螺接搭接件的载荷传递特性试验及三维有限元分析

在考虑螺栓与孔壁间的非线性接触、摩擦、干涉配合和螺栓预紧力等因素影响的基础上,利用非线性有限元软件MSC.Marc构建了螺接搭接件的三维有限元分析模型。数值模拟结果与试验结果的对比表明:所建三维模型能有效地模拟搭接件的载荷传递特性。基于三维有限元模型,讨论了无裂纹搭接件的螺栓孔形式、干涉配合和螺栓预紧力对载荷传递比的影响规律,同时对含裂纹搭接件的载荷传递比随裂纹扩展的变化规律进行了分析,计算结果和结论可作为该类结构损伤容限设计的参考依据。     

基于子模型的车钩裂纹扩展特性研究

为保证货车运营安全和车钩维修成本控制,基于子模型法在钩体和钩舌疲劳裂纹易发生区建立了含椭圆形表面裂纹模型。采用有限元法与交互积分法相结合的方法,分析了裂纹前缘3种开裂形式下的应力强度因子,确定了不同部位裂纹开裂的主要形式;分析了钩体牵引突缘和钩舌牵引面处裂纹在不同扩展阶段的前缘应力强度因子和扩展路径。结果表明,钩体牵引突缘过渡区和钩尾销孔处、钩舌的牵引面与牵引突缘过渡区的裂纹扩展形式主要以I型裂纹为主,钩体锁腔处裂纹扩展以II型裂纹和III型的复合型裂纹为主;随着裂纹扩展长度的增加,钩体牵引突缘过渡区和钩舌牵引面尖端处的应力强度因子大于裂纹深度尖端处的应力强度因子,表明当裂纹扩展到一定尺寸时,裂纹沿表面长度扩展大于沿深度方向的扩展,模拟的扩展路径与实际扩展路径相似,验证了数值模拟的准确性。     

碳纤维布胶接修复含裂纹钢管仿真分析

在胶接修复工艺中,裂纹的形式和不同的胶接方案影响结构的修复效果.以裂纹尖端应力强度因子(Stress Intensity Factor,SIF)为依据,分别对含有2种裂纹形式的钢管进行了仿真分析,探讨钢管的裂纹大小、碳纤维布的长度和层数对胶接修复强度的影响.分析结果表明,增加碳纤维布长度可以有效提高修复结构的强度,当长度超过有效胶接长度后,提高幅度不明显.裂纹面积所占比例越大,裂纹处应力集中程度越高,胶接碳纤维布的修复效果越显著.2层碳纤维布胶接修复对SIF的增长抑制效果比1层碳纤维布提高了10％以上,对于圆周裂纹损伤程度较小时,使用1层碳纤维布修复已能有效改善钢管的结构性能,对于圆弧裂纹和损伤程度较大的圆周裂纹,建议使用2层碳纤维布修复.     

碳纤维布胶接修复含裂纹钢管仿真分析

在胶接修复工艺中,裂纹的形式和不同的胶接方案影响结构的修复效果.以裂纹尖端应力强度因子(Stress Intensity Factor,SIF)为依据,分别对含有2种裂纹形式的钢管进行了仿真分析,探讨钢管的裂纹大小、碳纤维布的长度和层数对胶接修复强度的影响.分析结果表明,增加碳纤维布长度可以有效提高修复结构的强度,当长度超过有效胶接长度后,提高幅度不明显.裂纹面积所占比例越大,裂纹处应力集中程度越高,胶接碳纤维布的修复效果越显著.2层碳纤维布胶接修复对SIF的增长抑制效果比1层碳纤维布提高了10％以上,对于圆周裂纹损伤程度较小时,使用1层碳纤维布修复已能有效改善钢管的结构性能,对于圆弧裂纹和损伤程度较大的圆周裂纹,建议使用2层碳纤维布修复.     

高强度螺栓在预紧力及微裂纹作用下的有限元分析

采用考虑螺纹细节的有限元模型对高强度螺栓在预紧力作用下的受力状况进行了仿真分析。研究了四棱锥形开口微裂纹及近表面椭圆形微裂纹对螺栓表面应力集中处受力分布的影响。结果表明:应力集中主要产生于最末端螺纹处以及旋合段的第一、二扣螺纹处,螺牙根部是同一横截面上的最大等效应力处;微裂纹的存在会极大地加强应力集中,并且最末端螺纹比旋合段螺纹对微裂纹更敏感。此外,四棱锥形开口微裂纹趋于周向扩展,近表面椭圆形微裂纹趋于向表面扩展。     

枕垫应力对飞机搭接件完整性的影响研究

根据腐蚀产物化学特性和板壳理论,建立搭接件接触面腐蚀厚度与枕垫应力定量关系的数学模型。在此基础上,利用非线性有限元软件MSC.Marc分析枕垫应力对搭接结构完整性的影响。分析时考虑螺栓与孔壁间的非线性接触、摩擦、干涉配合、材料损失、枕垫应力及几何非线性等因素影响。模拟结果表明,搭接件的最大应力点位置随腐蚀水平的增加而变化,腐蚀初期和腐蚀量大于4%时,搭接件应力对枕垫应力比较敏感。随着腐蚀程度的加重,内表面裂尖应力强度因子随之增大,而外表面裂尖应力强度因子随之减小。另外,分析腐蚀对搭接件的影响时,只考虑蒙皮厚度的变化,而不考虑枕垫应力得出的结果是保守和危险的。计算结果和结论可作为该类结构损伤容限设计的参考依据。     

基于断裂力学的射孔套管孔边开裂行为分析

针对内压作用下的射孔套管的孔边开裂行为,应用断裂力学分别对线弹性条件和弹塑性条件下的孔边开裂进行分析,给出线弹性条件下圆柱壳体孔边裂纹应力强度因子和临界开裂内压公式,以及弹塑性条件下含孔边裂纹管道的临界开裂内压公式;通过MATLAB对两种条件下的力学模型进行解析,首先从线弹性条件下内压、裂纹长度以及孔径对应力强度因子的影响展开分析;然后从弹塑性条件下孔径和裂纹长度对临界开裂内压的影响进行分析;最后对小范围屈服情况下的两种断裂判据的套管临界开裂内压进行了对比。     

螺接搭接件的力学特性试验及三维有限元分析

在考虑螺栓与孔壁间的非线性接触、摩擦、干涉配合和螺栓预紧力等因素影响的基础上,利用非线性有限元软件MSC.Marc构建螺接搭接件的三维有限元分析模型.数值模拟结果与试验结果的对比表明,文中所建三维模型能有效地模拟搭接件的表面应变、载荷传递和第三弯矩等三维力学特性,同时搭接件的三维应力、应变特性及干涉配合和螺栓预紧力对载荷传递比的影响规律也进行了讨论,计算结果和结论可作为该类结构损伤容限设计的参考依据.     

部分裂纹面受力情形下无限大板孔边双裂纹的张开位移研究

针对航空结构中常见的孔边裂纹问题,利用Muskhelishvili复变函数法和Cauchy积分理论推导了无限大板内圆孔边任意长度双裂纹在部分裂纹面受均布应力情形下的位移表达式,并计算了孔边裂纹对称和孔边裂纹不对称两种情况下的裂纹面张开位移。孔边双裂纹对称时,计算值与权函数方法的求解结果进行了对比,最大误差为16.21%。研究表明,应用复变函数法和Cauchy积分理论推导的裂纹面张开位移表达式,不仅适用于无限大板内孔边裂纹对称的情况,孔边裂纹不对称时同样适用,从而为圆孔边任意长度双裂纹的疲劳裂纹闭合分析和张开应力求解提供了研究基础。     

拆除铆钉法在飞机结构修理中的应用与探讨

介绍了飞机翼梁损伤试验,针对试验中蒙皮孔边早期出现疑似可检裂纹可能导致试验无法正常进行的情况,提出了拆除裂纹孔边铆钉的方法达到延缓裂纹扩展的目的。通过有限元分析软件,建立含裂纹结构应力强度计算模型,研究了拆除铆钉法在飞机整体翼梁损伤容限试验中的具体应用,通过静强度理论及断裂力学理论分析,对蒙皮孔边铆钉孔的受力状态、临界裂纹长度、疲劳寿命进行计算,指出拆除铆钉法本质是通过疲劳危险部位的逐渐转移来延长结构的疲劳寿命。给出的理论分析方法,可供飞机结构设计及修理参考。     

惯导系统螺栓连接结构的有限元分析与试验验证

以一个惯导系统的螺栓连接结构为对象,建立了结构有限元模型,以模态试验数据为依据修改有限元模型,对模型中螺栓连接的建模方法进行了修改,获得了理想的结果,为后续的工程应用奠定了基础。     

Generic element formulation for modelling bolted lap joints

Joints have significant effects on the dynamic response of the assembled structures due to existence of two non-linear mechanisms in their interface, namely slipping and slapping. These mechanisms affect the structural response by adding considerable damping into the structure and lowering the natural frequencies due to the stiffness softening. Neglecting these effects in modelling of joints produces errors in predictions of the structure responses. In this paper, a non-linear generic element formulation is developed for modelling bolted lap joints. The generic element is formed by satisfying all conditions that are known for a joint interface and hence providing a non-linear parametric formulation for the families of allowable joint models. Dynamic response of the developed model for the assembled structure including the generic joint interface element is obtained using the incremental harmonic balance (IHB) method. The generic parameters of the joint are identified by minimising the difference between the model response obtained from IHB method and the observed behaviour of the structure. The procedure is demonstrated by modelling an actual structure containing a single lap bolted joint in the middle. The frequency responses of the structure around the first two resonance frequencies are measured by exciting the structure using a sinusoidal force at each individual frequency. The measured responses are compared with the predictions of the model containing a parametric generic joint element. The parameters of the joint interface model are successfully identified by minimising the difference between the measured responses and the model predictions.     

螺栓连接单搭接件疲劳特性试验与全寿命估算方法研究

飞机搭接件结构在疲劳载荷下会产生裂纹并扩展,而目前对搭接件结构参数与其疲劳寿命的关系研究还不够系统,且寿命估算模型只考虑了全寿命的一部分。对不同结构参数的三螺栓单搭接件的疲劳特性进行了试验研究,并以现有工程方法为基础,构建了基于材料初始不连续状态的搭接件全寿命估算模型。结果表明,搭接件的疲劳破坏具有一定的隐蔽性,在一定条件下,采用直孔形式、增大孔间距和螺栓预紧力、减小孔直径等都可以改善搭接件的疲劳特性。数值估算结果与试验结果的对比表明,所建寿命模型具有一定的精度,能满足工程需要,计算结果和结论可作为该类结构损伤容限设计的参考依据。     

Segment-to-segment contact elements for modelling joint interfaces in finite element analysis

This paper presents an efficient approach to model contact interfaces of joints in finite element analysis (FEA) with segment-to-segment contact elements like thin layer or zero thickness elements. These elements originate from geomechanics and have been applied recently in modal analysis as an efficient way to define the contact stiffness of fixed joints for model updating. A big advantage of these elements is that no global contact search algorithm is employed as used in master–slave contacts. Contact search algorithms are not necessary for modelling contact interfaces of fixed joints since the interfaces are always in contact and restricted to small relative movements, which saves much computing time. We first give an introduction into the theory of segment-to-segment contact elements leading to zero thickness and thin layer elements. As a new application of zero thickness elements, we demonstrate the implementation of a structural contact damping model, derived from a Masing model, as non-linear constitutive laws for the contact element. This damping model takes into account the non-linear influence of frictional microslip in the contact interface of fixed joints. With this model we simulate the non-linear response of a bolted structure. This approach constitutes a new way to simulate multi-degree-of-freedom systems with structural joints and predict modal damping properties.     

螺栓连接接口轴向振动能量耗散特性研究

根据螺栓连接接触面的轴向接触微观特征,将接触面的接触方式分为峰-峰接触和峰-谷切向接触,提出了螺栓连接轴向振动的动力学模型。在假定接触面出现简谐运动条件下,推导出接口阻尼力的解析表达式和接口能量耗散的关系式。该式表明,轴向振动单位周期内的能耗包括粘性阻尼和干摩擦阻尼能耗两部分,这两部分能耗都与振动幅值和固有频率的平方成正比。粘性阻尼能耗与频率比和阻尼比成正比,干摩擦阻尼能耗与接触面峰-谷切向接触压力与总压力之比成正比,而与振动幅度和压缩位移比成反比,与接口的拉压刚度比成非线性关系。     

Surface contact stress-based nonlinear virtual material method for dynamic analysis of bolted joint of machine tool

The components of machine tools are mainly fixed and connected by bolts. The performance of the assembly can be affected by the dynamic characteristics of the bolted joints. This paper presents a nonlinear virtual material method based on surface contact stress to describe the bolted joint for accurate dynamic performance analysis of the bolted assembly. Fractal geometry theory is used to describe the surface topography. The elastic modulus and shear modulus of one micro-contact are derived based on fractal contact theory. The equivalent elastic modulus, Poisson ratio, and density of the bolted joint can be obtained through the weighted mean method. In order to obtain the stress distribution, the contact surface is assumed flat in the macro-scale, and the uneven distribution of contact stress can be obtained by the finite element method (FEM). The contact surface can be divided into several sections, and the parameters of a virtual material layer can be determined based on the mean contact stress. Both theoretical and experimental results for a bolted joint are obtained for a box-shaped specimen under equal pre-tightening force and bending moment effect. The results show that the theoretical mode shapes are in good agreement with the experimental mode shapes. The relative errors between the theoretical and experimental natural frequencies are less than 4.41%, which indicates that the present nonlinear virtual material method is appropriate for the bolted joint in modeling CNC machine tools.     

Bolted joint torque setting using numerical simulation and experiments

In vehicle design process, the torque setting for a bolted joint is mainly determined based on hardware tests. For a newly designed joint of a vehicle, making prototypes and performing tests is expensive and time consuming. Numerical simulation can help predict joint behavior and detect potential failure modes prior to hardware testing. This study developed a numerical simulation using the finite element method to set the installation torque for a joint based on torque-angle signature curves. A three-dimensional detailed model of the joint was constructed. Then, finite element dynamic simulation was used to simulate the installation process of the bolt by gradually applying a torque until the bolt failed. Using these simulations, the torque-angle curves were generated and were used to determine the installation torque of the joint. This was different from the majority of earlier approaches which mainly used hardware tests, two-dimensional or three-dimensional simplified models, and static analyses instead of dynamic analyses. Material nonlinearity and contact were used in the study to capture the joint failure and contact conditions. For comparison, experiments were conducted. The study showed that the finite element analysis accurately predicted the bolt behavior. These results show that numerical simulation can be used to determine torque settings analytically, and can be developed as a standard practice for determining joint torque when designing vehicles.     

Three-dimensional finite element analysis of the mechanical properties of helical thread connection

Conventional analytical and numerical methods for the mechanical properties of helical threads are relied on many assumptions and approximations and thus hardly yield satisfied results. A parameterized 3D finite element model of bolted joints with real helical thread geometry is established and meshed with refined hexahedral elements. The Von Mises plasticity criterion, kinematic hardening rule of materials and interfacial contacts are employed to make it possible for the suggested model be able to approach real assembly conditions. Then, the mechanical properties of bolted joints with different thread pitches, thread numbers and modular ratios are investigated, including the contact pressure distribution at joint interfaces, the axial load distribution and stress concentration in screw threads during the loading and unloading process. Simulation results indicate that the load distribution in screw threads produced by the suggested model agrees well the results from CHEN’s photoelastic tests. In addition, an interesting phenomenon is found that tightening the bolt with a large preload first and then adjusting the clamping force by unloading can make the load distribution more uniform and reduce the maximum residual equivalent stress in thread roots by up to 40%. This research provides a simple and practical approach to constructing the 3D finite element model and predicting the mechanical properties of helical thread connection.     

螺栓法兰接头用碟形弹簧压缩回弹性能研究

为研究螺栓法兰接头用碟形弹簧压缩回弹性能,建立碟形弹簧力学性能分析的弹塑性有限元模型,并通过试验验证其可靠性。应用ABAQUS软件对碟形弹簧压缩回弹过程进行分析,讨论碟簧外内径比、倾角和厚度对碟簧压缩回弹性能的影响。结果表明:碟簧的压平载荷随厚度、倾角的增加呈上升趋势,随外内径比的增加呈下降趋势;回弹率随厚度、倾角、外内径比的增加均呈下降趋势。基于正交试验分析方法,结合量纲分析,建立螺栓法兰接头用碟形弹簧压平载荷和回弹曲线的预测模型,并验证其可靠性。