搭接长度对胶接接头工作应力分布影响的数值分析

运用弹塑性有限元法对单搭接金属胶接接头承载后的应力分布特征进行分析，重点研究搭接长度对分别采用酚醛树脂和丙烯酸酯制备的接头应力分布和接头强度的影响。结果表明，胶粘剂的性能对应力分布有较大影响，酚醛树脂胶粘剂制备的接头中胶瘤承担了相当多的载荷，且随搭接长度的增加,von Mises等效应力峰值和剪切应力峰值均趋于向胶层内转移，胶层中各部位的应力亦均有下降；当采用丙烯酸酯胶制备的接头时，胶瘤承载作用并不明显，其应力峰值出现在胶层中被粘物拐角处。     

有间隙胶接劈裂接头应力分布的数值模拟

建立了有间隙胶接劈裂接头的有限元模型，并运用弹塑性有限元法，研究了间隙位置和长度对劈裂接头胶层中部应力分布的影响。研究结果表明：合理的间隙不仅对劈裂接头的应力峰值和接头的承载能力无明显影响，而且有利于提高接头的胶接质量；间隙的中心位置对接头的应力峰值影响显著，而间隙长度对接头的应力峰值无明显影响；当接头末端无胶层时，因应力峰值显著增大，可能导致接头的名叉强度降低。     

Creep simulation of adhesively bonded joints using modified generalized time hardening model

Creep behavior of double lap adhesively bonded joints was investigated using experimental tests and numerical analysis. Firstly, uniaxial creep tests were carried out to obtain the creep characteristics and constitutive parameters of the adhesive at different stress and temperature levels. Generalized time hardening model was used to predict the creep behavior of the adhesive. This model was modified to simulate the creep behavior at different stress and temperature levels. Secondly, the developed model was used to simulate the creep behavior of bonded joints using finite element based numerical analysis. Creep deformations of the joints were measured experimentally and good agreement was observed in comparison with the results obtained using numerical simulation. Afterward, stress redistribution due to the creep along the adhesively bonded joint was obtained numerically. It was observed that temperature level had a significant effect on the stress redistribution along the adhesive thickness.     

The free vibration analysis and optimal design of an adhesively bonded functionally graded single lap joint

In this study, three-dimensional free vibration and stress analyses of an adhesively bonded functionally graded single lap joint were carried. The effects of the adhesive material properties, such as modulus of elasticity, Poisson's ratio and density were found to be negligible on the first ten natural frequencies and mode shapes of the adhesive joint. Both the finite element method and the back-propagation artificial neural network (ANN) method were used to investigate the effects of the geometrical parameters, such as overlap length, plate thickness and adhesive thickness; and the material composition variation through the plate thickness on the natural frequencies, mode shapes and modal strain energy of the adhesive joint. The suitable ANN models were trained successfully using a series of free vibration and stress analyses for various random geometrical parameters and compositional gradient exponents. The ANN models showed that the support length, the plate thickness and the compositional gradient exponent played important role on the natural frequencies, mode shapes and modal strain energies of the adhesive joint whereas the adhesive thickness had a minor effect. In addition, the optimal joint dimensions and compositional gradient exponent were determined using genetic algorithm and ANN models so that the maximum natural frequency and the minimum modal strain energy conditions are satisfied for each natural frequency of the adhesively bonded functionally graded single lap joint.     

考虑弯曲效应的混元胶接单搭接头应力模型

混元胶接接头是利用多种不同剪切弹性模量的胶层来传递被粘物载荷的单搭接头。它兼具胶层连续性连接和降低端头应力集中等优点,因此能充分利用被粘物材料性能(如复合材料)以提高接头强度。以典型双元胶接接头为对象,考虑加载作用线偏心引起的弯曲效应和胶层剥离正应力,建立被粘物为各向同性的线弹性双元胶接接头应力解析模型。理论模型中的胶层切应力、剥离正应力和上被粘物纵向正应力与精细有限元模型吻合得较好,证实了理论模型的正确性。参数研究中确定了影响混元胶层应力分布的关键耦合参数。     

硬度影响压痕弹塑性行为的有限元分析

以具有不同硬度40Cr为研究对象,根据集中载荷下的接触模型和赫兹理论,计算了压痕接触半径和压痕附近弹性区域的表面局部接触应力,并采用有限元法,分析硬度物理量对压痕弹塑性行为、局部接触应力、卸载后保留在内部的残余应力的影响,探讨压痕参数、压痕接触应力、残余应力与硬度之间的关系以及载荷增加时它们的发展.结果表明,相同载荷下塑性隆起量、压痕接触半径、压痕量和塑性区范围随着硬度值的提高而减小,弹性回弹量、最大接触应力和残余应力随硬度提高而增加;压痕周围处接触应力和残余应力、其分布范围和塑性区域随载荷的增加而增加.     

Indentation modulus and hardness of viscoelastic thin films by atomic force microscopy: A case study

We propose a nanoindentation technique based on atomic force microscopy (AFM) that allows one to deduce both indentation modulus and hardness of viscoelastic materials from the force versus penetration depth dependence, obtained by recording the AFM cantilever deflection as a function of the sample vertical displacement when the tip is pressed against (loading phase) and then removed from (unloading phase) the surface of the sample. Reliable quantitative measurements of both indentation modulus and hardness of the investigated sample are obtained by calibrating the technique through a set of different polymeric samples, used as reference materials, whose mechanical properties have been previously determined by standard indentation tests. By analyzing the dependence of the cantilever deflection versus time, the proposed technique allows one to evaluate and correct the effect of viscoelastic properties of the investigated materials, by adapting a post-experiment data processing procedure well-established for standard depth sensing indentation tests. The technique is described in the case of the measurement of indentation modulus and hardness of a thin film of poly(3,4-ethylenedioxythiophene) doped with poly(4-styrenesulfonate), deposited by chronoamperometry on an indium tin oxide (ITO) substrate.     

仪器化压入硬度与维氏硬度的关系研究

对理想Berkovich压头和维氏压头几何形状的分析表明,名义硬度Hn与维氏硬度Hv间存在如下近似函数关系：Hv=Hn/1.08。以37种碳钢材料的单轴拉伸实验数据为例,利用非线性有限元分析软件ABAQUS,模拟分析了这组碳钢材料的仪器化压入响应,将得出的名义硬度除以1.08,并与这些碳钢材料维氏硬度的实验数据相比较,两者吻合较好,以上关系的正确性得到了验证。这一关系使仪器化压入硬度与传统硬度间的直接比较成为可能。同时,为薄膜材料、纳米材料等小尺度材料传统硬度的预测提供了可行性方法。     

胶瘤弹性模量对铝单搭接接头应力分布的影响

利用弹塑性有限元法,研究四种不同弹性模量的胶粘剂 (丙烯酸酯胶、聚氨基甲酸乙酯胶、环氧树脂胶和酚醛树脂胶粘剂等) 形成的胶瘤对铝合金单搭接接头应力分布的影响.结果表明,当胶瘤采用不同于胶层的胶粘剂时,随着胶瘤弹性模量的减小,在胶层与胶瘤的连接处胶层中应力峰值显著提高,且均高于由单一胶所形成接头的应力峰值.对被粘物中紧邻界面层中的应力分布而言,峰值应力出现在胶瘤与胶层的连接处及靠近搭接区两端部处.随着胶瘤弹性模量的增加,靠近被粘物承载端的区域的应力越大,而自由端的应力越小,且靠近承载端的区域的应力峰值由胶瘤与胶层的连接处向承载端一侧转移,因而采用弹性模量低的胶粘剂形成胶瘤对接头的承载不利.     

表面粘贴式MEMS应变传感器的应变传递分析

表面粘贴式MEMS应变传感器已被广泛运用于航空航天、汽车工业及土木工程等领域的应变测量和监测中。但由于粘接层的影响,结构的应变并不能全部准确、有效地传递到MEMS应变传感器上,造成传感器的测量值与结构的真实应变之间存在一定误差。为了分析表面粘贴式MEMS应变传感器的应变传递机理,基于剪滞理论建立了MEMS应变传感器的力学分析模型,推导出基体和MEMS应变传感器基底上的应变分布、粘接层中的剪力分布及表征MEMS应变传感器应变传递效果的应变传递率,并与有限元数值模拟结果进行了比较。特别地,具体分析了粘接层及MEMS应变传感器基底的几何参数和物理特性参数对应变传递率的影响。结果表明,金属类粘接材料的应变传递率明显高于有机胶的应变传递率,且粘接层厚度越薄,应变传递效果越好。此外,在制造MEMS应变传感器时,采用厚度较薄的Si或Si C基底能保证较高的应变传递率。     

Finite element analysis of spherical indentation to study pile-up/sink-in phenomena in steels and experimental validation

The ball indentation technique based on deforming a material with a spherical indenter is an useful non-destructive tool for evaluating mechanical properties from a very small volume of material. In this work, the indentation test carried out using a 1.0 mm diameter tungsten carbide ball to penetration depths of around 100–200 μm is modeled using finite element (FE) method and analyzed for three steels having different yield stress and strain hardening exponent. The FE generated load–depth curve is compared and verified with the experimental load–depth data for the three materials. The role of the contact friction at the indenter–specimen interface on both the load—depth plot and indentation profile are examined. The development of pile-up/sink-in during indentation and its dependence on strain hardening characteristics of the material, contact friction and indentation depth are analyzed using the FE model. The indentation profiles obtained from simulation are compared with experimental profiles and the implication of pile-up phenomenon on accurate evaluation of stress–strain values from the experimental indentation load–depth data is discussed.     

一种考虑胶瘤的胶接简化有限元模型:应力与刚度分析

胶接接头中总存在胶瘤,由于建模复杂,胶接接头有限元分析中胶瘤常被忽略.但胶瘤能减少峰值应力,提高结构强度和刚度.为此,提出一种简化的胶接有限元模型,即用壳单元代表胶瘤,体单元代表被粘体和胶层,并用弹性理论建立壳单元等效厚度公式.以体单元精细模型结果作为对比的真实解,考察五种载荷工况下,单搭接头简化有限元模型的胶层应力和刚度.分析表明,壳单元等效厚度公式正确,胶接简化有限元模型精度高,可用于诸如汽车等大型结构中;用壳单元简单模型可定量分析胶瘤大小和形状对接头应力和总体刚度性能的影响.     

40Cr钢磨削强化的试验与数值仿真

利用磨削过程中产生大量的磨削热使40Cr钢表层的温度升高,超过奥氏体化的温度,然后快速冷却,使40Cr钢表层发生马氏体相变,达到强化40Cr钢表层的目的。在磨床上对40Cr钢进行磨削试验,观测并分析工件横断面相变层的组织变化、厚度值和硬度变化,以及加工后工件表面的粗糙度。借助有限元分析方法,对工件的温度场进行仿真,得出工件各处的温度变化历程,由马氏体相变条件来获得表层马氏体相变层的厚度值。试验结果表明,40Cr钢的表层发生了马氏体相变,表层的硬度值得到极大提高,表面粗糙度也满足常规磨削的要求。由有限元仿真得出的相变层厚度值和试验结果相吻合。因此利用磨削强化技术替代40Cr钢高频淬火强化工艺是可行的,并且这项技术可以对其他合金钢进行强化。借助有限元方法对工件表层的温度场进行仿真,可以预测相变是否发生和相变层的厚度,优化磨削参数,减少试验研究的次数和成本。     

胶层厚度对胶接波纹板三点弯曲力学性能影响研究

三明治波纹板采用轻质化和薄壁化的结构设计方法，可以作为承载和吸能结构应用于汽车底盘前纵梁、车身Y字梁等，而现有文献缺少针对胶层厚度对波纹板性能影响的研究。通过制备胶接波纹板并开展三点弯曲工况准静态加载失效试验，分析了不同胶层厚度对三明治波纹板整体承载和吸能特性的影响规律。试验发现，不同胶层厚度下铝合金胶接波纹板结构承载能力和破坏样貌存在差异，相比于0.5 mm和1.0 mm,0.2 mm胶层厚度的三明治结构的各项力学性能和稳定性较好。随后建立胶接波纹板三点弯曲加载有限元模型，实现了对波纹板整体加载变形过程和胶层损伤的模拟，通过与试验结果对比验证了有限元建模方法的有效性，为轻质金属胶接波纹板结构设计和性能评价提供可靠方法。     

单搭接接头胶层间隙对强度和应力的影响

研究单搭接接头胶缝中预留间隙对接头拉剪强度和应力分布的影响。结果表明,随着间隙长度的增加,接头的承载能力趋于减小,但接头的实际剪切强度却持续上升;当间隙长度继续增加时,接头的实际强度趋于下降。研究中还发现间隙所处的位置对接头的抗剪强度有较大的影响,胶层端部预留间隙使接头的承载能力和实际强度均显著下降。有限元数值分析结果表明,间隙长度超过某特定值后胶层中的应力集中程度会急剧上升,间隙位于端部时胶层中的应力集中程度明显高于位于中部的场合。     

Wettability characterization and adhesion enhancement of arc-treated surface of aluminum alloys

The aim of this study is to determine the wettability-enhancing effects of an atmospheric pressure, direct current (DC) plasma arc discharge on the surface of aluminum alloys. Wettability is a critical factor in engineering applications such as biomedical implants, painting, and adhesive bonding. For example, in the realm of adhesive bonding, greater wettability improves a metal substrate's attraction to an adhesive material and results in a higher bond quality. In this study, the contact angle was determined and compared as a measure of the wettability using two different techniques: the sessile drop and the ballistic deposition with water as a test liquid. The effect of different arc discharge process parameters on the wettability, including arc current and plasma torch velocity, was studied. A two-dimensional finite element analysis based on the volume-of-fluid model was carried out to explore the behavior of droplet (e.g., spreading and stabilization) on an ideal surface. Additionally, the values of the dynamic receding contact angle were measured through the simulation by applying the tilted plate method and considering the surface roughness to compare the results with the values obtained from the ballistic deposition method. Studying the wettability alteration of the surface of aluminum alloys subjected to the arc treatment revealed the wettability reduction over time. Additionally, it was found that there was a linear correlation between the contact angle value and the strength of adhesively bonded joints using two structural adhesives. The results of this study in the wettability modification of aluminum subjected to the arc treatment and wettability alteration of the treated substrate over time may be used as a quality assurance tool to design the production process and achieve the desired quality and strength in adhesively bonded joints.     

轴与轴套粘接／紧配合连接接头的性能研究

用实验方法研究轴对称粘接结构及粘接／紧配合连接接头的一般力学性能，结果表明，在压紧配合装置配时辅以使用胶粘剂，能提高的工艺性；粘接／紧配合复连接接头的力学性能明显优越于纯压紧配合的接头。用有限元方法计算轴瑟轴套粘接／冷缩配合接头在扭矩载荷下的应用受力分布发现，连接层面上的应力分布状态与轴套的变形能力有关。     

Hardness estimation for pile-up materials by strain gradient plasticity incorporating the geometrically necessary dislocation density

A plastic strain gradient theory incorporating the geometrically necessary dislocation density based on the low order displacement finite element method is proposed for calculation of the hardness value by Berkovich indentation. The obtained analysis results by this work are found to be in good agreement with the experimental data. Three-dimensional modeling technique of Berkovich indentation is also suggested. An empirical coefficient that includes the strain gradient effect into the yield stress formula is introduced and determined by reviewing area factors and hardness curves generated from the analyses. As pile-up occurs, classical plasticity theory gives a higher area factor and lower hardness value than those from experiment. However the strain gradient plasticity theory used in this work gives corrected area factor and hardness values. Dislocation density plots are generated that can explain the size effect during indentation and the availability of the three-dimensional modeling of Berkovich indentation.     

补片形状和尺寸对复合材料胶接修补的影响

与传统的机械修补技术相比,复合材料胶接修补具有结构增重小、可设计性强、成形简单和成本低等明显的优点。因此,复合材料胶接修补技术已成功地应用于一些军用和民用飞机的受损结构。借助于ANSYS软件,以三维逐渐损伤理论为依据,分别建立含不同形状补片的复合材料胶接修补模型,其中母板和补片采用正交各向异性损伤模型,胶层采用各向同性损伤模型。在单向拉伸载荷作用下,同时考虑层合板和胶层的损伤形式和扩展趋势,确定层合板的最终失效载荷,并与已有文献进行对比,验证模型的正确性。损伤模型计算结果表明,补片的形状和尺寸均是胶接修补的重要设计参数,其对层合板的最终失效载荷影响显著。斜放的方形补片的修补效果较佳,当对方形补片进行圆角化处理时,受损层合板的拉伸承载能力得到提高。     

镁合金激光胶接焊接头微观及力学性能

采用激光胶接焊焊接镁舍金，利用现代测试手段分析接头的微观组织特征，并分别研究激光焊、胶接和激光胶接焊3种接头在相同工艺参数下的剪切力和抗剥离力，在较好的工艺参数下，激光胶接焊焊缝成形良好。在激光热源的作用下，焊缝区内胶层受热分解并以气体形式逸出焊缝，并未影响焊缝的组织熔舍；焊缝边缘附近胶层炭化裂解，存在胶层失效区，虽减小胶层的承载面积，但该区域很窄，对接头的实际承载能力影响不大。激光胶接焊接头剪切力最大，胶接接头次之，激光焊接接头剪切力最小；激光胶接焊接头的抗剥离力远大于胶接接头的抗剥离力。激光胶接焊有效提高接头的实际承载能力，因此具有很大的发展潜力。