低碳钢焊缝金属强度组配对焊接残余应力分布的影响规律

采用热弹塑性有限元方法,对平板对接接头中焊缝金属强度组配对焊接残余应力分布的影响进行了研究。结果表明,对于高组配接头,纵向残余应力的峰值接近焊缝金属的屈服极限,出现在焊缝中心。对于低组配接头,纵向残余应力的峰值接近母材的屈服极限,并发生在焊缝附近。随着对含有残余应力的接头施加外载,焊缝金属强度组配对纵向应力分布的影响依然存在,但残余应力的影响在减小。对承受外载的焊接接头,逐步卸除外载后,焊缝横截面     

共晶基复相陶瓷中缺陷的稳定性分析

共晶基复相陶瓷材料中,不同相间的热膨胀系数的差异产生的缺陷是降低材料强度的重要因素。基于等效夹杂理论和相互作用直推估计法,计算得到颗粒周围缺陷在热残余应力和外载应力作用下的应力强度因子,研究了缺陷的扩展稳定性,并分析了颗粒刚度、形状、含量等参数对扩展稳定性的影响规律。结果显示:扁平形的颗粒环向最容易产生热裂纹;刚性颗粒能够在一定程度上降低外载应力在基体中平均作用效果,且长椭球状刚性颗粒的降低程度要大于扁椭球颗粒,因此有利于缺陷的稳定,柔性颗粒作用相反;当缺陷扩展量很小,应力强度因子主要受残余应力控制,缺陷扩展量较大时,应力强度因子主要受基体平均应力控制,长椭球形柔性颗粒有利于提高材料强度。     

冷胀提高6005铝合金疲劳寿命的机理

针对冷胀对6005铝合金疲劳裂纹产生和扩展的影响,用单边预切口试样研究了含缺陷结构冷胀后的疲劳寿命,分析了不同情况下新裂纹产生的循环数;并用ANSYS软件进行了数值模拟,确定冷胀产生的残余应力场和塑性区及在不同参数下冷胀度对其的影响.结果表明:孔径和冷胀度对最大残余压应力值影响不大,都在材料屈服强度1～1.1倍的限定范围内,而冷胀度对塑性变形区和残余压应力区大小的影响则非常显著.     

应力比对25Cr2Ni2MoV钢焊接接头近门槛值区疲劳裂纹扩展曲线转折点的影响

在常温下采用逐级降载法进行不同缺口位置、不同应力比下25Cr2Ni2Mo V钢焊接接头的疲劳裂纹扩展试验,研究疲劳裂纹扩展曲线上近门槛值区转折点的变化规律。结果表明,焊接接头的疲劳裂纹扩展曲线在近门槛值区内存在一个转折点,其对应的应力强度范围随应力比的增大而减小,其大小为疲劳门槛值的0.5~0.8。近门槛值区疲劳裂纹扩展转折点前后扩展曲线斜率发生变化表明裂纹扩展机理的改变,热影响区缺口处的转折行为对疲劳裂纹扩展影响较小。应力比R低于0.5时,循环塑性区尺寸总体接近于材料特征组织尺寸;应力比R高于0.5后,两者偏差加大。应力比低于0.5时转折点对应的循环塑性区尺寸同特征组织尺寸接近,驱动力由ΔK控制向Kmax主导的转变是引起转折点随应力比变化的原因。     

焊缝金属的屈服强度和材料的加工硬化对Q345钢焊接残余应力与变形计算精度的影响

建立合适的材料模型是有限元法准确预测焊接残余应力与变形的关键.基于有限元软件ABAQUS,采用热-弹-塑性有限元方法模拟Q345低合金高强钢平板对接接头的焊接残余应力与变形,探讨焊缝金属的屈服强度和材料的加工硬化对焊接残余应力和变形的影响.数值模拟结果表明,与理想弹塑性模型预测的结果相比,材料模型区分考虑母材和焊缝金属的屈服强度会明显增加焊缝及其附近区域的纵向残余应力,材料模型考虑材料的加工硬化及退火软化效应会显著增加焊接接头下表面的纵向和横向残余应力,材料模型考虑焊缝金属的屈服强度和材料的加工硬化及退火软化效应对平板对接接头角变形的影响较小.比较计算结果与试验结果可知,为准确地预测Q345钢接头焊接残余应力与变形,材料模型要区分考虑母材与焊缝金属的屈服强度、材料的加工硬化及退火软化效应.提出的材料模型为采用数值模拟方法高精度地获得Q345低合金高强钢接头或结构的残余应力与变形奠定了理论基础.     

用小孔释放法测量焊接高残余应力时孔边塑性变形对测量精度的影响及修正方法

研究了用小孔释放法测量焊接残余应力时孔边的塑性变形对测量精度的影响。根据弹塑性理论分析了孔边屈服的条件，并据此得到了孔边屈服后应变释放系数的修正公式，使小孔释放法测量焊接残余应力的精度得到提高，并且扩大了应力值的测量范围。对平板对接埋弧焊焊接接头残余应力的实测表明，修正后的残余应力分布更趋于合理。     

晶须长径比对树脂基复合材料力学行为影响的数值模拟

在单向晶须增强树脂基复合材料的轴对称模型和已有研究成果基础上,利用有限元分析方法,研究该类复合材料中晶须长径比的变化对材料整体力学行为的影响.结果表明:晶须长径比对晶须应力作用明显大于对基体的影响;晶须的长径比h/r≤30时,随着晶须长径比的增大,发生在晶须端部处的集中应力急剧增加;但当长径比h/r＞30时,长径比的进一步增加对集中应力影响不大;随着晶须长径比的增大,界面剪切应力减小,分布曲线下移;但当长径比h/r＞30时,长径比的进一步增加对剪切应力影响不大;随着晶须长径比的增加,复合材料的拉伸强度逐渐增大.     

残余应力对材料疲劳性能影响的某些进展

材料经表面形变强化可有效地提高材料的疲劳性能.以往主要研究形变强化工艺与零件疲劳寿命的关系.为进一步发挥材料强度潜力,近年来着重研究形变强化后残余应力、组织强化及表面光洁度等各因素对不同强度、不同缺口形状等材料的影响。本文从经典理论及断裂力学两方面结合所作的工作,介绍残余应力对材料疲劳性能影响研究的一些新进展。残余应力对疲劳极限的影响涉及如何选取残余应力值,残余应力对不同强度材料的作用,残余应力的多轴性,残余应力在缺口处的集中效应及其对缺口疲劳极限的影响等。断裂力学方法适用于分析裂纹在残余应力场中的扩展问题。研究表明残余应力不仅改变了载荷比,而且还使裂纹的闭台力发生变化,改变了有效应力强度因子范围及相应的裂纹扩展速率,它和残余应力导致的闭合力变化有较好的对应关系.     

基于Oxley理论的40CrMnMo合金钢车削过程剪切区应力应变行为研究

基于Oxley-Welsh切削理论和40Cr Mn Mo工件材料的车削试验,综合考虑剪切区材料尺寸变化、温度及加工硬化等因素对剪切区应力应变行为的影响,探讨了40Cr Mn Mo工件材料切削过程中切削用量对剪切区应力应变的作用规律。研究结果表明:车削过程中工件材料40Cr Mn Mo剪切区的静水压应力与剪切流动应力的差对40Cr Mn Mo工件材料的均匀塑性变形有显著影响;静水压应力大表明剪切区材料加工硬化作用明显,温度对工件材料热软化作用弱,材料塑性变形均匀;当v_c=115m/min、f=0.42mm/r、a_p=3.5mm时,40Cr Mn Mo工件材料剪切区静水压应力与剪切流动应力的应力差最大,其均匀塑性变形最佳,抗不均匀塑性变形能力最强。     

用小孔释放法测量焊接高残余应力时孔边塑性变形对测量精度的影响及修...

研究了用小孔释放法测量焊接残余应力时孔边的塑性变形对测量精度的影响。根据弹塑性理论分析了孔边屈服的条件，并据此得到了孔边屈服后应变释放系数的修正公式，使小孔释放法测量焊接残余力的精度得到提高，并且扩大了应力值的测量范围。对平板对接埋弧焊焊接接头残余应力的实测表明，修正后的残余应力分布更趋于合理。     

基于微塑性变形的振动时效激振力的选择

振动时效使残余应力峰值降低并得到均化的主要原因是材料内部微塑性变形的局部性。本文分析了静载荷及循环载荷下的微塑性变形行为，认为振动时效动应力的选择应以材料的疲劳极限作为依据。     

Effects of fiber aspect ratio evaluated by elastic analysis in discontinuous composites

An elastic stress analysis to investigate the effects of fiber aspect ratio in short fiber reinforced discontinuous composite materials has been done for different fiber volume fractions. In order to examine the elastic internal behavior, an evaluation of the load bearing capacity of discontinuous reinforcements is needed in advance. Accordingly, analytical derivation of composite mechanics has been carried out to predict fiber stresses and fiber/matrix interfacial shear stresses in discontinuous composites. The model is based on the theoretical development of conventional shear lag theory developed by Cox. However, the major shortcoming of the Cox model is due to the calculation without normal stress transfer from the end of fibers. In order to overcome the shortcoming, both of the normal and shear stress transfer mechanisms between the fiber and the matrix are accounted for with the stress concentration effects as well as material and geometrical properties. Results of predicted stresses concerning the various fiber aspect ratios are described by using the present model that is the closed form solution and compared with the Cox model and Taya model. It is found that the effect of fiber aspect ratio is significant to composite strengthening through load transfer from the matrix to the fiber, whereas the effect of fiber volume fraction is not so sensitive, relatively. It is also found that the present model has the capability to correctly predict the values of fiber stresses and fiber/matrix interfacial shear stresses.     

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.     

Simulation of thermal stresses due to grinding

An efficient finite element procedure has been developed to calculate the temperatures and stresses arising due to a moving source of heat. The procedure is applied to calculate the thermal stresses produced in hardened steels during grinding. The thermal load during grinding is modeled as a uniformly or triangularly distributed, 2D heat source moving across the surface of a half-space, which is insulated or subjected to convective cooling. The grinding of elastic and elastic–plastic workpiece materials has been simulated. The calculated transient stresses and temperatures in an elastic solid are found to be in good agreement with prior analytical and numerical results. In an elastic–plastic workpiece material, for which no analytical solution is available for the residual stress distributions, the finite element calculations show that the near surface residual stress is predominantly tensile and that the magnitude of this stress increases with increasing heat flux values. Based on an analysis of the effects of workpiece velocity, heat flux magnitude and convective cooling, on the residual stress distributions in an elastic–plastic solid, it is seen that the calculated thermal stress distributions are consistent with experimentally measured residual stresses on ground surfaces. Furthermore, the results explain often cited observations pertaining to thermally induced grinding stresses in metals.     

Residual stress analysis of an external grooved thick-walled pressure vessel

Residual stress analysis of an autofrettaged thick-walled pressure vessel containing an external groove was described in order to calculate the stress concentration at the external groove. The autofrettage residual stress distributions of the external grooved thick-walled pressure vessel were simulated using an equivalent thermal loading from the analogy of thermal and autofrettage residual stress fields. Thermal stresses due to the simulated thermal loadings for various degrees of autofrettage overstrain level were computed using finite element methods. Very high stress concentration factors due to autofrettage loadings were obtained at the external groove root that contained a sharp root radius. Experimental measurement of residual stresses for a fully autofrettaged smooth thick-walled pressure vessel using an equivalent saw cut method resulted in very close agreement with the theoretical autofrettage residual stress distributions. The stress analysis results implied that the autofrettage residual stress concentration might cause a cracking problem at the external groove root of the thick-walled pressure vessel, indicating that lower autofrettage overstrain and a groove geometry change were desirable for enhanced durability.     

陶瓷材料磨削表面残余应力的产生机理

在磨削加工过程中产生表面残余应力,其产生机理是磨粒刃作用引起的挤压应力和切削应力及热应力的综合作用效应。挤压应力产生残余压应力;切削引起的残余应力存在拉、压应力两种可能,但比挤压应力要小得多;热应力产生残余拉应力。     

线切割与真空热扩散焊组合工艺制备微模具

采用线切割和真空压力热扩散焊组合工艺制备了高深宽比的三维微结构。分别研究了线切割与热扩散焊工艺并获得了较好的工艺参数用于制备微模具。首先,在脉冲宽度为10μs,脉冲间隔为40μs,线切割电流为0.28A,电压为60V的条件下,对100μm厚的铜箔进行线切割,获得了多层二维微结构。然后,在热扩散温度为850℃,热扩散时间为10h,压力为1.0μPa的工艺参数作用下,对多层铜箔二维微结构进行真空压力热扩散焊接,通过多层二维微结构的叠加形成微模具,并制备了六棱台微型腔模具及微型级联齿轮模具。实验结果表明:三维微模具表面形貌较好,制作结果较理想,与设计模型基本相符。最后,通过超声模压成型分别获得了二阶和三阶的塑料级联齿轮。这些微塑件质量良好,验证了该工艺方法的可行性。     

风力机叶片原生缺陷转捩的能量释放机理研究

针对风力机叶片原生缺陷演化为裂纹进而扩展导致断裂的问题,分析细观缺陷在外载荷作用下转捩为宏观裂纹的能量释放定量关系明晰裂纹萌生机理。首先根据风力机叶片的载荷特点构造一个新的应力函数,基于正交异性复合材料基本公式求解原生缺陷层间开裂的应力强度因子、应力应变和位移分量,由此获得细观缺陷变形过程释放的塑性应变能;使用红外热像仪采集原生缺陷转捩过程的温度场并计算热能耗散量,基于不可逆热力学定律获得内储能随着疲劳周期的变化规律;最后,在万能试验机上对含有气泡和纤维断裂的叶片试件进行疲劳试验。结果表明,应用提出的应力函数的计算结果与试验结果误差较小,可作为细观缺陷变形时塑性应变能的计算依据。原生缺陷转捩为微小裂纹时,内储能的变化规律可作为判断缺陷类型和程度的依据。这项研究探索复合多层材料跨尺度的疲劳能量理论,有助于实现风电机组关键部件的全寿命周期监测。     

Micromechanical simulations of biaxial yield, hardening and plastic flow in short glass fiber reinforced polyamide

Mean-field homogenization (MFH) is used to predict the biaxial yield behavior, hardening and plastic flow of composite materials made of an elasto-plastic matrix reinforced with misaligned short fibers. The procedure is applied to short glass fiber reinforced polyamide, which represents an important industrial application of those composites. First, MFH is verified against full-field accurate finite element simulations of representative volume elements with multiple fibers. Next, a parametric study is carried out with MFH in order to predict the biaxial plastic behavior of numerous microstructures corresponding to various values of volume fraction, aspect ratio and second-rank orientation tensor components of the glass fibers. Results demonstrate the loss of both isotropic hardening and plastic flow normality, except for 2D random orientation. For illustration, a fit of Hill's orthotropic plasticity criterion is conducted for several orientation tensors.