车削加工工艺对EA4T车轴钢疲劳性能的影响

对不同工艺车削加工的EA4T车轴钢进行旋转弯曲疲劳试验,研究了车削加工工艺对该钢疲劳性能的影响.结果表明:在不同车削加工工艺下,试验钢轴向残余压应力的最大值与最小值相差50MPa,周向残余拉应力的最大值与最小值相差25MPa,车削加工工艺对残余应力的影响不大;不同车削加工工艺下试验钢表面粗糙度均小于0.8μm,且表面粗糙度的最大值与最小值相差0.15μm,车削加工工艺对表面粗糙度的影响不大;当表面粗糙度小于0.8μm时,车削加工工艺对疲劳寿命的影响不大;疲劳断口均分为裂纹源区、裂纹稳态扩展区和瞬断区,且均只有一个裂纹源,疲劳裂纹都是在表面较深车痕的根部萌生并向内扩展.     

压应力对长短疲劳裂纹尖端塑性区影响的有限元分析

应用弹塑性有限元方法,研究压应力对长短疲劳裂纹塑性区的影响.分别建立两个具有长短中心穿透裂纹高强铝合金板的有限元模型,进行拉压加载模拟分析.结果表明,压应力对长短疲劳裂纹尖端塑性区有显著影响,相同的应力强度因子条件下,在一个拉一压加载周期,当拉载荷减小到零时裂纹尖端应力不为零,裂纹尖端应力对裂尖的挤压作用产生反向塑性区,裂尖反向塑性区随压应力的增加而增加,压应力的大小是决定裂纹尖端塑性区大小的主要因素,压应力对短裂纹的影响比长裂纹大.     

不同加载条件压载荷对疲劳裂纹尖端塑性区的影响

应用弹塑性有限元方法,研究不同加载条件下压载荷对疲劳裂纹尖端塑性区的影响.建立两个具有中心穿透裂纹的高强铝合金板的有限元模型,分别进行不同载荷的拉压加载模拟分析.结果表明,压载荷对疲劳裂纹尖端塑性区有显著影响,在一拉一压加载周期,当拉载荷减小到零时裂纹尖端应力不为零,裂纹尖端应力对裂尖的挤压作用产生反向塑性区,裂尖反向塑性区随压载荷的增加而增加,压载荷的大小是决定裂纹尖端塑性区大小的主要因素,压载荷越大塑性区越大.     

喷丸对脱碳板簧用钢疲劳强度的影响和残余应力的作用

本文研究了经不同预应力喷丸后的55SiMnVB板簧用钢残余应力分布特点以及喷丸对其疲劳强度的影响。疲劳试验配合电镜断口观察表明,应力喷丸产生的残余压力是改善疲劳性能的一个决定性因素,残余压应力的主要作用是减缓疲劳裂纹的扩展过程。还提出了一个评价残余应力作用的新的指标。     

压缩载荷对冷胀孔残余应力的影响

用考虑组合强化、增量理论的有限元法计算了２１２４－Ｔ８５１ 板件开缝衬套冷胀孔的残余应力场及其在压缩载荷作用下的变化情况。结果表明冷胀之后的压载循环将引起冷胀残余应力的衰减。一个足够大的压缩载荷能够使冷胀工艺给疲劳寿命带来的增益完全丧失。文中说明压缩载荷对冷胀的作用可以和超载后半周压载对裂纹的作用相比拟,建议在确定合理胀孔量时应当把它对所承受的载荷谱中压缩载荷的敏感性考虑在内,应当加强有关的疲劳对比试验研究及残余应力场测量研究。     

基于冷滚压工艺的谐波减速器柔轮疲劳寿命分析

依据冷滚压工艺产生的初始残余压应力对裂纹萌生,裂纹扩展的抑制机理,以冷滚压谐波减速器柔轮为研究对象,采用SWT方法和断裂力学理论对冷滚压柔轮分别进行裂纹萌生寿命、裂纹扩展寿命理论分析,并运用疲劳分析软件nCode Design-Life仿真分析进行相互验证。结果表明,冷滚压柔轮疲劳寿命在各阶段均优于机加工柔轮,能够有效延长谐波减速器使用寿命,验证了柔轮冷滚压工艺的优越性,并对延长柔轮的使用寿命提供了参考价值。     

拉压载荷对疲劳裂纹扩展影响的有限元分析

利用弹塑性有限元方法研究了压应力对裂纹尖端塑性区的影响和长短裂纹尖端的塑性区和裂纹张开剖面.通过分析表明,压应力对裂纹尖端塑性区和疲劳裂纹的扩展有显著的影响.     

42CrMo4钢疲劳裂纹扩展时的残余应力及其变化

对４２ＣＣｒＭｏ４钢质调质试样疲劳裂纹扩展时的表面残余应力测定表明，在裂纹尖端前方和裂纹两则一定范围生成残余应力，裂纹尖端处压应力最大。随着裂纹的扩展压应力范围增大，最大压应力增加，表明残余应力始终处于一动态再分布过程中，与裂纹尖端区域的塑性变形直接相联系。裂纹扩展时残余应力的真实分布状态，按理想模型已不能作出圆满描述。由于裂纹尖端塑性变形区较小，选用合适的Ｘ线光栅孔长测的残余应力较为真实。     

应力比和残余应力对Ti-6Al-4V高周疲劳断裂模式的影响

对钛合金Ti-6Al-4V进行室温空气环境下的高周疲劳试验,研究消应力和未消应力试样在多个应力比下的疲劳强度,分析和检测表面残余应力在不同应力比和载荷水平下随循环次数而松弛情况,探讨表面残余应力随循环次数而松弛的规律以及残余应力和应力比对Ti-6Al-4V疲劳强度影响的机理。结果表明,随着应力比的提高,残余压应力对Ti-6Al-4V疲劳强度的提升影响逐步减小并消失;与消除残余应力后疲劳破坏源于表面相比,表面残余压应力使得低应力比下疲劳源于内部;当应力比R=-1.0时,疲劳循环导致表面残余压应力松弛且保持稳定,其产生的表面裂纹闭合是疲劳强度提高的主要机制;当R=-0.6~0.1时,未见疲劳循环导致表面残余应力松弛,由于表面层的平均应力减小使得疲劳破坏主要为内部缺陷和局部应力集中控制。     

砼管支撑加强环焊接工艺研究

臂架砼管支撑的破坏类型有焊接裂纹、焊接结构的延性破坏和脆性破坏、疲劳破坏,但以冷裂纹、疲劳开裂为主.从3个方面进行了开裂原因分析,并通过MSC.Marc焊接数值模拟方法,计算了不同拘束及焊接顺序对砼管支撑焊接残余应力的影响.研究结果表明,减少砼管支撑结构的拘束和改变焊接顺序均可明显降低焊接残余应力.     

TC4板孔冷挤压强化残余应力分布与疲劳寿命

开展了不同挤压量下TC4钛合金板孔冷挤压强化有限元仿真研究,得到了挤压强化后最小截面的切向残余应力分布规律,分析了挤压量对受载试样孔边应力分布的影响,探讨了挤压量、残余应力和疲劳增益三者之间的内在关系。采用开缝衬套冷挤压强化工艺对TC4带孔板件进行冷挤压和疲劳验证试验。研究结果表明,挤压强化后的孔边切向压缩残余应力可以有效降低孔周应力集中程度,优化受拉试样最小截面应力分布,改变裂纹源的位置并延长疲劳裂纹的萌生和扩展寿命,有效提高试样疲劳寿命。综合仿真和疲劳试验得到TC4板孔最优挤压量为4%。     

Prediction of fatigue life in cold expanded Al-alloy 2024-T3 plates used in double shear lap joints

To predict fatigue crack initiation and fatigue crack growth lives in cold expanded double shear lap joints a numerical method has been employed. The total estimated fatigue lives were compared with available experimental fatigue test results for plain hole and cold expanded hole specimens of Al 2024-T3 in double shear lap joints. Three-dimensional finite element simulations have been performed in order to obtain the created residual stresses field due to cold expansion and subsequent far field longitudinal loading in the double shear lap joint. The obtained stress and strain distributions from the finite element analyses were employed to predict stress concentration factors to calculate fatigue crack initiation and fatigue crack growth lives using AFGROW computer code. The predicted fatigue lives demonstrate that there is a good agreement between the proposed method and experimental fatigue test results.     

高速列车锻钢制动盘热疲劳裂纹耦合扩展特性研究

据制动盘裂纹剖面的宏观形貌,发现盘面长裂纹的形成以多条半椭圆表面裂纹连通为主。针对制动盘在运行过程中的典型运用工况,采用有限元法计算制动盘在300 km/h紧急制动后的热应力,发现周向残余应力较大,并以此推测周向残余应力是驱动制动盘热疲劳裂纹扩展的主要原因。在此基础上,建立制动盘盘面的裂纹网格,研究了裂纹扩展过程中的应力强度因子和多裂纹耦合扩展规律。通过研究发现对于给定的载荷条件,不同初始形状比时,裂纹前缘应力强度因子的分布规律存在一定的规律性,随着裂纹的扩展,裂纹形状趋于扁平化;多裂纹扩展时,裂纹间距越小,裂纹间的相互作用越明显,扩展速度越快;但受制动盘结构和尺寸限制,共线裂纹数越多,每条裂纹扩展到临界值时的应力强度因子越小。     

Fretting fatigue crack initiation behavior using process volume approach and finite element analysis

This study investigates crack initiation behavior by incorporating fretting fatigue process volume. Three critical plane based fretting fatigue crack initiation parameters are characterized by computing their averaged values over the process volume and then comparing with their counterparts obtained from the localized approach. Two approaches are used: first one involves the computation of parameter at several points over a rectangular region and then its average, and second approach computes the average state of stress/strain over a radial region from which the averaged parameter is calculated. Both approaches require pre-determination of a critical location at or around which the process volume needs to be placed. Effects of size and location of process volume on the averaged value of parameters are studied in detail. Two radii of cylindrical pad are analyzed to investigate the effect of severity of stress gradient on process volume approach. Effects of finite element mesh refinement are also investigated. Averaged value of parameter decreases with the increase of process volume size. This decrease is higher when the process volume is located in the region that is away from the contact zone. Further, a parameter based on normal stress on the critical plane shows more dependence on the size of process volume than that based on shear stress or on a combination of both shear and normal stresses. Orientation of crack initiation changes within a range that is well within the scatter band of experimental observations as the process volume size increases. Averaged value of parameter for a pad with higher stress gradient has a larger reduction with the increase of process volume size than that with a lower stress gradient. Process volume size has less effect on the averaged value of parameter with coarser finite element mesh. Finally, the localized approach provides a conservative value of fretting fatigue crack initiation parameter compared to its counterpart based on the process volume.     

恒幅和单峰超载疲劳裂纹尖端区域残余应力场的数值模拟

采用弹塑性有限元方法,对恒幅及不同超载比的单峰超载作用下的裂纹扩展进行有限元模拟.通过模拟得到的裂纹扩展过程中裂尖塑性区及应力(残余应力)场分析产生裂纹闭合的原因以及对裂纹扩展的影响.结果表明,从残余应力角度分析裂纹扩展是可行的,为建立基于残余应力的裂纹扩展模型提供分析基础.     

Influence of Nano/Micro CBN Particle-Coated Tools on Rolling Contact Fatigue Performance of Hard-Machined AISI 1053 Steel

In this article, we study the influence of the cubic boron nitride (CBN) particle size in nano/micro CBN particle-coated tools on the fatigue performance of hard-machined AISI 1053 steel. The effect of the CBN particle size on the crack initiation life and the crack propagation life is reduced significantly with increased loading, whereas the crack propagation life is more influenced by the CBN particle size compared with the crack initiation life. The CBN particle size can influence the crack initiation life by 96 % and the crack propagation life by 130 %. As a result, it can influence the fatigue life by 370 % at the maximum Hertzian stress of 2,724 MPa. The results demonstrate that the CBN particle size influences the fatigue life and that the effect of the CBN particle size on the fatigue life can be lessened significantly if the loading is increased to a certain level that depends on the function of machined surfaces.     

考虑残余应力的螺旋锥齿轮接触疲劳裂纹萌生-扩展寿命计算方法研究

考虑渗碳、磨齿、喷丸等工艺产生的齿面残余应力,建立齿面接触应力与残余应力的复合应力场,提出一种螺旋锥齿轮接触疲劳裂纹萌生-扩展寿命计算方法。构建齿轮有限元接触分析模型,计算多轴交变接触应力场。考虑空间螺旋曲面残余应力分布的复杂性,将变曲率齿面离散为网状节点;测量各节点表面与次表面的残余应力,建立齿面残余应力场。基于Dang Van多轴疲劳准则,构建齿面裂纹萌生模型;计及残余应力与裂纹闭合效应,构建齿面裂纹扩展模型。计算复合应力场下齿轮接触疲劳寿命,研究残余应力对齿面裂纹萌生-扩展寿命的影响规律。结果发现：复杂齿面空间变曲率会影响喷丸等工艺产生的残余应力分布,中心区域的残余压应力高出齿面边缘区域约20%;复合应力场下齿面裂纹萌生位置与寿命主要取决于接触应力,残余应力会改变齿面节点平均应力进而影响疲劳寿命;齿面裂纹扩展寿命约占全寿命的10%,表征齿轮接触疲劳快速失效至迅速断裂。上述研究对于高性能齿轮传动的长寿命、高可靠性设计具有一定的参考价值。     

A Comparative Study of Residual Stress Distribution Induced by Hard Machining Versus Grinding

This study investigates the residual stress distribution induced by hard machining and grinding and compares its impact on fatigue parameters. The residual stress distribution below hard turned and ground surfaces is investigated after a thermally damaged layer is removed. Fatigue parameters are computed based on the residual stress distribution to compare the impact of the residual stress distribution on the fatigue performance. Rolling contact fatigue tests are then performed to substantiate the computations. The effect of residual stresses on crack initiation depth is shown to be significant for the ground specimen. The maximum shear stress at crack initiation depth of the hard turned specimen is smaller than that of the ground specimen. Due to a significant increase in crack initiation life, the predicted rolling contact fatigue life of the hard turned specimen is longer than that of the ground specimen. The overall average in the ratios of predicted life to experimental life for the hard turned specimen is closer to 1 than that for the ground specimen. The results demonstrate that the hard turned specimen shows better rolling contact fatigue performance and better accuracy in the fatigue life prediction.     

循环压载下缺口旁疲劳裂纹扩展

对承受循环压载的缺口试件的疲劳问题进行了试验和理论研究。结果表明，疲劳裂纹是在残余拉应力和循环压应力作用下萌生和扩展的，压塑性变形是裂纹萌生和扩展和扩展的必要条件。循环压载下仍存在着裂纹张开和裂纹闭合，其机理与拉伸循环下不同。以试验中采用的ＬＹ１２ＣＡ材料边缺口试件为例，提出了考虑裂纹闭合效应的扩展率计算模型，结果与试验吻合得较好。     

Residual stress field of ballised holes

Ballising, involving pushing a slightly over-sized ball made of hard material through a hole, is a kind of cold working process. Applying ballising process to fastener holes produces compressive residual stress on the edge of the holes, and therefore increases the fatigue life of the components or structures. Quantification of the residual stress field is critical to define and precede the ballising process. In this article, the ballised holes are modeled as cold-expanded holes. Elastic-perfectly plastic theory is employed to analyze the holes with cold expansion process. For theoretical simplification, an axially symmetrical thin plate with a cold expanded hole is assumed. The elasticplastic boundaries and residual stress distribution surrounding the cold expanded hole are derived. With the analysis, the residual stress field can be obtained together with actual cold expansion process in which only the diameters of hole before and after cold expansion need to be measured. As it is a non-destructive method, it provides a convenient way to estimate the elastic-plastic boundaries and residual stresses of cold worked holes. The approach is later extended to the case involving two cold-worked holes. A ballised hole is looked upon as a cold expanded hole and therefore is investigated by the approach. Specimens ballised with different interference levels are investigated. The effects of interference levels and specimen size on residual stresses are studied. The overall residual stresses of plates with two ballised holes are obtained by superposing the residual stresses induced on a single ballised hole. The effects of distance between the centers of the two holes with different interference levels on the residual stress field are revealed.