问题。采用一种新的下料工艺-周向加载低周疲劳精密下料技术,利用V形槽的应力集中效应,促使棒料V形槽底尖端处疲劳裂纹的萌生及疲劳裂纹的快速扩展。描述周向加载低周疲劳精密下料机的工作原理。给出在低周疲劳下棒料V形槽根部裂纹是否起裂的判据。采用两种控制曲线对5种材料(20钢、H59、45钢、20Cr和LY12)的棒料进行试验研究,实现加速棒料裂纹的产生、扩展并获得良好的棒料断面质量。试验结果表明,V形槽的应力集中效应可以有效地减小棒料下料过程中的平均应力,在不断增加打击位移的同时减小冲击频率可以保证棒料裂纹的稳定扩展和断裂。     

双频振动载荷下带V形槽铝合金棒料的断裂行为

针对金属棒料低应力分离过程中裂纹萌生扩展速率低的问题,提出一种基于双频振动的加载方法,探究带V形槽7A09铝合金棒料的断裂行为。研究了双频振动对带V形槽金属棒料裂纹萌生扩展的作用机理,通过研发双频激振装置,对带V形槽7A09铝合金棒料进行了实验研究。实验结果表明,相对于单频振动加载方法,双频振动载荷能够大幅缩短带V形槽7A09铝合金棒料的分离时间,有效提高裂纹萌生扩展的速率与稳定性,棒料断面几何精度高。     

修正剪切GTN模型的缺口张角数值模拟

人为预制含特定几何参数的对称环状V型缺口是新型金属棒料低应力旋弯致裂精密下料的关键工艺之一,合理的缺口效应不仅降低下料所需外载荷,还能有效节约下料时间。为获取合理缺口,使用细观损伤理论和数值模拟相结合的方法,以金属棒料作为研究对象,通过修正剪切GTN模型,对缺口张角为30°、60°和90°对称时进行分析;结合ABAQUS/Explict有限元分析软件中VUMAT子程序建立修正剪切GTN模型,对修正剪切GTN模型参数进行识别,并分析了不同缺口张角损伤分布规律。结果表明,与应力集中系数和应变率集中系数相似,随着缺口张角的不断增加,缺口根部的损伤不断降低。本文提出的修正剪切GTN模型可用于新型金属棒料低应力旋弯致裂精密下料缺口的选取。     

下料时初始激振频率的选择方法

针对金属棒料的精密下料问题,采用断裂力学和材料力学相结合的方法,获得棒料下料时临界最大初始激振频率和最小激振频率的计算公式.分析不同材质棒料下料时初始激振频率的选择方法.45钢棒料的下料实验结果表明,该公式所得的结果和下料实验结果相吻合.     

热应力预制裂纹技术在低应力精密下料中的实验研究

针对棒料的精密下料问题,给出了一种热应力预制裂纹的新的下料方法,简述了热应力变频振动下料系统的组成。建立了新的激振频率控制曲线和专门针对这种下料所获断面质量的评价方法。20号钢棒料的下料实验结果表明,通过采用热应力预制棒料V型槽尖端区域微小裂纹的方法,下料时间减少了20%左右,且仍可获得高质量的断面平整度。     

新型低应力弯曲下料外力加载模式的研究

针对新型低应力弯曲下料中棒料V型槽尖端形状的特殊性,提出对V型槽尖端起裂和裂纹扩展分别处理,采用应力集中系数计算V型槽尖端起裂所需的初始外力,采用裂纹扩展门槛值计算V型槽尖端裂纹扩展所需的外力。利用曲线拟合方法,耦合出外力与裂纹起裂扩展长度间呈近似1/4凹圆弧递减关系。基于低应力下料特点,设计4种形式的外力控制曲线。下料实验结果表明,所提出的凹圆弧递减外力控制曲线能使下料时间最短、断面质量最好。     

304不锈钢棒料连续旋弯低应力精密下料断裂预测

低应力下料近净成形方法是制造轴类零部件毛坯的新工艺,具有能耗低、下料效率高及坯料断面精度高等特性,然而其下料机理一直不清晰,难以获取理想的下料工艺参数,因此基于累计损伤理论提出断裂强度因子预测断裂模型进行研究。以304不锈钢为研究对象,将断裂强度因子耦合到连续旋弯低应力下料有限元模型进行断裂预测。通过连续旋弯低应力下料试验,依托断面平整度及下料时间的下料综合评价方法,验证基于断裂强度因子的连续旋弯低应力下料断裂预测数值模拟的正确性。结果表明：基于断裂强度因子断裂预测模型模拟得到的断裂位置位于环状“V”型缺口根部,与下料分离结果保持一致;断面平整度与下料时间随着加载位置提升而降低,当加载位置为L₁=5 mm,L₂=10 mm能够实现棒料高效精密下料。该下料方法利用断裂强度因子预测断裂模型建立了连续旋弯低应力下料断裂机理,为实现低应力下料工业化奠定理论基础。     

激光冲击对金属板料裂纹的影响模型

研究了含有裂纹的金属板料在激光冲击波载荷作用下裂纹尖端应力强度因子和裂纹扩展速度的变化,利用断裂力学理论,对激光冲击加载下裂尖参数计算模型进行优化,采用应力强度因子叠加法,将外加载荷引起的应力强度因子和激光冲击后残留的残余压应力引起的应力强度因子叠加,推导出下裂纹尖端应力场强度因子表达式,由此可精确计算出金属板料的裂纹萌生寿命和裂纹扩展速度,实验验证了航空钛合金Ti6Al4V激光冲击后残余应力对裂纹扩展速度的影响,从而建立了激光冲击作用对板料裂纹扩展的影响的理论模型。     

应力断料

甘肃工业大学研究成应用裂纹技术进行下料,称之为应力断料的方法。应力断料就是利用制造敏感应力状态的人为切口裂纹,使之失稳扩展来实现下料。应力断料的工艺过程:在下料要求切断的地方,预先切出切口,然后加过载旋转弯曲疲劳载荷,使沿切口尖端产生疲劳裂纹,并在临界扩展过程很短暂的情况下迅速进入     

连杆裂断力参数的数值分析及其裂断质量研究

针对基于连杆裂断时所需裂断力的问题,利用断裂力学理论及有限元方法,采用KIC判据对与拉杆位移、裂断力及应力强度因子KI三者关系展开了研究。通过数值分析求解了应力强度因子达到断裂韧性KIC时拉杆所需的位移,以确定拉杆提供的裂断力。理论分析结果显示:裂纹槽宽为0.2 mm、槽深为0.4 mm的BYD473连杆,拉杆在位移27.25 mm处,连杆应力强度因KI达到断裂韧性KIC,此时连杆裂断所需的裂断力为32.75 kN,拉杆裂断力与应力强度因子KI呈线性关系。采用实验的方法分析了连杆裂断所需的裂断力及连杆的裂断质量。研究结果表明,连杆裂断时,所需的裂断力为32.75 kN,连杆裂断质量良好。数值分析与裂断实验数据对比结果显示,数值分析误差为11.4%,数值分析结果良好,可为液压系统参数的确定提供理论依据。     

Research of stress intensity factor of V-shaped notch tip in precision cropping

For carrying out the precise cropping of metal bar with different geometrical sizes, it is very important to obtain the reasonable stress intensity factor of V-shaped notch tip rapidly and accurately. At first, a new precise cropping method, which is the high-speed peripheral low-stress bending fracture cropping is presented in the paper, and its working mechanism is also given in detail. The stress field near V-shaped notch tip is analyzed, and the stress extrapolation method is presented to compute the stress intensity factor of V-shaped notch tip. Based on it, the correctional expression of theoretical stress intensity factor in a handbook of stress intensity factor is also given. The contrasts between stress intensity factor results obtained by means of the stress extrapolation method and the corresponding theoretical results in the handbook of stress intensity factor are also carried out in detail. The results show that the two errors are not more than 5 % and are within a reasonable engineering range. The cropping experimental results for initial loading force and crack propagation life have also confirmed that the correctional expression of theoretical stress intensity factor is feasible.     

钢筋桁架角折弯机构的设计与分析

为了提高钢筋桁架角折弯的效率,降低劳动强度,设计了一款钢筋桁架腹筋自动折弯机构。首先应用CATIA软件建立三维实体模型,然后利用ABAQUS软件对其进行准静态的分析计算,分析钢筋桁架成型过程应力和应变情况,验证了折弯成型有效性。结果表明钢筋桁架角折弯机构符合设计要求,为钢筋桁架角折弯机构关键部件的设计提供了重要依据,并为后续设计奠定了基础。     

Investigation on a new type of low-stress cropping system with variable frequency vibration

This paper presents a new type of precision cropping system with variable frequency vibration by which the high-quality cutting surface can be obtained. On the basis of D’Alembert’s principle, the approximate relationship between the exciting force and the excited frequency in the cropping is acquired through computation. Five types of excited frequency control curves are designed and applied in the cropping experiments and the influences of these control curves on the cropping cross-section and the cropping time are investigated by experiment in details. According to the special feature of the cross-section obtained in the course of variable frequency vibration cropping, a new measurement method is proposed and applied to assess the quality of the cross-section. The theoretic and experimental results show that the exciting force acted on the bar in the vertical direction is larger than that in the horizontal direction and the linear decrease control curve, by which the high quality cross-section is obtained and the cropping time is reduced, is an ideal control mode compared with other control modes mentioned in the paper. The experiment also proves that the width of the bar instantaneous fracture region is decreased by reducing the value of every step frequency change, and the cropping time is also shortened by reducing the durative time of every step variable frequency under the action of the linear decrease frequency curve.     

带环向切口金属杆的断裂强度

对带环向切口的金属圆杆进行了断裂拉伸实验,由实验数据分别计算了净截面应力强度和名义截面应力强度,对切口试件的应力集中问题进行了应力集中系数的讨论和断裂力学的强度因子分析。利用非线性断裂理论推导出计算带环向切口裂纹拉伸杆承载力计算公式,并将数值计算结果与实验结果进行比较。     

轧机油膜轴承锥套接触疲劳损伤的机理分析

研究了油膜轴承锥套与辊颈接触表面在轧制载荷作用下发生微动疲劳损伤的力学机理。在分析油膜轴承油膜压力分布特征的基础上,采用有限元法给出了锥套与辊颈接触区边缘产生接触应力集中和微滑移的分布规律,阐明了弹性结合连接的锥套与辊颈接触表面产生微动疲劳损伤的原因。利用断裂力学裂纹尖端应力场与接触边缘区域应力局部渐近场的等效原则,给出了疲劳裂纹自点蚀处萌生与扩展的力学条件。上述结果为锥套和辊颈的实际损伤状态及模拟试验所验证。     

关于夹芯梁四点弯曲试验的计算分析

在材料力学推导出的矩形截面梁剪应力公式基础上,利用夹芯梁轴向位移,弯曲挠度与剪切应变的几何关系,推导出了夹芯梁截面弯曲应力及弯曲挠度表达式,弹性理论及有关试验结果都证明了该方法的计算精确度较高.理论计算分析表明:外载荷作用下夹芯梁四点弯曲时,在外载荷作用处夹芯梁面板与芯材结合部位应采用强度理论进行校核;均布载荷作用下剪...     

斗式提升机输送链销轴断裂的分析

通过化学成分、显微组织和裂纹、断口特征的分析以及应力强度校核,对一台输送水泥用斗式提升机输送链销轴的断裂原因进行了综合分析。分析结果显示:失效销轴表面的最大弯曲应力偏大,并且在淬火期间失效销轴会产生微裂纹,在交变应力载荷作用下,销轴表面发生疲劳损伤并最终发生疲劳断裂。建议严格遵照热处理工艺条件操作,避免产生淬火裂纹;通过改造销轴结构或减小工作载荷,降低表面的最大弯曲应力。     

基于ANSYS的焊接箱形梁裂纹断裂分析

以断裂力学理论为基础,推导了焊接箱形梁裂纹尖端应力强度因子计算公式,以ANSYS作为计算工具,模拟焊接箱形梁裂纹扩展,并采用奇异单元计算在不同长度初始裂纹下起重机焊接箱形梁应力强度因子范围。     

Investigation of constantly and transiently propagating cracks in functionally graded materials by dynamic photoelasticity

In this study, the stress intensity factors (SIFs) for steady and transient propagation of cracks in transparent homogeneous functionally graded materials were analyzed by using the photoelasticity technique. The fracture analysis was carried out for the cracks propagating from a region with high elasticity towards low elasticity, as well as the cracks propagating from a region with low elasticity towards high elasticity. The analysis includes cracks propagating (1) at an almost steady speed, and (2) with the rapid increase, followed by a decrease in speed. For cracks with almost constant velocity, the SIFs were greater when a crack started from a high elasticity region, as compared to the cracks which initiated from a low elasticity region. For cracks propagating with rapid acceleration and deceleration, when the strain energy accumulated in the material due to an increase in load or stress was released at the moment of crack propagation, the SIF was momentarily lowered by approximately 45 %–50 % of the static SIF(before crack initiation), which subsequently increases by approximately 30 % eventually, the crack acceleration approaches nearly zero; the SIF decreases and increases respectively as the crack propagates in a material with decreasing and increasing modulus of elasticity.