HDPE瓶顶部负载仿真分析

目的 针对一款吹塑成型的牛奶包装HDPE瓶易瘪瓶的问题,研究瓶体不同部位的厚度比对HDPE瓶顶部负载的影响,并轻量化设计HDPE瓶。方法 通过3D扫描获得HDPE瓶的3D实体模型,测量瓶体厚度,并在ABAQUS中构建不等壁厚的HDPE瓶壳体有限元模型,通过静压试验验证有限元模型的准确性。仿真分析厚度比对整瓶顶部负载能力的影响,并拓扑优化HDPE瓶材料分布。结果 顶部负载时,有限元模型仿真分析和实验得到的临界载荷和临界位移误差分别为2.49%和5.11%;结合厚度比优化与轻量化分析可知,HDPE瓶单瓶材料用量减少了12 g。结论 考虑了瓶体实际厚度的HDPE瓶有限元模型具有较高的准确度。在设计HDPE瓶时,应关注瓶体各部位的厚度组成,以获得更好的瓶体力学性能。     

厚壁管温热缩口与管壁增厚的数值模拟研究

目的主要研究厚壁管两端同时温、热锥形缩口工艺的特点,以及缩口过程不同工艺参数对壁厚增厚的影响。方法通过选择合理的材料模型与热力耦合等温度场模拟参数,建立了有限元模型,使用DEFORM体积成形软件对厚壁管两端同时温热缩口工艺进行了分析,探究了温、热缩口两种条件下应力应变分布特点。结果模拟实验获得了管材缩口系数、模具半锥角、t/d0值、摩擦因子、成形温度等工艺参数,在温、热两种条件下对壁厚增厚量的影响曲线。结论管材缩口过程具有典型的变形阶段:入锥弯曲阶段、反弯曲阶段和缩口稳定阶段;管材高温下缩口变形特点为周向、轴向的压缩变形和径向的增厚变形;厚壁管缩口的增厚变形量随着模具半锥角的增大和缩口系数的减小而增大,同时受摩擦因子、成形温度、管材壁厚的影响较大。研究结果为管材缩口壁厚增厚工艺提供了基础技术数据。     

Failure mode of laser welds in lap‐shear specimens of high strength low alloy (HSLA) steel sheets

In this paper, the failure mode of laser welds in lap‐shear specimens of non‐galvanized SAE J2340 300Y high strength low alloy steel sheets under quasi‐static loading conditions is examined based on experimental observations and finite element analyses. Laser welded lap‐shear specimens with reduced cross sections were made. Optical micrographs of the cross sections of the welds in the specimens before and after tests are examined to understand the microstructure and failure mode of the welds. Micro‐hardness tests were also conducted to provide an assessment of the mechanical properties in the base metal, heat‐affected and fusion zones. The micrographs indicate that the weld failure appears to be initiated from the base metal near the boundary of the base metal and the heat‐affected zone at a distance away from the pre‐existing crack tip, and the specimens fail due to the necking/shear of the lower left load carrying sheets. Finite element analyses based on non‐homogenous multi‐zone material models were conducted to model the ductile necking/shear failure and to obtain the J integral solutions for the pre‐existing cracks. The results of the finite element analyses are used to explain the ductile failure initiation sites and the necking/shear of the lower left load carrying sheets. The J integral solutions obtained from the finite element analyses based on the 3‐zone finite element model indicate that the J integral for the pre‐existing cracks at the failure loads are low compared to the fracture toughness and the specimens should fail in a plastic collapse or necking/shear mode. The effects of the sheet thickness on the failure mode were then investigated for laser welds with a fixed ratio of the weld width to the thickness. For the given non‐homogenous material model, the J integral solutions appear to be scaled by the sheet thickness. With consideration of the plastic collapse failure mode and fracture initiation failure mode, a critical thickness can be obtained for the transition of the plastic collapse or necking/shear failure mode to the fracture initiation failure mode. Finally, the failure load is expressed as a function of the sheet thickness according to the governing equations based on the two failure modes. The results demonstrate that the failure mode of welds of thin sheets depends on the sheet thickness, ductility of the base metal and fracture toughness of the heat‐affected zone. Therefore, failure criteria based on either the plastic collapse failure mode or the fracture initiation failure mode should be used cautiously for welds of thin sheets.     

Determining true stress–strain curve for isotropic and anisotropic materials with rectangular tensile bars: method and verifications

Based on an extensive numerical study, the authors have recently developed a method for determining the true stress–strain curve for isotropic materials by using rectangular tensile specimens. In this method only load versus thickness reduction (at the diffuse necking zone) curve is needed. This method has been further developed for anisotropic materials. For anisotropic materials, both thickness and width reduction at the diffuse necking zone should be measured. In this paper, the effect of plastic anisotropy on the deformed cross-section profile has been further studied, and the proposed method has been experimentally verified against steel which was assumed to be isotropic (width to thickness strain ratio, r_y≈1) and aluminium alloys which were anisotropic with r_y varied in the range 0.28<r_y<0.66. It has been shown that the numerically predicted deformed cross-section shape is very close to the experimental one, measured from sectioned interrupted specimens. The true stress–strain curves determined from the rectangular tensile specimens were compared with the one determined from the conventional round tensile specimens, and very good agreement has been obtained. It has been found that the method using rectangular tensile specimens gives very consistent true stress–strain curves with small scatter.     

316LN不锈钢高温拉伸颈缩区塑变行为

为准确测量颈缩发生后的应力-应变行为,本文综合物理实验、有限元模拟和MLR模型的方法确定颈缩区的塑变行为,建立316LN不锈钢高温本构模型.模型中,颈缩前的真应力-真应变呈幂函数关系,颈缩发生后,较低温度时应力随着应变的增加迅速下降,而当较高温度时应力随着应变的增加而缓慢下降,真应力-真应变呈非线性关系.基于MLR模型,修正了颈缩后不同温度、不同应变速率下的真应力-真应变曲线,并将有限元模拟的颈缩区长度与实测值相对比,相对偏差为4.73%.这说明修正后的应力-应变本构模型能够准确地描述316LN的高温塑性行为.     

On the dynamics of necking and fragmentation—II. Effect of material properties, geometrical constraints and absolute size

In this series of papers, we investigate the mechanics of deformation localization and fragmentation in ductile materials. The behavior of ductile metals at strain rates between 4000 and 15,000 s^?1 is considered. The expanding ring experiment is used as the primary tool for examining the material behavior in this range of strain rates. In Part I, the details of the experiment and the experimental observations on Al 6061-O were reported. Statistics of necking and fragmentation were evaluated and the process was modeled through the idea of the Mott release waves both from necking and fragmentation. Finally, it was shown that the strain in the ring in regions that strained uniformly never exceeded the necking strain. In the present paper, Part II, we address the issue of strain hardening and strain-rate sensitivity. Specifically, we examine different materials—Al 1100-H14, and Cu 101—in order to determine the role of material constitutive property on the dynamics of necking. These experiments reinforce the conclusion presented in Part I that the onset of necking essentially terminates the possibility of further straining in other parts of the ring and even more importantly that there is no influence of material inertia on the strain at the onset of necking in this wide range of materials. Furthermore, the effect of aspect ratio of the specimen is evaluated; this reveals that as the aspect ratio increases beyond about five, in addition to or instead of diffuse necking, localization into the sheet necking mode is observed; in this mode, the effect of ring expansion speeds is demonstrated to result in an increase of the strain at the onset of localization. In addition, an absolute size effect is observed: larger specimens exhibit localization at larger strain levels. These observations are explained in terms of plastic wave propagation and reproduced with finite element simulations. In future contributions as part of this sequel, we will explore the effect of other geometrical constraints and the effect of a compliant cladding or coating on the development of necking and fragmentation.     

高密度聚乙烯材料在大变形条件下的数值模拟研究

针对高密度聚乙烯(HDPE)在大变形条件下有限元模型不易收敛、本构关系较为复杂的问题,对HDPE片材进行了单轴拉伸试验和数值模拟研究。通过对比试验结果和模型计算结果发现:非线性粘弹性本构模型与小变形条件下HDPE的单轴拉伸试验结果较为吻合,但与大变形条件下的试验结果相差较大;而Kwon模型的计算结果与大变形和小变形条件下的试验结果均较为吻合。同时,对Kwon模型的参数选择进行了优化,得到了100mm/min和150 mm/min拉伸速率下的优化参数,对大变形下片材的数值模拟具有较好的参考价值。此外,通过对条带单元的应力应变分析,可知HDPE条带在单轴拉伸下的应力应变呈不均匀分布,中心点区域是片材最大应力应变的集中点,这也解释了HDPE条带断裂多出现在中心区域的原因。     

5182-O铝合金塑性成形性能表征

目的 结合复杂加载状态试验、塑性和损伤断裂本构模型及有限元应用,实现AA5182-O铝合金在复杂加载状态下塑性变形和损伤断裂行为的精确表征。方法 通过拉伸、剪切等试验,研究5182-O在剪切、单向拉伸、平面应变拉伸等复杂应力状态下的力学性能,应用pDrucker方程来表征其复杂加载状态下的塑性变形和损伤断裂特性。采用逆向工程方法实现pDrucker屈服方程和pDrucker断裂准则的精确标定。将标定后的塑性本构模型和损伤断裂准则应用到ABAQUS/Explicit中,预测不同试件的塑性变形和损伤断裂情况。结果 通过有限元模拟与试验结果的对比,发现有限元仿真准确预测了5182-O在复杂加载状态下的力-位移曲线和损伤断裂情况。结论 有限元模拟与试验结果的对比表明,pDrucker方程可以实现5182-O铝合金在复杂加载状态下塑性成形性能的精确表征。标定的pDrucker方程可应用于5182-O冲压成形过程的有限元分析、模具设计和工艺优化中。     

各向同性均质弹塑性材料圆棒试样单向拉伸试验变形特性与应力应变本构关系的相关性分析

针对各向同性均质弹塑性材料圆棒试样单向拉伸试验,分别从理论上以及采用有限元法分析了变形特性与应力应变本构关系的相关性,探讨了形成颈缩的必要条件及实际颈缩形貌的形成过程。结果表明,等效塑性应变ε_p达到一定临界值后,流变应力σ₀不再随等效塑性应变ε_p的增大而增大的材料的应力应变本构特性,以及试样为非理想圆柱体是产生颈缩的必要条件,颈缩后期内部形成断裂是导致颈缩区最小截面位置弧形轮廓线曲率半径较小的原因。      

Perforation of clamped,woven E-glass/polyester panels

Analytical solutions to predict the perforation of fully clamped, woven E-glass/polyester panels subjected to static indentation by a blunt cylinder were derived. Three panel aspect ratios of 12.5, 25 and 50 were considered in order to show how modes of failure vary with panel flexibility. The analytical solutions for the deformation and interlaminar shear stresses compared well to finite element predictions using ABAQUS. It was found that the panel with an aspect ratio of 50 underwent large deformation and deformed in a membrane phase before fracture due to tensile necking. Failure of panels with aspect ratios of 12.5 and 25 was predicted using ply-by-ply failure analysis and the Tsai–Wu failure criterion.     

钢板混凝土组合墙轴压受力性能有限元分析

为了研究核电工程中钢板混凝土组合墙的承载能力以及设计参数对承载力的影响,以4个核电工程中钢板混凝土组合墙的轴压试验为基础,采用ABAQUS建立钢板混凝土组合墙的有限元模型,模型中混凝土、钢板和栓钉均采用实体模型模拟,考虑了材料非线性和钢板焊接残余应力等。研究了栓钉的受力机理,模拟了试件中钢板的屈曲变形,分析不同参数如钢板与混凝土的强度、距厚比和含钢量对承载力的影响。分析结果表明:有限元模型计算结果与试验结果吻合较好,栓钉在受力过程中始终处于弹性受力状态,混凝土强度对承载力影响最大,距厚比对钢板的屈曲影响较大,较小的距厚比能保证钢板与混凝土协同工作。     

新型钢-混凝土组合板的力学性能研究

以加劲肋形式、组合板厚度和栓钉布置为参数，进行了9块新型组合板的力学性能试验．试验结果表明，组合板的正截面承栽力可按基于修正平截面假定的极限状态计算；组合板的跨中挠度，可在按现行规范计算的基础上，加上考虑界面滑移影响的附加变形值予以修正．     

Interfacial fracture of piezoelectric multilayer actuators under mechanical and electrical loading

The elastic stress and strain fields in a plate of finite thickness containing an elliptical hole are systematically investigated using the 3D finite element method. It is found that the stress and strain concentrations are different in the plate of finite thickness even if the plate is in an elastic state. The relation between the stress and the strain concentration factors depends on Poisson’s ratio, the hole’s geometric configuration and the plate thickness. The stress concentration factor is equal to the strain concentration factor only at the notch root of the plate surface. The stress (or strain) concentration factor at the notch root of the plate surface decreases rapidly with increasing thickness and becomes lower than the stress and strain concentration factors corresponding to the plane stress state or at the notch root of the mid plane. It is too low to reflect the overall stress concentration as the thickness increases or as the b/a ratio decreases. The maximum stress concentration factor occurs on the mid plane only when the plate is thinner than the transition thickness of the stress concentration factor. When the plate is thicker than the transition thickness of the stress concentration factor, the distance between the location of the maximum stress concentration factor and plate surface tends to be constant with increasing thickness for the plate with a given  b/a ratio. The differences between the maximum value and the surface value of the stress and strain concentration factors increase rapidly and tend to their respective constant values with increasing plate thickness. The smaller the b/a ratio, the larger these differences. The difference of the stress concentration factor is larger than that of the strain concentration factor in the same plate.     

NUMERICAL PREDICTION OF FATIGUE CRACK GROWTH OF A SURFACE DEFECT

Fatigue crack growth is modelled by an improved step-by-step finite element technique for a shallow and long surface crack in a finite thickness plate under different combinations of tension and bending loads. The predicted crack shape development is presented for growth through the plate thickness and the shape compared with the widely assumed semi-elliptical profile. The predictions of the present simulation technique for the aspect ratio and the number of crack growth cycles are compared with those obtained both by Newman and Raju's method, and experimental results for aspect ratio changes taken from the literature.     

带内筋筒形件滚珠旋压的数值模拟

利用有限元软件 ABAQUS 对带内筋筒形件的滚珠旋压进行了数值模拟,分析了带内筋筒形件成形过程中金属塑性变形区的应力状态、金属流动规律,在此基础上分析了不同压下量、进给比和壁厚对内筋饱满度以及筒形件表面质量等成形效果的影响规律。 根据数值模拟结果,设计并制造了工装和模具,同时进行了工艺试验,成功试制出内筋成形效果良好的筒形件试样。     

薄壁管壳体环矢挤压缩径工艺仿真分析与研究

目的 针对空心薄壁件在缩径成形工序中力学性质难以观测且缩径成形加工效率较低的问题,提出一种使用18瓣环矢挤压模具进行环矢挤压一次性成形的缩径工艺,并研究了该工艺下薄壁管壳体的弹塑性变形规律。方法 以外径6.3 mm、壁厚2 mm、颈缩宽度1 mm的小尺寸薄壁管壳体（Q255材料）为研究对象,基于Barlat’96屈服准则和M–K沟槽理论,结合L.H.Donnell理论,建立管壳体环矢挤压缩径的塑性微元应力模型,通过ANSYS软件建立环矢挤压缩径工艺有限元模型,并进行数值模拟分析,获得管壳体环矢挤压过程中内壁面和颈缩区厚度方向的应力分布规律;最后进行实验验证,利用千分尺测量外径,采用应力测定仪测量中心位点应力,验证了该工艺下仿真结果的准确性。结论 颈缩区域宽径比越大,缩径成形越远离弹性区;内壁面的应力整体呈凸状分布;卸载后,壁厚方向的残余应力呈从外壁到内壁逐渐增大的线性分布趋势,缩径区中心点最大残余等效应力为319.76MPa,分布在挤压部位的内表面;经实验验证,内壁面中心位点的最大残余应力为183MPa,其与仿真分析结果（202.5MPa）的吻合度高达91.5%,验证了仿真结果的准确性...     

型钢高延性水泥基材料粘结性能试验研究与有限元分析

为了研究型钢与高延性水泥基材料(ECC)界面粘结滑移性能,对型钢ECC试件进行推出试验,分析PVA纤维掺量、横向箍筋配箍率、ECC保护层厚度及型钢锚固长度对型钢ECC试件破坏形态、荷载-滑移曲线及粘结应力的影响,提出粘结应力沿型钢锚固长度分布规律,研究表明:PVA纤维掺量和ECC保护层厚度对型钢ECC粘结应力影响较大,粘结应力最大值出现在靠近加载端的位置,随着荷载增大,等效粘结应力也相应增大。根据试验结果,建立不同状态下型钢ECC粘结应力计算表达式,提出粘结应力-滑移本构关系。在此基础上,利用非线性弹簧考虑型钢与ECC界面间的粘结性能,建立型钢ECC推出试件的有限元模型,并将有限元分析结果与试验结果进行对比,结果表明,该文提出的有限元模拟方法能够准确地分析型钢ECC的粘结滑移性能。     

FRP增强重组竹梁受弯性能数值模拟

通过有限元软件ABAQUS对纤维增强聚合物基复合材料（FRP）增强重组竹梁受弯性能进行了分析,有限元模拟结果与试验结果相一致,两者荷载-位移曲线相吻合,跨中截面应变发展过程基本一致,70 kN荷载时,截面应变误差在13.96%内,承载力预测具有很好的精度,预测最大误差为9.04%,FRP的增强使竹梁截面的应力重新分布,受压区竹材得到更加充分的利用;进一步参数化分析了截面宽高比、FRP层数、FRP种类对FRP增强重组竹梁受弯性能的影响。发现:FRP层数的增加对重组竹梁极限承载力和截面刚度提升作用显著;相同层数、相同种类FRP增强重组竹梁时,截面高度减小,极限承载力和截面刚度提高幅度增加;相同截面宽高比和FRP层数时,碳纤维增强聚合物基复合材料（CFRP）增强效果优于玄武岩纤维增强聚合物基复合材料（BFRP）增强效果。      

Mapping of Deformation-Induced Magnetic Fields in Carbon Steels Using a GMR Sensor Based Metal Magnetic Memory Technique

Giant magneto-resistive (GMR) sensor based metal magnetic memory (MMM) technique is proposed for mapping of deformation-induced self-magnetic leakage fields (SMLFs) in carbon steel. The specimens were subjected to different amounts of tensile deformation and the deformation-induced SMLFs were measured using a GMR sensor after unloading the specimens. 3D-nonlinear finite element modeling was performed to predict stress–strain state in a steel specimen under tensile load. The experimentally obtained SMLF images were correlated with the finite element model predicted stress–strain states. Studies reveal that the MMM technique can detect the plastic deformation with signal-to-noise ratio better than 20 dB. The technique enables the mapping of plastic deformation in carbon steels for the evaluation of the severity of deformation. The study also reveals that deformation-induced SMLF is influenced by the presence of initial surface residual stress, introduced by shot peening. The intensity of SMLF signal is found to increase with increase in tensile load and decrease with shot peening.