涡旋盘啮合条件下流固耦合分析与结构改进

针对涡旋齿变形量通过试验难以测得,进而动、静涡旋盘之间的啮合间隙值难以确定的问题,建立了带有轴向和径向泄漏间隙涡旋盘三维流体域模型,结合CFD动网格技术对涡旋盘内部流场进行模拟,得到压力场和温度场的瞬态分布。将流场计算结果施加到固体边界上,得到涡旋盘的应力分布和变形规律,其中固体变形考虑了包括涡旋齿和端板在内的整体变形,使变形计算结果更贴近实际工作情况,结合试验验证了模拟结果的准确性。对动涡旋盘在仅受气体力作用、仅受温度作用和受热力耦合场作用下的应力分布和变形规律进行对比分析,得到温度升高是造成涡旋齿变形的主要原因。根据上述分析结果,提出一种涡旋齿结构改进方法,对改进后的涡旋盘的变形和应力分布进行了模拟,结果表明:改进后的涡旋盘的应力和变形都有所降低,为进一步改进涡旋盘结构提供了参考。     

自卸车侧厢板交汇结构焊接的应力分析与结构优化

采用ANSYS软件对自卸车侧厢板的横竖槽钢交汇处的焊接过程进行了数值模拟,得到了交汇处的焊接应力和变形。为减小交汇处的焊接应力,提出了"预凹变形"的焊接结构优化方案,并进行了模拟。将焊接优化方案应用于实际生产中,减少了后期矫正量,使得车厢的整体质量与外观效果均获得了明显的提升。     

焊接顺序对Cr13型抗磨板表面堆焊变形的影响

基于热弹塑性有限元法,在仅考虑单向耦合的基础上,建立了抗磨板表面堆焊情况下的有限元计算模型,并对三种不同焊接顺序下的温度场、应力应变场进行了数值模拟,分析了焊接顺序对抗磨板表面堆焊变形的影响规律.结果表明,不同焊接顺序下导叶轴孔圆周度变形程度不同,与水平面间隙大小不一,焊后最大残余应力位于螺栓孔处,且最大残余应力沿螺栓孔周向呈正弦分布.综合比较,焊接顺序3引起的焊接变形小,且焊后残余应力分布均衡,有利于提高抗磨板的可靠性和安全性.模拟结果为Cr13型抗磨板实际焊接修复时的焊接顺序选择提供了理论依据.     

基于灵敏度分析的挤压机后梁主缸优化设计

本文以25MN铝挤压机后梁主缸作为研究对象,首先采用传统的理论计算及设计经验确定出后梁主缸的初始结构方案,再利用有限元数值分析,直观获取后梁主缸的应力分布及应力集中情况。基于后梁主缸各设计参数对于应力集中区域的灵敏度分析,以降低结构最大应力为目标,有针对性的合理改进缸体外径、缸底厚度、缸底圆角等主要结构参数,最终确定优化的结构方案,并通过有限元分析对比,优化后的后梁主缸各部位受力状况较初始结构均有显著改善,为挤压机后梁主缸的结构优化设计提供了一种有效的方法。     

EN-AW6082铝合金焊接及多次调修的数值模拟方法

采用Sysweld软件对EN-AW 6082铝合金试板进行多道焊焊接及焊后200℃和300℃温度下的火焰调修过程的数值模拟,获得了焊接及调修过程的温度场、应力场分布以及铝合金试板的整体变形分布规律,与试验所得结论相符,并提供了一种焊接及多次调修过程的模拟方法,为实际生产工作提供了一定的指导意义.     

薄板单面密集焊缝焊后弯曲变形分析

针对2 mm的316L薄板单面密集焊缝结构,采用数值模拟的方法分析了两种焊接方案下的薄板焊接弯曲变形. 利用高度测量装置建立了薄板弯曲变形测量方法,进行了两种焊接方案的工艺试验,对焊后弯曲变形进行了测量. 在此基础上,对数值模拟和工艺试验的结果进行了对比. 结果表明,薄板单面密集焊缝结构焊接后呈船形变形,拉通焊弯曲变形中心接近于板中心,而两端向中间焊弯曲变形中心偏向板的先焊位置. 两端向中间焊在长度方向弯曲变形量小于拉通焊,两端向中间焊的焊接方案较优.     

地铁侧梁应力以及变形的数值模拟优化

构架侧梁为典型的箱形结构,由内隔板、两侧腹板以及上下盖板等焊接而成,焊缝数量多,不同的焊接顺序和约束方式产生不同的焊接变形和应力分布。因此,通过数值模拟技术进行模拟,寻找焊接残余应力和焊接变形均较小的焊接方案。利用Sysweld软件,对不同约束和顺序下的侧梁进行数值模拟,观察最优方案下的应力分布状况和不同阶段的变形状况,为侧梁实际焊接生产提供指导。     

大型机翼整体壁板喷丸延展量数值模拟

分析了大型机翼整体壁板在喷丸成形及强化过程中产生延展变形的机理,并介绍了几种喷丸成形数值模拟的方法;对于弹丸不重叠排布的情况,采用长方形和三角形两种喷丸覆盖率计算模型,对于弹丸随机排布发生重叠的情况下,采用Avrami覆盖率计算模型,通过多弹丸撞击长方体胞元的有限元模拟方法,得到弹丸撞击后靶材的表层诱导应力场的分布规律;进而采用直接应力法建立了预测喷丸成形及强化延展变形的有限元模拟方法,通过试板喷丸成形参数和试板弯曲及延展的变形规律的试验,验证了其有效性,进而将其应用于C919机翼下前整体壁板板坯延展量的模拟,取得了与试验吻合较好的结果。     

变形镁合金触变塑性挤压的数值模拟

采用有限元模拟技术对变形镁合金的触变塑性挤压和常规挤压进行了数值模拟,获得了两种挤压变形过程中的行程--载荷曲线、应力、应变分布及温度场分布规律,并对两者的模拟结果进行了对比分析.分析结果表明,变形镁合金触变塑性挤压较常规挤压具有载荷力小、应力较小及温度分布均匀、温差小等优点.进行了相应的工艺实验,实验结果与数值模拟结果基本吻合,表明数值模拟与计算正确.     

某轿车侧围内板冲压成形的数值模拟

对由激光拼焊板制成的整体侧围内板进行了基于Dynaform成形软件的冲压成形模拟及参数的优化,分析了零件在冲压成形过程中的金属流动及应力应变分布规律。根据冲压后的模拟结果,进行参数优化,通过改变压边力、改进等效拉深筋等措施,抑制了成形中焊缝的移动,消除了起皱、破裂等成形缺陷。实践证明,产品质量与数值模拟结果吻合良好。     

Effects of Post-weld Heat Treatment on Microstructure,Mechanical Properties and the Role of Weld Reinforcement in 2219 Aluminum Alloy TIG-Welded Joints

In as-welded state, each region of 2219 aluminum alloy TIG-welded joint shows diff erent microstructure and microhardness due to the diff erent welding heat cycles and the resulting evolution of second phases. After the post-weld heat treatment, both the amount and the size of the eutectic structure or θ phases decreased. Correspondingly, both the Cu content in α-Al matrix and the microhardness increased to a similar level in each region of the joint, and the tensile strength of the entire joint was greatly improved. Post-weld heat treatment played the role of solid solution strengthening and aging strengthening. After the post-weld heat treatment, the weld performance became similar to other regions, but weld reinforcements lost their reinforcing eff ect on the weld and their existence was more of an adverse eff ect. The joint without weld reinforcements after the post-weld heat treatment had the optimal tensile properties, and the specimens randomly crack in the weld zone.     

The First Phase of the SRIF Industrialized Base in ＂West Area＂ Has Been Put into Operation

After nearly two years＇ tense construction, the first phase of industrialized base of Shenyang Research Institute of Foundry （SRIF）, located at the Tiexi Casting and Forging Industrial Park in the west of Tiexi District, has now been completed and formally put into operation.     

Thermodynamics Study on the Decomposition of Chromite with KOH

Institute of Process Engineering, Chinese Academy of Sciences, China, has proposed a method for oxidative leaching of chromite with potassium hydroxide. Understanding the mechanism of chromite decomposition, especially in the potassium hydroxide fusion, is important for the optimization of the operating parameters of the oxidative leaching process. A traditional thermodynamic method is proposed and the thermal decomposition and the reaction decomposition during the oxidative leaching of chromite with KOH and oxygen is discussed, which suggests that chromite is mainly destroyed by reactions with KOH and oxygen. Meanwhile, equilibrium of the main reactions of the above process was calculated at different temperatures and oxygen partial pressures. The stable zones of productions, namely, K2CrO4 and Fe2O3, increase with the decrease of temperature, which indicates that higher temperature is not beneficial to thermodynamic reactions. In addition, a comparison of the general alkali methods is carried out, and it is concluded that the KOH leaching process is thermodynamically superior to the conventional chromate production process.     

Influence of Heat Treatment on Damping Behaviour of the Magnesium Wrought Alloy AZ61

The effect of isochronal heat treatments for 1h on variation of damping, hardness and microstructural change of the magnesium wrought alloy AZ61 was investigated. Damping and hardness behaviour could be attributed to the evolution of precipitation process. The influence of precipitation on damping behaviour was explained in the framework of the dislocation string model of Granato and Lücke.     

Effect of Rare Earth Doping on Impedance,Modulus and Conductivity Properties of Multiferroic Composites:0.5(BiLa_xFe_(1-x)O_3)–0.5(PbTiO_3)

The Lanthanum-doped bismuth ferrite–lead titanate compositions of 0.5(Bi LaxFe1-xO3)–0.5(Pb Ti O3)(x = 0.05,0.10,0.15,0.20)(BLxF1-x-PT) were prepared by mixed oxide method.Structural characterization was performed by X-ray diffraction and shows a tetragonal structure at room temperature.The lattice parameter c/a ratio decreases with increasing of La(x = 0.05–0.20) concentration of the composites.The effect of charge carrier/ion hopping mechanism,conductivity,relaxation process and impedance parameters was studied using an impedance analyzer in a wide frequency range(102–106Hz) at different temperatures.The nature of Nyquist plot confirms the presence of bulk effects only,and non-Debye type of relaxation processes occurs in the composites.The electrical modulus exhibits an important role of the hopping mechanism in the electrical transport process of the materials.The ac conductivity and dc conductivity of the materials were studied,and the activation energy found to be 0.81,0.77,0.76 and 0.74 e V for all compositions of x = 0.05–0.20 at different temperatures(200–300 °C).     

Quantitative Analysis of the Crystallographic Orientation Relationship Between the Martensite and Austenite in Quenching–Partitioning–Tempering Steels

The orientation relationships(ORs)between the martensite and the retained austenite in low-and medium-carbon steels after quenching–partitioning–tempering process were studied in this work.The ORs in the studied steels are identified by selected-area electron diffraction(SAED)as either K–S or N–W ORs.Meanwhile,the ORs were also studied based on numerical fitting of electron backscatter diffraction data method suggested by Miyamoto.The simulated K–S and N–W ORs in the low-index directions generally do not well coincide with the experimental pole figure,which may be attributed to both the orientation spread from the ideal variant orientations and high symmetry of the low-index directions.However,the simulated results coincide well with experimental pole figures in the high-index directions{123}_(bcc).A modified method with simplicity based on Miyamoto’s work was proposed.The results indicate that the ORs determined by modified method are similar to those determined by Miyamoto’method,that is,the OR is near K–S OR for the low-carbon Q–P–T steel,and with the increase of carbon content,the OR is closer to N–W OR in medium-carbon Q–P–T steel.     

Using Finite Element and Contour Method to Evaluate Residual Stress in Thick Ti-6Al-4V Alloy Welded by Electron Beam Welding

This work was to reveal the residual stress profile in electron beam welded Ti-6Al-4V alloy plates(50 mm thick) by using finite element and contour measurement methods.A three-dimensional finite element model of 50-mmthick titanium component was proposed,in which a column–cone combined heat source model was used to simulate the temperature field and a thermo-elastic–plastic model to analyze residual stress in a weld joint based on ABAQUS software.Considering the uncertainty of welding simulation,the computation was calibrated by experimental data of contour measurement method.Both test and simulated results show that residual stresses on the surface and inside the weld zone are significantly different and present a narrow and large gradient feature in the weld joint.The peak tensile stress exceeds the yield strength of base materials inside weld,which are distinctly different from residual stress of the thin Ti-6Al-4V alloy plates presented in references before.     

Microstructures and Tensile Properties of Ultrafine-Grained Ni–(1–3.5) wt% SiC_(NP) Composites Prepared by a Powder Metallurgy Route

Silicon carbide nanoparticle-reinforced nickel-based composites(Ni–Si CNP),with a Si CNPcontent ranged from1 to 3.5 wt%,were prepared using mechanical alloying and spark plasma sintering.In addition,unreinforced pure nickel samples were also prepared for comparative purposes.To characterize the microstructural properties of both the unreinforced pure nickel and the Ni–Si CNPcomposites transmission electron microscopy(TEM) was used,while their mechanical behavior was investigated using the Vickers pyramid method for hardness measurements and a universal tensile testing machine for tensile tests.TEM results showed an array of dislocation lines decorated in the sintered pure nickel sample,whereas,for the Ni–Si CNPcomposites,the presence of nano-dispersed Si CNPand twinning crystals was observed.These homogeneously distributed Si CNPwere found located either within the matrix,between twins or on grain boundaries.For the Ni–Si CNPcomposites,coerced coarsening of the Si CNPassembly occurred with increasing Si CNPcontent.Furthermore,the grain sizes of the Ni–Si CNPcomposites were much finer than that of the unreinforced pure nickel,which was considered to be due to the composite ball milling process.In all cases,the Ni–Si CNPcomposites showed higher strengths and hardness values than the unreinforced pure nickel,likely due to a combination of dispersion strengthening(Orowan effects) and particle strengthening(Hall–Petch effects).For the Ni–Si CNPcomposites,the strength increased initially and then decreased as a function of Si CNPcontent,whereas their elongation percentages decreased linearly.Compared to all materials tested,the Ni–Si CNPcomposite containing 1.5% Si C was found more superior considering both their strength and plastic properties.     

Directional Growth of Tin Crystals Controlled by Combined Solute Concentration Gradient Field and Static Magnetic Field

A new method was introduced to achieve directional growth of Sn crystals. Microstructures in liquid(Pb)/liquid(Sn) diffusion couples were investigated under various static magnetic fields. Results show that the β-Sn crystals mainly reveal an irregular dendritic morphology without or with a relatively low static magnetic field(B0.3 T). When the magnetic field is increased to 0.5 T, the β-Sn dendrites close to the final stage of growth begin to show some directional character. With a further increase in the magnetic field to a higher level(0.8–5 T), the β-Sn dendrites have an enhanced directional growth character, but the dendrites show a certain deflection. As the magnetic field is increased to 12 T, the directional growth of the β-Sn dendrites in the center of the couple is severely destroyed. The mechanism of the directional growth of the β-Sn crystals and the deflection of the β-Sn crystals with the application of static magnetic field was tentatively discussed.     

Growth Kinetics of Single Inclusion Particle in Molten Melts

On the basis of the single-particle framework, a new theory on inclusion growth in metallurgical melts is developed to study the kinetics of inclusion growth on account of reaction and collision. The studies show that the early growth of inclusion depends on reaction growth and Brawnian motion collision, and where the former is decisive, the late growth depends on turbulence collision and Stokes＇ collision, and where the former is dominant; collision growth is very quick during the smelting process, lessened in the refining process, but nearly negligible in the continuous casting process.