环保无铅黄铜材料的研究进展

传统易切削黄铜多为含铅黄铜,如HPb59—1、HPb63—3等,广泛应用于五金件、手表零件、汽车零件、制冷设备、家电以及卫浴等领域。含铅黄铜零部件报废后,以各种途径污染环境。近年来,随着环保要求的提高,促进了无铅易切削黄铜的研制,发展低铅及无铅黄铜材料已成为一种趋势。用铋、锑、硅、碲、镁等元素来代替铅是实现无铅易切削黄铜材料的较好途径,许多研究单位已经开发了无铅易切削黄铜产品,其切削性能和强度等接近于普通铅黄铜,但是,这些产品的冷、热加工性能尚需要进一步提高,以达到替代铅黄铜的目的。本文综述了国内外环保易切削黄铜的研究现状并且对其发展前景进行了展望。     

无铅易切削黄铜的研究进展

随着世界各国对铅造成的污染和危害的重视,含铅黄铜的使用受到越来越多的限制,开发低成本无铅易切削黄铜迫在眉睫。本文根据无铅黄铜第三组元的选择特性,从组织结构、易切削机理、加工工艺、耐腐蚀性能四个方面综述了国内外无铅易切削黄铜合金的研究现状,并详细分析了铋、锑的凝固行为对合金显微组织和性能的影响,重点介绍了无铅易切削钙磷黄铜合金的微观组织、能谱分析结果、力学性能和切削性能,提出了当前工作中存在的问题,并对今后的研究趋势进行了展望,期待能够在无铅易切削黄铜的研究及实际应用中起到一定的指导作用。     

无机非金属材料中的无铅化研究进展

在目前的材料生产中,大量的无机非金属材料都含有铅。随着社会对环境保护和人类健康意识的加强,环境友好型高性能无铅材料的开发研究已成为世界范围内材料产业可持续发展的趋势。综述了铅在目前日常生活中的应用和危害以及无机非金属材料无铅化的研究进展。指出在尖端科技、军事领域产品的开发中,目前其它元素是无法完全替代铅的,而在民用生产中,完全可用铋、锡及其它元素去取代铅,开发无铅材料产品。     

铋对无铅易切削黄铜性能的影响

考察了0.3～0.9%的铋对无铅铋黄铜合金力学性能、切削性能的影响.通过力学性能的检测和切削性能的测定,表明随着铋含量的增加,合金的强度没有显著变化,延伸率降低,硬度增加,切削性能得到改善.添加了0.3%Ti的铋黄铜中,0.6%的铋含量的易切削黄铜力学性能适中,且切削性能与铅黄铜相当,具有广阔的应用前景.     

石墨化易切削钢的变形抗力

石墨化易切削钢是顺应易切削钢无铅、低硫这一发展趋势而提出的。本文制备了以铁素体和石墨为组织特征的石墨化易切削钢的试验用钢,同时利用Gleeble-1500热模拟试验机,在变形温度T为850~1050℃,应变速率为1.0、10s-1条件下,对试验用钢进行了单道次高温轴向压缩试验,测得了高温应力-应变曲线。曲线分析结果表明,该钢的变形抗力随着变形温度的升高而降低,随着应变速率的增加而增加,应变速率10s-1时的应力-应变曲线呈现为再结晶型。基于上述分析,建立了试验用钢的变形抗力数学模型,并给出其具体参数。变形抗力实测值与按照模型计算的预测值吻合较好。     

添加锡铋元素对铅钙电极合金性能的影响

从金相、硬度、析氧电压及板栅腐蚀,对铅酸蓄电池铅钙(Ca 0.08%)板栅合金中添加锡、铋的作用与影响进行了研究,对实验数据进行了整理、分析和讨论.实验结果表明,锡、铋在铅钙板栅合金中的作用与影响有明显差别,且不同含量的锡、铋对合金的影响不同.     

无铅易切削铝合金

综述了国内外无铅易切削铝合金的研究概况,介绍了目前在美国铝业协会注册的易切削铝合金以及它们的化学成分范围,阐明了无铅易切削铝合金的两种切削机制以及合金元素对合金性能的影响,简述了易切削铝合金切削性能的等级分类,并指出了今后无铅易切削铝合金的研究方向.     

从发明专利看无铅压电陶瓷的研究与发展--无铅压电陶瓷2O年发明专利分析之一

无铅压电陶瓷的研究与开发已引起世界各国的高度重视.本文综合分析了近20年无铅压电陶瓷发明专利约140篇,从发明专利角度评述了无铅压电陶瓷的研究与发展现状,简要介绍了目前受到广泛研究的BaTiO3(BT)基无铅压电陶瓷、Bi1/2Na1/2TiO3(BNT)基无铅压电陶瓷、铋层状结构无铅压电陶瓷及铌酸盐系无铅压电陶瓷,并侧重介绍这些无铅压电陶瓷的组分、性能和制备方法.从无铅压电陶瓷发明专利的进展可以看出,在过去20年中,为促进人类社会的可持续发展,无铅压电陶瓷得到了广泛的研究和开发,并取得重要进展.     

稀土元素对无铅焊料性能的影响

随着公众环保意识的增强,含铅焊料的发展和应用受到了极大的限制,研制新型的、环境友好的无铅焊料来取代传统的锡铅焊料成为近年来研究的热点,而添加微量元素合金化以获得性能优异的无铅焊料尤其受到研究者的关注。本文系统地综述了添加微量稀土元素对无铅焊料物理化学性能、显微组织、力学性能、电迁移及锡晶须生长等的影响,并对稀土元素在无铅焊料中的应用及发展趋势进行了展望。     

铜基石墨复合材料的研究进展

铜基石墨复合材料是一种广泛应用于摩擦材料和电接触材料等领域的金属基复合材料.综述了铜基石墨复合材料在改善铜基体与石墨增强体结合方面的研究进展,主要包括基体合金化、石墨的表面处理、添加粘结剂等,重点介绍了铜基石墨复合材料的制备工艺方法,并概述了其导电导热性能、摩擦磨损性能、工艺性能及应用,最后展望了铜基石墨复合材料的研究重点和发展方向,认为取代现有的易切削铅黄铜合金将成为铜基石墨复合材料今后研究和应用的一个亮点.     

300M超高强度钢车削加工性能仿真模拟分析研究

目的研究不同切削参数对300M超高强度钢切削性能的影响。方法通过单因素试验法,采用Advant Edge切削仿真软件,建立300M钢三维有限元模型,对不同切削参数下车削300M钢的切削力、刀片温度、刀片应力及切屑形状进行分析。结果在300M钢车削过程中,刀片温度随着切削速度增大而增大,但切削力和刀片应力反之;背吃刀量和进给量越小,切削力、刀片应力及刀片温度越小;切削刃半径越小,切削力越小,但小的切削刃半径使得刀片应力变大,容易导致刀片磨损。车削300M钢的切屑呈锯齿螺旋状,切屑温度为带状分布,切削速度越高,进给量、背吃刀量越大,切削刃半径越小,切屑温度越高。结论在300M钢车削加工中,应选用较高的切削速度,适中的切削刃半径,较小的进给量和背吃刀量。     

Experimental and finite element predictions of residual stresses due to orthogonal metal cutting

The development and implementation of a finite element method for the simulation of plane-strain orthogonal metal cutting processes with continuous chip formation are presented. Experimental procedures for orthogonal metal cutting and measurement of distributions of residual stresses using the X-ray diffraction method are also presented. A four-node, eight degree-of-freedom, quadrilateral plane-strain finite element is formulated. The effects of elasticity, viscoplasticity, temperature, friction, strain-rate and large strain are included in this formulation. Some special techniques for the finite element simulation of metal cutting processes, such as element separation and mesh rezoning, are used to enhance the computational accuracy and efficiency. The orthogonal metal cutting experiment is set-up on a shaper, and the distributions of residual stresses of the annealed 1020 carbon steel sample are measured using the X-ray diffraction method. Under nominally the same cutting conditions as the experiment, the cutting processes are also simulated using the finite element method. Comparisons of the experimental and finite element results for the distributions of residual stresses indicate a fairly reasonable level of agreement. The versatility of the present finite element simulation method allows for displaying detailed results and knowledge generated by orthogonal metal cutting processes, such as the distribution of temperature, yield stress, effective stress, plastic strain, plastic strain-rate, hydrostatic stress, deformed configuration, etc. Such knowledge is useful to provide physical insights into the process as well as to better design the process for machining parts with improved performance.     

圆弧刃精密切削试验及其三维有限元分析

在商业化软件Marc的基础上建立了圆弧刃精密切削三维有限元模型,研究不同半径的圆弧刃精密切削条件下主切削力、切屑形状和切削温度场分布．该模型运用更新拉格朗日法的有限元方程、网格重划分准则,其刀一屑摩擦采用修正的库仑摩擦模型．模拟结果表明,圆弧刃的圆弧半径对主切削力、切屑形状和切屑的最高温度都有较大的影响．通过试验研究精密切削马氏体3J33在不同半径的圆弧刃条件下对主切削力的影响,结果表明模拟的主切削力与试验值在一定程度下是吻合的.     

A thermal stress and failure model for laser cutting and forming operations

A transient, full three-dimensional mathematical model that describes the ablation phenomena, the thermal stress evolution, and the failure process that occur during laser cutting or forming operations on ceramic plates is developed. The model development is based on the finite element simulation of thermal field and stress development during laser cutting or forming operations. To treat the ablation phenomena during laser cutting, a fixed-grid algorithm is applied to handle complex ablation geometries with discontinuities. This algorithm is essential for applications to multiple-laser cutting operations. The thermal and stress evolution model is further integrated with a probabilistic fracture model to assess the failure probability during both laser cutting and forming processes. Numerical results show that the groove shapes as well as the temperature and stress distributions are similar in front of the cutting laser for both single and dual lasers but differ in the region when the lead laser becomes effective in dual-beam machining.     

Nondestructive Evaluation of Welding Residual Stresses in Dissimilar Welded Pipes

This paper investigates the nondestructive capability of ultrasonic waves in residual stress evaluation of dissimilar welded pipes. Longitudinal critically refracted (L _CR ) waves are employed to measure the residual stresses in a pipe-pipe joint of stainless steel 304 and carbon steel A106. Measuring the acoustoelastic constant is usually accomplished through the tensile test which needs cutting the tested material to extract tensile test specimens. However, cutting the tested pipe to complement the nondestructive ultrasonic measurement was not considered here. Instead, a dissimilar welded plate with the same welding specification, joint geometry, thickness and the same dissimilar materials is used to extract tensile test samples. The measured acoustoelastic constant of the plate along with the measured time of flight of the L _CR wave on the pipe, are utilized for ultrasonic stress measurement. A finite element model of welding process validated by hole-drilling method is used to verify the ultrasonic results. The results show good agreement between finite element and ultrasonic measurements in the pipe measured without any destructive process.     

板式剪切型铅阻尼器的试验研究及有限元分析

提出一种新型的剪切型铅阻尼器,该装置中铅块直接嵌于滑动钢板与固定钢板的凹槽之间,构造简单。基于性能试验和有限元分析对该装置的滞回性能及关键参数进行了研究,研究结果表明:该阻尼器的滞回性能可以采用双线性模型加以模拟;阻尼器屈服阻尼力由铅块的剪切面积决定;加载曲线中弹性阶段与完全塑性阶段之间的过渡弧段的曲率半径与剪切铅块的长厚比成反比。     

填充不同材料条件下管材三维自由弯曲变形行为研究

目的 研究三维自由弯曲过程中,不同填充材料对管材成形性能的影响,比较不同填充材料的影响效果。方法 建立相关力学模型,分析比较固体填充物以及柔性填充物对成形质量不同的影响机理,并基于ABAQUS有限元仿真软件,对成形过程进行数值模拟分析。结果 与填充PU棒时成形结果相比,当填充SS304钢珠时,管材具有更好的成形性以及更小的厚度变化率,同时,当内部填充材料时,管材椭圆率均会降低,且当填充材料为SS304钢珠时,椭圆度最低可达2.6%。结论 将三维自由弯曲技术与填充成形技术相结合,可以有效提高管材成形性能,并且固体填充物要好于柔性填充物,有限元模拟及实验验证了模型的正确性。     

Failure Analyses of Six Cylinder Aircraft Engine Crankshafts

Results of failure analyses of two aircraft crankshafts are described. These crankshafts were forged from AMS 6414 (similar composition to AISI 4340) vacuum arc remelted steels with sulfur contents of 0.003% (low sulfur) and 0.0005% (ultra-low sulfur). A grain boundary sulfide precipitate was caused by overheat of the low sulfur steel, and an incipient melting of grain boundary junctions was caused by overheat of the ultra-low sulfur steel. The precipitates and incipient melting in these two failed crankshafts were observed during the examination. As expected, impact fractures from the low sulfur steel crankshaft contained planar dimpled facets (PDF) along separated grain boundaries with a small spherical manganese sulfide precipitates within each dimple. In contrast, PDFs along separated grain boundaries of impact fractures from the ultra-low sulfur crankshaft steel contained a majority of small spherical particles consisting of nitrogen, boron, iron, carbon, and a small amount of oxygen. Some other dimples contained manganese sulfide precipitates. Fatigue samples machined from the ultra-low sulfur steel crankshaft failed internally at planar grain boundary facets. Some of the facets were covered with nitrogen, boron, iron, and carbon film, while other facets were relatively free of such coverage. Results of experimental forging studies defined the times and temperatures required to produce incipient melting overheat and facets at grain boundary junctions of ultra-low sulfur AMS 6414 steels.     

游离磨料多股线线锯切割实验研究

游离磨料线锯切割是将磨浆中的磨粒通过一定速度的细钢丝线带入切割区域,达到去除工件材料的目的。多股线由多根细金属线绕制而成,表面具有很多凹槽,与钢丝线光滑表面相比,可以输送更多的磨粒进入切割区域,从而提高切割效率。应用0.25 mm的多股线和0.25 mm的钢丝线对光学玻璃K9进行切割对比实验,结果表明,在相同工艺条件下,多股线的切割效率和表面粗糙度均优于钢丝线,但切缝宽度大于钢丝线。     

热处理软点对圆锯片模态参数和刚度的影响

圆锯片己经被广泛应用于切割石材、木材、钢材等工程中。热处理作为圆锯片加工中重要的一道工序,热处理的质量对圆锯片的使用性能有很大的影响。热处理缺陷导致圆锯片产生软点,使得圆锯片的固有频率及刚度发生变化。本文采用有限元分析了热处理软点对圆锯片的模态参数以及刚度的影响。通过改变软点的弹性模量、软点直径大小以及软点的位置,分析了圆锯片的固有频率以及径向和切向刚度的变化规律。结果表明软点的存在降低了圆锯片的固有频率,软点直径越大,固有频率越小,软点距离中心越近,固有频率越小。软点的弹性模量越小,圆锯片的固有频率越小。软点的存在使得圆锯片的径向刚度和切向刚度都有所减小。