RELATIONSHIP BETWEEN J-INTEGRAL AND FRACTURE SURFACE AVERAGE PROFILE

To investigate the causes that led to the formation of cracks in materials, a novel method that only considered the fracture surfaces for determining the fracture toughness parameters of J-integral for plain strain was proposed The principle of the fracture-surface topography analysis （FRASTA） was used. In FRASTA, the fracture surfaces were scanned by laser microscope and the elevation data was recorded for analysis. The relationship between J-integral and fracture surface average profile for plain strain was deduced. It was also verified that the J-integral determined by the novel method and by the compliance method matches each other well.     

DETERMINATION OF SOME PARAMETERS OF CRACK BASED ON FRASTA SIMULATION

A new method, using the fracture-surface topography analysis （FRASTA）, of determining the parameters of rotation factor and CTOA is provided. The fracture surfaces are scanned by laser microscope and the height data is recorded to analyze. By comparing the crack extension, plastic rotation factor and COA obtained by the method of double clip gauge and by this new method respectively, the validity of it is verified. It is then used to determine the CTOA. .The critical CTOA is well determined in this paper. Also by the new method, the variation of crack opening deformation （COA and CTOA） through specimen thickness can be obtained which can＇t be obtained by the usual methods. It also can provide much information of crack extension such as direction and ratio.     

Study on the Relationship Between J-Integral and COD

J-integral and crack opening displacement δ (COD) were important parameters for characterization of fractures in engineering materials. The relationship between J-integral and COD has been investigated for a long time and was generally represented as J = m σyδ, where σy is the yield strength and m is a function of specimen geometry and material properties. To determine the value of m, extensive studies and experiments have been performed. The method that used the fracture-surface topography analysis (FRASTA) for determining J-integral from fracture surfaces of materials was introduced. On the basis of the relationship between COD and fracture surface average profile, the relationship between J-integral and COD was deduced and compared with the generally used equation. The method was experimentally confirmed to be able to provide a new way to determine the relationship between J-integral and COD.     

不同加载频率下GCr15钢超高周疲劳行为的研究

分别采用常规和超声疲劳的试验方法,结合断裂力学理论以及FRASTA仿真,开展了GCr15钢超高周疲劳破坏行为的研究。结果表明,根据裂纹萌生位置的不同,疲劳破坏分为表面和内部破坏两种,其中内部破坏伴有granular bright facet(GBF)现象的产生,整个内部裂纹具有Fish-eye形貌特征。材料的疲劳S-N曲线呈现持续下降的趋势,ΔKGBF(4～4.2MPa·m1/2)是控制内部裂纹扩展的临界参数,超声疲劳试验提高了材料的疲劳强度,高强度钢的超高周疲劳行为的研究应采用常规试验为主,超声为辅的试验方法。     

Springback prediction for incremental sheet forming based on FEM-PSONN technology

In the incremental sheet forming (ISF) process, springback is a very important factor that affects the quality of parts. Predicting and controlling springback accurately is essential for the design of the toolpath for ISF. A three-dimensional elasto-plastic finite element model (FEM) was developed to simulate the process and the simulated results were compared with those from the experiment. The springback angle was found to be in accordance with the experimental result, proving the FEM to be effective. A coupled artificial neural networks (ANN) and finite element method technique was developed to simulate and predict springback responses to changes in the processing parameters. A particle swarm optimization (PSO) algorithm was used to optimize the weights and thresholds of the neural network model. The neural network was trained using available FEM simulation data. The results showed that a more accurate prediction of springback can be acquired using the FEM-PSONN model.     

Molecular Dynamics Simulation of the Surface Energies of High—Index Surfaces in Metals

利用嵌入原子型原子间相互作用势的分子动力学，计算了金属A1，Cu，Ni位于两个晶带上([001］晶带和[110］晶带)一系列高Miller指数面的表面能．推广了基于表面结构单元模型的经验公式,计算结果表明，利用本文推广的经验公式可根据几个低Miller指数面的表面能估计出高Miller指数面的表面能和表面结构特征,最密排面的表面能最低；最密排面(111)和次密排面(110)，(100)的表面能分别是表面能值随晶向角度θ变化曲线上的极小值；理论模拟结果、公式计算结果和已有的实验数据三者符合得较好。     

A New Method to Calculate Threshold Values of Ductile Fracture Criteria for Advanced High-Strength Sheet Blanking

A new approach is presented in this paper to calculate the critical threshold value of fracture initiation. It is based on the experimental data for forming limit curves and fracture forming limit curves. The deformation path for finally a fractured material point is assumed as two-stage proportional loading: biaxial loading from the beginning to the onset of incipient necking, followed plane strain deformation within the incipient neck until the final fracture. The fracture threshold value is determined by analytical integration and validated by numerical simulation. Four phenomenological models for ductile fracture are selected in this study, i.e., Brozzo, McClintock, Rice-Tracey, and Oyane models. The threshold value for each model is obtained through best-fitting of experimental data. The results are compared with each other and test data. These fracture criteria are implemented in ABAQUS/EXPLICIT through user subroutine VUMAT to simulate the blanking process of advanced high-strength steels. The simulated fracture surfaces are examined to determine the initiation of ductile fracture during the process, and compared with experimental results for DP780 sheet steel blanking. The comparisons between FE simulated results coupled with different fracture models and experimental one show good agreements on punching edge quality. The study demonstrates that the proposed approach to calculate threshold values of fracture models is efficient and reliable. The results also suggest that the McClintock and Oyane fracture models are more accurate than the Rice-Tracey or Brozzo models in predicting load-stroke curves. However, the predicted blanking edge quality does not have appreciable differences.     

基于内聚力模型的AISI4135高强钢氢致滞后断裂数值模拟

基于有限元ABAQUS软件,利用内聚力模型和与H相关的线性内聚力—张开位移率关系,开发了顺次耦合的氢致滞后断裂有限元计算程序,预测了预充H的AISI4135高强钢圆柱缺口试样在常载荷拉伸条件下的滞后断裂时间和裂纹萌生位置,同时考察初始H含量、缺口尖端应力集中系数和拉伸载荷对滞后断裂的影响,并和文献报道的相关实验结果进行比较.结果表明,CZM模型能够较好地模拟预充H高强度钢的氢致滞后断裂过程,预测结果和实验结果基本一致.氢致滞后断裂存在H临界值,当缺口尖端高应力区聚集的H浓度达到临界值时,裂纹才会在此萌生,此临界值与材料所受的载荷大小、缺口尖端的应力集中系数(缺口半径)有关,而与初始H浓度无关随着缺口尖端应力集中系数、拉伸载荷的降低,滞后时间将显著增大,临界H浓度也增大.     

Investigation of Mechanical Properties and Fracture Simulation of Solution-Treated AA 5754

In this work, mechanical properties and fracture toughness of as-received and solution-treated aluminum alloy 5754 (AA 5754) are experimentally evaluated. Solution heat treatment of the alloy is performed at 530 °C for 2 h, and then, quenching is done in water. Yield strength, ultimate tensile strength, impact toughness, hardness, fatigue life, brittle fracture toughness \((K_{\text{Ic}} )\) and ductile fracture toughness \((J_{\text{Ic}} )\) are evaluated for as-received and solution-treated alloy. Extended finite element method has been used for the simulation of tensile and fracture behavior of material. Heaviside function and asymptotic crack tip enrichment functions are used for modelling of the crack in the geometry. Ramberg-Osgood material model coupled with fracture energy is used to simulate the crack propagation. Fracture surfaces obtained from various mechanical tests are characterized by scanning electron microscopy.     

EFFECT OF GRAPHITE NODULES ON FRACTURE TOUGHNESS OF NODULAR CAST IRON

本文在球铁三点弯曲试件的裂纹尖端区模拟球铁材料的微观结构,建立了宏观与微观相结合的局部复相离散计算模型和复相材料中J积分基本关系式,编制了适合计算多相材料弹塑性大应变及J积分的有限元程序,对石墨形状、大小及体积百分比等对球铁应力强度因子及断裂韧性的影响作了比较全面的分析,和相应实验结果符合得较好。     

复合加载方式作用下熔合线上含裂纹焊接接头的裂端场与断裂参量

针对复合载荷作用下熔合线含裂纹的焊接接头,应用弹塑性有限元方法分析了其裂端应力场的分布规律.并对不同组配焊接接头的COD断裂参量及其复合角进行了数值计算,讨论了加载角度和接头强度组配对焊接接头断裂行为及断裂参量的影响机制.研究结果表明,对于复合载荷作用下的熔合线含裂纹焊接接头,其裂端应力场同时受到加载角度以及材料非均匀性的影响.当加载角度较小时,复合载荷对接头性能的影响相对于接头组配的影响更为显著.而当加载角度达到并超过30°时,情况与之相反.     

基于扩展有限元的Q345R材料平板裂纹扩展模拟研究

Q345R钢具有良好的综合力学性能和工艺性能,是制造压力容器最常用的材料之一。裂纹是造成压力容器失效和破坏的首要原因,在压力容器的检测和维护过程中,对裂纹的产生和发展进行模拟和分析具有重要的意义。本研究针对Q345R钢使用过程中常出现的中心裂纹和单边裂纹两种典型的裂纹形式,运用扩展有限元方法,分别模拟在拉伸状态下的中心裂纹、在低周疲劳作用下的单边裂纹扩展过程;并分析裂纹扩展过程中不断变化的裂纹尖端处的应力、应变,研究裂纹在Q345R材料中的扩展规律。结果表明:在裂纹扩展变化的过程中,应力集中现象首先会在裂纹尖端处出现,裂纹面处的应力最小,裂纹面两端应力对称分布,整个应力分布趋势符合断裂力学理论,证明通过运用扩展有限元方法来对Q345R材料中的裂纹扩展过程模拟分析的可靠性。     

Effect of three dimensional stress state on unstable fracture condition and crack opening level in a new crack growth model

A new model for the analysis of fatigue crack growth in the metal structures was proposed. This model shows a promising capability of explaining various fatigue phenomena. The new crack growth model is further completed by a continuous empirical formula for estimating the value of variable fracture toughness during crack propagation and a modified continuous equation for the crack tip stress/strain constraint factor used to calculate the stress intensity factor at the opening level. The prediction results are proved to agree well with the observed phenomena in test.     

800MPa级DP钢冲压成形及裂纹扩展机理

通过冲压弯曲试验研究800MPa级DP钢的极限拉伸,采用扫描电子显微镜观察分析钢板的微观组织及动态拉伸过程,探讨其微观组织与其稳机理的关系。结果表明,DP800钢断口为剪切型断裂。凸模圆角半径较小时,拉深弯曲断裂是由于折弯角过小而在凸模圆角处折弯断裂;凸模圆角半径较大时,冲压弯曲断裂由于受到板料延伸率的限制,在材料流动受限的凹模圆角附近断裂。DP800的断口均分布着大量韧窝的韧性断裂,其裂纹扩展机理是微裂纹,主要产生于铁素体或马氏体/铁素体相界面,主裂纹沿两相界面或贯穿铁素体而继续扩展。     

单边缺口拉伸试样的断裂韧性计算方法对比

在工程临界评估（engineering critical assessment）中,裂纹尖端张开位移（CTOD值）的精确性将极大影响设计安全裕度与服役寿命.单边缺口拉伸（SENT）试样裂纹尖端的应力应变场与管道在实际服役状况下相似,被认为比较适用于测量管道CTOD值.目前有几种针对SENT断裂韧性的计算方法,但是并没有统一的标准.文中采用API X70管线钢,进行SENT试样断裂韧性试验并对比各计算方法与双刀口法之间的区别.采用Crackwise 4.0评估了不同计算方法得到韧性值对裂纹极限尺寸的影响.结果表明,几种CTOD计算方法相较于双引伸计法都有较大误差,断裂韧性的精确度对于ECA评估极限裂纹尺寸有极大影响.     

A micromechanical bridging law model for CFCCs

In the present work, a methodology is presented for the assessment of bridging laws for continuous fibre-reinforced ceramic matrix composites based on material properties as well as micromechanics of fibre deformation and failure. A load–displacement model is initially formulated that utilizes weakest-link statistical concepts to analyse and relate the individual contributions of matrix, intact/bridging and failed/pull-out fibres during the composite fracture process. The total and individual contributions to the bridging law and crack growth resistance of the material are determined by identifying the non-elastic part of displacement as crack opening. The model is validated against the experimentally recorded load–displacement behaviour of a notched SiC-fibre-reinforced glass–ceramic matrix composite tested under monotonic tension. The output parameters of the converged regression procedure remain within a small scattering range from the corresponding mean values that compare favourably with known material properties. A parametric analysis of the effect of fibre volume fraction, Weibull modulus of fibres and interfacial shear stress in overall composite performance is presented in view of the ability of the model to serve as an a priori fracture prediction tool.     

弹壳引深工序中断裂研究

针对弹壳引深工序中盂子断裂的问题,根据经典的单模引深理论推导了多模引深应力计算理论模型,结合Deform软件对枪弹弹壳多模连续引深过程进行仿真分析,得到弹壳引深过程中影响盂子毛坯断裂处应力变化的参数及其应力变化曲线,分析了盂子毛坯口部的材料流动情况。结果表明,弹壳引深工序中盂子毛坯断裂的原因是下模定径部盂子材料富集,增大了下模变薄比与材料变形抗力。将引深下模的锥角减小后,口部富余体积变小。对比引深过程中应力的实验测量数据与数值模拟数据,吻合度较好,验证了模拟的可靠性,为弹壳引深工序中模具设计及其参数优化、提高材料利用率提供了可靠的依据。     

高强铝板韧性断裂准则参数求解及其成形极限

为确定符合高强铝板变形规律的韧性断裂准则的断裂参数,设计了10种不同形状和缺口的拉伸试样,分别采用积分式方程组法、解析式方程组法和曲面拟合法求解韧性断裂准则的多组断裂参数。通过分析统计理论断裂应变与试验断裂应变之间的相对误差评价了断裂参数的预测精度。结果表明:采用积分式方程组法和解析式方程组法依据误差分析分别筛选出的两组试样组合方案的预测精度均较好(误差均值小于30%),而曲面拟合法由于样本数据较少预测误差较大。根据积分式方程组法、解析式方程组法和曲面拟合法求解的最优断裂参数,应用Lou-Huh 2013准则绘制7075-T6高强铝板成形极限图,并采用半球形刚模胀形试验进行验证。验证结果表明:积分式和解析式方程组法预测7075-T6高强铝板破裂失稳偏于安全,这与参数求解时断裂起始点的选取偏于安全有关。     

A study on distribution of plastic region near a crack tip using three-dimensional molecular dynamics simulation

Molecular dynamics simulation is emerging with recent advent of high-performance computers. This paper addresses an application of molecular dynamics simulation to calculation of stress intensity factors (SIF) of a material using a three-dimensional molecular model. Since the popular molecular models such as Lennard-Jones model fails to compute behaviors of materials correctly, in this paper the embedded atomic model (EAM) was utilized. A copper plate with a single edge crack is considered to calculate SIFs in opening mode. More than ten thousand of molecules were used for the simulation and due to a large amount of computation, a super computer CRAY C90 was employed. The results show good agreement with the theoretical SIF values.