基于SPH耦合有限元法的喷丸残余应力场数值模拟

针对有限元方法不能有效模拟喷丸加工过程中大量弹丸反复冲击的现状,使用光滑粒子流体动力学法(smoothed particle hydrodynamics,SPH)耦合有限元法(finite element method, FEM)模拟喷丸强化过程。工件采用FEM建模,弹丸采用SPH建模,通过接触算法实现SPH和FEM的耦合以模拟弹丸对工件的强化作用。提出弹丸流的材料模型,分析了相关参数对工件残余压应力分布和能量利用率的影响。结果表明,随着弹丸打击次数的增加,工件表面残余压应力分布逐渐趋于稳定;高覆盖率能有效改善工件表面残余压应力分布,低覆盖率则会降低喷丸效果;适当提高弹丸速度虽然可以使残余应力层深度和最大残余压应力值增加,但会降低能量利用率。通过与相关实验数据的比较,验证了仿真模型和结果的正确性。     

42CrMo钢超声喷丸强化模拟与实验研究

以42CrMo钢作为研究对象,利用超声喷丸工艺对42CrMo钢进行表面强化处理,并对超声喷丸过程进行有限元模拟,分析超声喷丸工艺与材料表面残余应力、显微硬度和表面形貌之间的关系。有限元模拟计算结果表明,超声喷丸冲击针头直径越小、冲击速度越大,喷丸后材料硬度越大,表面形貌越差;冲击针头直径对材料残余压应力场深度有显著影响;冲击速度对材料最大残余压应力值和残余压应力场深度有显著影响。     

喷丸工艺对DC53钢表面完整性的影响试验研究

为了探究喷丸角度、喷丸压力等喷丸工艺参数对DC53钢表面完整性的影响,通过试验研究了不同喷丸角度、喷丸压力对DC53钢表层残余应力场分布及硬度场分布的影响规律,同时分析了喷丸后的表面形貌及喷丸工艺参数对表面粗糙度的影响.结果表明:喷丸后DC53钢引入了一定深度的残余压应力层,残余压应力随深度的增加呈现"U"型分布,当喷...     

水射流工艺对渗碳钢圆棒表层改性影响的研究

研究了后混合水射流喷丸对18CrNiMo7-6齿轮渗碳钢圆棒试样的表层改性工艺,在满足试样圆周面水射流喷丸全覆盖的条件下,采用单因素试验分别研究了圆棒试样转速、喷嘴移动速度、高压水射流泵压力和处理次数对试样材料的表面形貌、表面粗糙度、表层残余应力和硬度的影响,并分别运用超景深三维显微镜、三维表面形貌测量仪、X射线残余应力分析仪及HV-1000显微硬度计等仪器对上述结果进行测量。试验结果表明:后混合水射流喷丸时弹丸和水会对试样表层产生一定的冲蚀和磨损,改变试样表面形貌,试样表面粗糙度、表层残余应力和硬度随着试样转速和喷嘴移动速度的增加而减小,随着泵压力和冲击次数的增加而增大;当试样转速n=100 r/min,喷嘴移动速度v=50 mm/min,泵压力P=300 MPa,处理次数N=1时残余应力最大值约为-1 176. 25 MPa,硬度最大值为64 HRC,比原始试样提升了6. 7%。     

航空发动机钛合金叶片残余应力喷丸-电磁场复合调控技术

为改善航空发动机叶片残余应力分布状态、消除喷丸对叶片表面造成的微损伤,提出了喷丸-电磁场复合调控新技术。采用X射线衍射技术分别测试了叶片残余应力在喷丸前、喷丸后和喷丸-电磁场复合调控工艺处理后的分布规律。通过叶片材料微观组织分析,探讨了喷丸-电磁场复合调控工艺影响钛合金叶片残余应力的机理。研究结果表明,喷丸-电磁场复合调控工艺使叶片表面残余压应力最大提升了7.7%,改善了喷丸造成的残余压应力分布不均匀状况,并在叶片近表层形成了较强的残余压应力场,残余压应力最大提升1.55倍。与喷丸处理叶片相比,经喷丸-电磁场复合工艺处理叶片的疲劳强度增加33%~36%。     

喷丸强化对NAK80钢表面完整性的影响

对析出硬化钢NAK80进行喷丸强化处理,测量了不同喷丸强度工艺下喷丸影响层显微硬度、表面残余应力沿层深的分布以及表面粗糙度,并分析了由喷丸引起的微观结构的变化,初步定性探讨了NAK80钢喷丸强化后表面完整性的改善。结果表明,NAK80钢对喷丸强度的要求不同于一般的钢,强度适当的喷丸强化可显著改善其表面完整性,而强度过高时将产生过喷效应,试验测得喷丸强化弧高值为0.40 mm.N时,NAK80钢具有良好的表面完整性能,喷丸影响层厚约为150~200μm。     

微粒子喷丸单颗粒冲击的因次分析与仿真研究

为了研究微粒子喷丸(喷丸直径0. 02～0. 20 mm)的工艺参数对靶材、残余压应力层深度和表面粗糙度的影响,应用因次分析技术,在微粒子喷丸单颗粒冲击条件下,推导出3个无量纲关系式,建立靶材残余压应力层深度、表面粗糙度、弹痕直径与微粒子喷丸工艺参数(材料、直径、速度)之间的联系。为求解无量纲关系式中的待定量,采用5种靶材、2种喷丸材料、3种喷丸直径、3种喷丸速度组成13组样本,应用ANSYS/LS-DYNA软件对13组样本进行仿真试验,根据仿真结果求解出3个无量纲表达式中的未知量。     

超声滚压18CrNiMo7-6齿轮钢表面变质层性能分析

研究了18CrNiMo7-6齿轮钢超声滚压后表面变质层的性能和加工工艺。分别运用三维表面形貌测量系统、显微硬度计、超景深三维显微系统和高速大功率X射线残余应力分析仪等工具观察试样加工前后的表面变质层变化,并采用单因素试验分析试验数据,研究超声滚压工艺参数对试样表面变质层的影响。结果表明:经过超声滚压加工,表面粗糙度由未经超声滚压处理的3. 003μm减少到0. 468μm,显著的加工硬化在该材料表面形成,表面显微硬度从最开始的360. 9 HV升高到442. 9 HV,升高了22. 7%,高硬度层达到了300μm;平整的表面在超声滚压加工后出现;在距离表面40μm处残余压应力形成峰值,其值约为-790. 97 MPa。超声滚压技术显著提高了材料的变质层性能。     

激光强化后7050凹槽铝板的残余应力分布规律研究

为了研究激光冲击强化后7050-T7451凹槽铝板残余应力场分布,测量了冲击后凹槽的残余应力分布规律:从凹槽中心到凹槽边缘,残余应力逐渐减小;在凹槽边缘底边处取最小值;然后沿凹槽边缘上升而增大,表面残余应力在凹槽曲面底边处取到最小值。采用ABAQUS有限元软件建立凹槽铝板的三维有限元模型,利用VDLOAD子程序施加载荷,进行数值分析得到了激光喷丸后残余应力分布并与试验测量结果对比,符合较好;然后研究了不同激光参数对凹槽铝板残余应力场的影响规律。结果表明:随着激光功率密度从0.84 GW/cm~2增加到5.29 GW/cm~2,残余应力先减小后增加,激光功率密度为3.06 GW/cm~2时达到最小值-230 MPa;随着光斑直径从4 mm增加到6 mm,残余应力由-214 MPa增加至-30 MPa;随着激光脉宽从10 ns增加到40 ns,残余应力由-21 MPa减小至-288 MPa,残余压应力层深度逐渐增加;表面残余应力的最小值在凹槽曲面处取得。     

光学石英玻璃加工表面微结构特征

光学石英玻璃是光学精密器件的常用材料,其表面加工质量直接决定光学器件性能。借助光学显微镜和AFM,研究光学石英玻璃加工后表面微观形貌与损伤层厚度,探索表面缺陷与亚表层损伤形成机理。结果表明,切片表面损伤最严重,损伤最大深度近50μm;粗磨表面次之,损伤最大深度近30μm;精磨后表面粗糙度与损伤层厚度皆大大降低;粗抛样表面存在少量划痕与破点;精抛样在显微镜下观察不到表面缺陷,损伤层厚度小于1μm。古典抛光表面粗糙度小、光洁度优于CMP表面,但CMP表面产生划痕或破点的几率远小于古典抛光。     

Analytical Modelling of Shot-peening Residual Stress on Welding Carbon Steel Surface Layer

The residual stress distribution was studied by an analytical model, due to shot peening on the welding carbon steel surface layer. The initial welding residual stresses before shot peening were taken into consideration in this analytical model. The Hertzian elastic contact theory was used to get the elastic compression stress state after impact on the surface layer. The initial welding stress field and the shot peening stress field would superpose and the welding surface layer would yield based on the elastic-plastic evaluation, then the residual stress after shot peening can be achieved. The influence of initial welding residual stress on the stress distribution after shot peening was analyzed and discussed. A series of experiments were carried out and the residual stress on the welding surface was determined by X-ray diffractometer before and after shot peening. The calculation results of the analytical model are consistent with the experimental results. The critical shot velocities when welding surface layer yielded and reverse yielded were calculated. While the welded joint surface material reversely yielded, the maximum compressive residual stress would not obviously increase with the increase of shot velocity, the thickness of the compressive stress layer would be increased. Welding residual tensile stress can enlarge the thickness of the compressive stress layer at the same shot velocity when reverse yield appeared.     

陶瓷磨削力对磨削表面残余应力的影响

主要研究陶瓷磨削力对残余应力和表面性能的影响。结果表明 :陶瓷磨削力主要是法向磨削力对残余应力的方向、作用深度、变化梯度均有较大的影响。在小切深、反复光磨的条件下 ,磨削力使残余应力的数值、变化梯度减小 ,作用深度增大。一般情况下 ,在磨削力作用下的残余压应力的作用深度随磨削条件而变化 ,一般小于 12 μm。残余压应力作用在塑性变形层内。     

Determination of residual stress distribution combining slot milling method and finite element approach

Residual stress plays a vital role in the structural strength and stability. The determination of residual stress at single-point has become mature at present. However, the method to determine residual stress distribution is still in shortage. For this problem, a finite element approach combined with slot milling method was developed in this study. In the method, firstly a slot is milled on the specimen surface to release the residual stress and then the released displacement field is measured by optical method, such as digital image correlation (DIC), finally the finite element approach is used to determine the residual stress distribution along the slot. In order to verify the feasibility of the method, it was applied to study the residual stress introduced by shot peening, mainly about the stress distribution along the direction vertical to the shot peened surface. Since the influence depth of shot peening was too small, we utilized focused ion beam (FIB) to determine the microscale residual stress distribution. The result measured by X-ray diffraction (XRD) demonstrated that the method was feasible to determine the residual stress distribution.     

Ti合金喷丸强化研究进展

概述了钛合金塑性变形和喷丸强化机理,同时叙述了钛合金强化层中的组织和残余应力,文中重点总结了喷丸强化对钛合金显微组织的影响,指出：喷丸形成的亚结构栅栏效应可显著提高构件的疲劳性能．     

Microstructure and properties of sputtered thermal barrier coatings

A 3 kW radio frequency (RF) magnetron-sputtering unit was used to produce zirconia ceramic coatings on hollow turbine blades and vanes, which had been deposited a NiCrAlY bond coat layer by cathodic arc deposition. The NiCrAlY coating surface was shot-peened, and the residual stress in the bond coat layer and the effects of heat treatment on the residual stress are presented. After shot peening porosities and microgaps disappear in the NiCrAlY bond coat, the whole depth profile is residual compressive stress. Coarseness tests show that the roughness value (Rz) decreases from 16.4 to 3.3 μm. The microstructure and phase composition of the coatings were investigated using electron probe microanalysis (EPMA) and X-ray diffraction (XRD). The results show that tho/NiCrAlY bond coat is composed of γ and Cr phases, and the Al2O3 scales are formed near the interface between the ZrO2 ceramic layer and the NiCrAlY bond coat. No degradation occurred to RF sputtered ceramic coatings after oxidating at 1150℃ for 100 h, heating at 1150℃ for 5 min and then air-cooling for 500 thermal cycles.     

对40Cr钢表层硬度残余应力及接触疲劳性能的研究

研究了表面淬火、离子氮化＋表面淬火的复合热处理以及复合热处理＋喷丸处理3种表面强化处理工艺对40Cr钢的表层硬度残余应力分布以及接触疲劳性能的影响,结果表明：经过复合热处理＋喷丸工艺处理的40Cr钢可获得最高的表层硬度和残余压应力,同时也表现出最为优异的接触疲劳性能。据此提出,高的表层硬度和残余应力能够有效地抑制接触疲劳裂纹在试样表面的萌生和扩展,因而可大大提高40Cr钢的接触疲劳寿命。     

钛合金的已加工表面残余应力的数值模拟

为了揭示高速切削对航空钛合金加工表面残余应力的影响，利用三维斜角切削有限元模型对钛合金Ti6Al4V的高速切削加工过程进行了模拟，获得了不同切削速度和不同切削深度下的已加工表面残余应力分布.模拟结果表明：切削速度对已加工表面残余应力具有重要影响，而切削深度对已加工表面残余应力影响较小; 已加工表面层残余应力为拉应力，沿深度方向由拉应力逐渐过渡到压应力; 3个主方向的残余应力值随切削速度的增加而增加，而随切削深度的增加无明显变化; 切削速度和切削深度对残余应力层的厚度影响都很小.     

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d treated within 1hour after trauma was significantly lower thaoys residual stress induced by intense laser to shape precisely the plate.In this paper,the aeronautic aluminum alloy LY12CZ was selected as an object to research experimentally the magnitude of deformation versus numbers of laser shot peening,and surface quality in laser shot zone was also investigated.The specimen was impacted along its centerline by the high-power,short-duration pulses laser.The experimental results show that the arc height and hardness becomes greater with numbers of shot peening increasing and eventually arrives to saturated state,and sur- face roughness after laser shot peening decreases slightly and dislocation density increases greatly,which indicates that the laser shot peening is a technique combining laser shock processing and metal forming.     

Experimental Research on Laser Shot Peening to Form Aluminum Alloy

Laser shot peening forming is a novel technology, which employs residual stress induced by intense laser to shape precisely the plate. In this paper, the aeronautic aluminum alloy LY12CZ was selected as an object to research experimentally the magnitude of deformation versus numbers of laser shot peening, and surface quality in laser shot zone was also investigated. The specimen was impacted along its centerline by the high-power, short-duration pulses laser. The experimental results show that the arc height and hardness becomes greater with numbers of shot peening increasing and eventually arrives to saturated state, and surface roughness after laser shot peening decreases slightly and dislocation density increases greatly, which indicates that the laser shot peening is a technique combining laser shock processing and metal forming.