线性摩擦焊过程数值模拟研究现状

线性摩擦焊是20世纪80年代出现的一种新型的固态焊接方法,主要用来焊接非圆截面的同种及异种金属结构材料,由于其具有一系列独特的优点,已成为航空发动机整体叶盘制造的关键技术。虽然关于线性摩檫焊的研宄已有文献报道,但是由于该过程的强烈热力耦合、快速大变形等特征,其界面结合机理和演变过程等问题还尚未揭示。因此,研究者尝试采用数值模拟方法来研究焊接过程中应力应变场、残余应力、温度场与变形等关键问题。文中主要综述了线性摩擦焊数值模拟的基础和近年来国内外的研究现状,最后展望了线性摩擦焊数值模拟的不足与发展前景,以期为今后研宄提供思路。     

A numerical study of various plastically unstable behaviors in tension and compression

Various types of behavior due to plastic instability under uniaxial tension and compression are numerically investigated regarding sheet materials, plane strain blocks, and cylindrical bars and hollow cylinders. The code GOLDA for analysis of large elastic-plastic deformation previously developed by the author is used, which is one of quasi-static explicit FEM programs. Both of diffuse type and localized type of instability are concerned with. The role of vertex-hardening in plastic instability is payed attention, by using the J2G (J2-Gotoh’s corner theory) as the plasticity constitutive equation, which was proposed previously by the author and is a kind of vertex-hardening theory. Following results are mainly derived. 1) In plane strain tension, shear-type strain localization is realized by the use of J2G, but not by the conventional J2F (J2-flow theory). In axisymmetric tension of a cylindrical solid bar, however, such strain localization would never appear even by J2G, as expected by the experiment. 2) In axisymmetric tension of a hollow cylinder under the condition of no contractlion of its bore (therefore, in almost plane strain state with no circumferential strain), it is found that shear-type strain localization could occur. This is realized again by the use of J2G, whereas J2F never allows such strain localization. 3) In compression under the embedded edges condition, it is found that a sheet with initial aspect ratio of 2:1 (in height:breadth) yields double barreling, whereas a plane strain block yields double barreling at the initial aspect ratio of 3:1, not at 2:1 though expected from the conventional slip-line theory. As for a cylindrical solid bar, double barreling appears for the initial aspect ratio of 2:1 but only for higher n-vaiue (the strain hardening exponent), say n=0.5. 4) As for barreling mode, when thick-walled axisymmetric tubes with the initial ratio of thickness to inner diameter 1/5 to 1/3 are compressed axially, corresponding to the initial aspect ratios of 3:1, 2:1 and 1:1, triple barreling, double barreling and single barreling appear, respectively. 5) It is found that thin-walled tubes buckle in a progressive periodic mode with almost stationary compressive load under axial compression. Thus it can be used as a simplified model for buckling of more complex structures such as the honeycomb.     

Mesoscale analysis of dynamic fragmentation of ceramics under tension

The fragmentation of a small ceramic specimen subjected to rapid uniform expansion is analyzed numerically at the mesoscale level using the cohesive/volumetric finite element (CVFE) scheme. The analysis is performed in plane strain and assumes intergranular crack motion. A combination of cohesive and optimization-based contact enforcement algorithms is used to model the complex contact events between the fragments generated in the process. The damage process is quantified using two parameters: one to capture the evolution of distributed damage in the ceramic specimen, and the other to represent the dynamic creation of discrete fragments. The basic features of the fragmentation process such as the initiation time and the evolution of the fragment size distribution are investigated. It is observed that the linear exponential distribution proposed by Grady and Kipp [Geometric statistics and dynamic fragmentation. J. Appl. Phys 1985;58(3)1210–22] adequately represents the cumulative fragment distribution throughout the fragmentation process. We also quantify the effect of the failure strength on the initiation and extent of damage. The granular microstructure of the specimen does not affect the initiation time of the fragmentation, but the average grain size influences the final damage of the material and has an effect on the average fragment size at higher loading rates. The average fragment size obtained numerically for a range of loading rates shows good agreement with existing theoretical models.     

Strategies for numerical simulation of linear friction welding of metals: a review

Linear friction welding (LFW) is a solid-state joining process used to weld non-axisymmetric components. Material joining is obtained through the reciprocating motion of two specimens undergoing an axial force. During this process, the heat source is determined by the frictional work transformed into heat. This results in a local softening of the material and plays a key role in the onset of the bonding conditions. In this paper, a critical analysis of the different approaches used to simulate the LFW processes is provided. The focus of the paper is the comparison of different modeling strategies and the most relevant outputs available, i.e. temperature, strain and stress distribution, material flow, axial shortening and residual stress. Major issues arising due to the complexity of the process are discussed, highlighting strengths and weaknesses of each approach.     

数控机床用直线式交流伺服电机及其控制策略

对现有的直线交流伺服电机进行了概述。就感应直线交流伺服电机和永磁直线交流伺服电机的结构及其控制策略等进行了阐述,指出了其相应的特点,并对发展我国直线式交流伺服系统提出了几点建议。     

数值模拟在焊接中的应用分析

焊接是一个复杂的物理化学过程,传统的试验方法研究焊接现象不仅成本高、效率低,而且其应用存在一定的局限性,但单纯采用理论方法又很难准确地解决生产中存在的实际问题.借助计算机技术对焊接现象进行数值模拟,可以研究各种复杂的焊接问题,对焊接结构生产具有重要的指导意义.讨论焊接数值模拟技术的基本原理和主要模拟方法,综述数值模拟技术在焊接温度场分析、焊接应力应变分析、焊接冶金和焊接接头组织性能分析方面的应用及研究现状,指出了焊接数值模拟技术的主要发展方向.     

Single block 3D numerical model for linear friction welding of titanium alloy

ABSTRACT

A two-stage approach for the simulation of Linear Friction Welding is presented. The proposed model, developed using the commercial simulation package DEFORM, is 3D Lagrangian, thermo-mechanically coupled. The first phase of the process was modelled with two distinct workpieces, while the remaining phases were simulated using a single-block model. The Piwnik–Plata criterion was set up and used to determine the shifting from the dual object to the single-block model. The model, validated against experimental temperature measurements, is able to predict the main field variables distributions with varying process parameters. Titanium alpha and beta phases evolution during the whole process has been predicted and the obtained results have been correlated to the experimentally measured micro-mechanical properties of the joints.     

Scanning Kelvin probe analysis of the potential distribution under small drops of electrolyte

The scanning Kelvin probe has been used to map the potential distribution under small drops of NaCl placed on carbon steel, galvanized steel, stainless steel and an aluminum alloy. The concentration of NaCl has been varied and the effect of chromate as inhibitor has been evaluated. In the absence of chromate local anodes and cathodes were established in a short time. For carbon steel similar potential profiles were observed in NaCl and NaClO₄. However for stainless steel a much larger potential decrease in the center of the drop occurred in 0.5 N NaCl than in 0.5 N NaClO₄ and a marked effect of chloride concentration was observed. When dichromate was added to NaCl a very uniform potential distribution was found for stainless steel and Al 2024. The main driving force for development of local anodes arises from oxygen reduction in very thin films of electrolyte surrounding the NaCl drop.     

Thermo-mechanical analysis and optimal tension control of micro wire electrode

The tension control of the micro wire electrode is a key technology for the micro wire electro-discharge machining (WEDM). Based on the coupled thermo-mechanical analysis, both the three-dimensional temperature and the stress distribution in the micro wire are determined. As a result, the tension of the micro wire electrode during the WEDM process can be optimized in accordance with the discharge energy, which is sampled and fed back to the tension control system in real time. Then the development of an optimal tension control system characterized by the form of master–slaver structure makes it possible to keep the wire tension optimal in the process of WEDM. The results of the machining experiments show that the optimal wire tension control is effective on the improvement of the machining accuracy with the prevention of wire breakage for the micro WEDM.     

Data perturbation analysis of a linear model

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3D numerical investigation of effects of density and surface tension on mixing time in bottom-blown gas-stirred ladles

In molten phase metallurgical processes, mixing via gas injection has a vital role in obtaining a homogeneous product. The efficiency of mixing depends on operational variables such as gas flow rate and slag height as well as physical properties of the molten phases. A numerical simulation is conducted to study the above parameters in the flow behavior of a bottom-blown bath. The molten metal and the slag are modeled by water and oil, respectively. The numerical results, particularly the mixing time, are validated against experimental data. The results show that mixing time increases as the slag height increases and decreases as the density of the slag material increases. The mixing time decreases with an increase in the density of the primary phase; however, it increases as the surface tension between air and water increases. A case with properties close to a real molten metal is also modeled. The performance of the system is influenced by the momentum rather than the dissipative forces. Thus, the effect of the density of the molten phase on the mixing process is more pronounced compared to the effect of the surface tension between the air and the molten phase.     

The surface and the linear tension and the contact angle of a small drop under isothermal conditions

A small lying drop is investigated considering the linear tension at the three-phase boundary under thermodynamic and mechanical equilibrium. Formulas for the surface tension at the liquid-vapor interface, the linear tension, and the contact angle are found by the Gibbs dividing surface method. It is shown that the surface tension and the contact angle decrease while the absolute value of the linear tension increases with decreasing radius of the surface curvature. Comparison of theoretical predictions with experimental data obtained by atomic-force microscopy shows a satisfactory agreement and evidences that the linear tension must be negative.