纳米CaCO3半金属摩擦材料摩擦磨损性能的研究

使用定速摩擦试验机研究了纳米CaCO3对半金属摩擦材料性能的影响。结果表明：在半金属材料中，用纳米CaCO3代替普通的CaCO3粉体，在混料过程中，纳米CaCO3粒子粘附在其他颗粒和钢纤维表面上，热压成型过程中，作为粘结剂的树脂材料与这些材料之间的结合强度降低。在摩擦过程中，造成表面颗粒在剪切力的作用下，很容易与基体脱离，从而使得摩擦材料的摩擦因数偏小，而磨损率却大大增加。     

粗糙表面计算机模拟

粗糙表面的计算机模拟是建立粗糙表面模型进而对粗糙表面间相互作用进行模拟研究的前提。提出一种基于时间序列模型、数字滤波技术和Johnson转换系统的粗糙表面模拟方法，分别模拟了各向同性与各向异性、高斯与非高斯分布条件下具有不同形式自相关函数的粗糙表面，并对复杂合成粗糙表面的模拟进行了尝试。最后，对粗糙表面模拟过程中的误差进行了初步分析。结果表明，提出的粗糙表面模拟方法能快速有效地模拟具有指定自相关函数的高斯或非高斯随机粗糙表面；在一定的条件下模拟表面的统计特征与规定值误差很小，但当相关长度比较大的时候，误差比较明显。     

基于Deform3D的30CrNiM08干硬车削温度仿真模拟研究

基于材料变形的弹塑性理论、热力耦合理论以及Usui磨损模型,采用有限元分析软件DEFORM-3D建立了Johnson&Cook材料本构模型.构建了反映金属车削过程高温、大应变及高应变率状态的切削模型,模拟了不同切削速度和不同切削进给量条件下30CrNiM08的加工过程,对车削加工区温度场、热流以及温度变化的仿真结果进行...     

玻化砖和花岗石磨抛加工表面特性分析

采用偏光显微分析、X射线衍射分析和X射线光电子能谱分析等测试手段，对玻化砖和花岗石磨抛加工后材料表面的组成、结构和生成机理进行了研究。结果表明：在不同的加工条件下，材料被加工表面均存在平均厚度为60-80μm的表面损伤层，它由加工过程中微观裂纹形成的纳米尺寸的破碎矿物颗粒组成；磨粒和工件材料之间的机械作用引起了材料表面各元素电子结合能的增大，未发现加工表面生成过程中存在化学作用和产生新物质。     

制动摩擦材料中的钢纤维摩擦磨损特性分析

通过模拟汽车制动过程,针对半金属摩擦材料中的钢纤维的摩擦磨损特性进行了研究.研究表明:钢纤维的磨损主要以氧化磨损、粘着磨损和磨料磨损为主.通过对参与摩擦的钢纤维表面以及部分磨屑形貌特征和表面成分的分析表明:表面Fe(钢纤维)很容易被氧化.在摩擦力和摩擦热的反复作用下,氧化层的厚度增大,强度降低,硬而脆的氧化铁易脱落并呈鳞片状.摩擦表面存在着大量的微粉再加上润滑材料的涂抹,以及摩擦高温形成的氧化层都影响了钢纤维与金属盘表面粘着的产生.同时,在接触表面存在的大量微粉颗粒包括氧化铁和部分硬的磨料,很容易在钢纤维表面产生磨料磨损.     

基于ANSYS/LS-DYNA的单颗粒金刚石切割氧化铝陶瓷表面温度场研究

对单颗粒金刚石切割氧化铝陶瓷过程中切削热、表面粗糙度、应变进行研究,通过利用ANSYS/LS-DYNA对切削过程进行3D模拟,热力耦合,分析在不同走丝速度条件下,工件表面裂纹和形貌情况;将切削温度场拟合进切削过程,研究切削热分布以及切削过程中应变问题。仿真结果显示,切削热基本维持在60℃左右,且温度传导较慢,范围较小;工件在切削过程中与磨粒底部接触的裂纹深于两侧,且受走丝速度影响较小;脆性材料切削主要以弹性应变为主。     

碳化硅研抛过程中表面损伤的仿真与实验研究

碳化硅在研抛加工过程中极易产生表面损伤,从而影响工件表面质量和疲劳性能。基于硬脆材料的研抛去除机理,建立有限元仿真模型,模拟单颗粒研抛过程,分析了工件材料的去除过程,以及不同工艺参数对表面应力分布和表面去除形貌的影响。通过计算机控制精密研抛工艺对碳化硅进行研抛试验,进一步分析了各工艺参数下表面形貌的变化,结果表明,较小的主轴转速、较大的磨粒尺寸和研抛深度对工件表面破碎损伤严重,而进给速度对工件表面去除效果的影响不明显,不同工艺参数对表面损伤影响变化趋势与模拟分析结果吻合较好。研究结果对于选择合理的研抛工艺参数以获得良好的表面质量具有重要意义。     

60Si2Mn半固态轧制有限元模拟

采用多孔材料的几何模型,利用MARC软件对弹簧钢60Si2Mn半固态轧制进行了有限元模拟,分析了在热力耦合条件下,将半固态材料视为可压缩的刚-粘塑性体时的应力场、速度场、温度场的状况,并研究了不同变形条件下,应力场、速度场的变化规律,由此所进行的模拟工作较好地反映了半固态轧制过程中金属的变形规律。     

碳化钛颗粒增强钢基复合材料超声振动辅助划痕仿真及试验研究

碳化钛(TiC)颗粒增强钢基复合材料具有较高的强度、硬度和耐磨性,在精密航空航天零件中广泛应用。由于材料中TiC硬质颗粒的存在,导致了加工表面质量差、刀具磨损严重等问题,超声振动辅助加工被尝试用于解决该问题,但在超声振动辅助条件下针对该材料的去除机理尚不明确,参数优化缺乏理论指导,通过开展超声振动辅助划痕仿真及试验研究,探究该材料在超声振动辅助条件下的去除机理和表面创成机制。首先基于TiC颗粒大小、形态、分布特征以及颗粒和基体的材料特性建立了材料的有限元仿真模型,然后分析了单颗金刚石超声振动辅助划痕过程中材料去除特性以及表面创成机制,并开展了验证试验。结果表明：仿真模型的划痕力预测值与试验值误差小于16%;在划擦过程中,TiC颗粒受到的最大应力为拉应力,基体受到的最大应力为压应力;与传统划痕相比,超声振动辅助划痕过程中单颗金刚石与工件间歇性分离,划痕力呈现周期性变化,平均划痕力降低16%-50%;在超声振动辅助条件下,由于单颗金刚石对TiC颗粒的锤击作用,基体材料塑性变形更大,更多的颗粒与基体脱粘变成切屑,导致划痕表面形成更大的空腔,此研究可为后续加工过程中工艺参数选择提供指导。     

SiCp增强铝基复合材料与Kevlar增强摩擦材料摩擦副摩擦磨损机理研究

采用盘销式摩擦磨损试验机，对SiCp含量为20vol％的铝基复合材料和Kevlar增强摩擦材料组成的摩擦副在于摩擦条件下的摩擦磨损机理进行了实验研究。结果表明：摩擦副在跑合过程中，铝基复合材料中的SiCp颗粒对较软的有机复合材料产生犁削和微观切削效应，磨损机理为铝基复合材料的硬质颗粒对较软的有机复合材料的磨粒磨损；在跑合后的磨损试验中，摩擦材料磨损表面呈现出粘着磨损和塑性变形特征，随着转动速度的增加，塑性流动加剧；摩擦副接触表面发生材料的相互转移，并在铝基复合材料表面形成转移膜，且在较高速度下转移膜更易形成；在高速条件下，摩擦材料表面可见从铝基复合材料的铝合金基体中脱离的SiCp颗粒和熔融迹象；摩擦材料的磨损机理主要为磨粒磨损、粘着磨损和塑性变形。     

基于有限元法催化剂颗粒撞击壁面的数值模拟

为解决催化裂化装置中的许多构件因为催化剂颗粒长期不断冲击而导致失效等的问题,将有限元法应用到其模拟仿真中,分析了单颗催化剂颗粒参数(角度、速度、材料)对不同壁面材料的撞击而造成壁面磨损的影响,建立了催化剂颗粒撞击壁面的数值分析模型,研究了催化剂颗粒以不同的速度、撞击角度,以及不同的催化剂颗粒的材料撞击不同材料的壁面对壁面造成的影响,并分析了催化剂颗粒变形对壁面磨损的影响,根据计算的结果,对催化剂颗粒参数进行了优化控制,提出了减少催化剂颗粒变形和构件磨损的技术措施.研究结果表明,该方法能够使催化裂化装置长期安全稳定地运行.     

TIG电弧辅助熔滴沉积增材制造SiCp增强铝基复合材料中的熔池动力学与颗粒迁移行为

基于计算流体力学方法,考虑电弧力、碳化硅颗粒(SiC_p)增强相与液态铝合金基体相之间的相互作用以及表面张力等因素,建立了Si C_p增强铝基复合材料钨极氩弧焊(TIG)电弧辅助熔滴沉积增材制造中的三维瞬态熔池行为数值模型,通过与堆积试样的横截面形貌、Si C_p分散状态实验结果对比,验证了熔池行为数值模型的有效性。通过数值模拟,揭示了堆积过程熔池峰值温度演变规律、熔滴冲击诱导的熔池动力学行为、熔池流态对Si C颗粒迁移行为的影响。结果表明,堆积过程涉及熔滴冲击、合并、铺展、熔池回弹4个阶段;冲击点附近出现重熔,熔滴冲击造成熔池中心区域产生明显的V字形凹陷,熔池边缘形成冠状隆起;在熔体拖拽力的作用下Si C颗粒更多的分布于堆积层两侧;熔滴冲击引起的熔池内局部高压以及熔池底部对流,抑制了Si C颗粒向熔池底部沉降。     

Effects of Morphological Characteristics of Alumina Particles and Interfacial Bonding Strength on Wear Behavior of Nano/Micro-alumina Particulates Reinforced Al/A206 Matrix Composites

Matrix/reinforcement interface has a critical role in determining the properties of metal matrix composites (MMCs). Properties of matrix/reinforcement interface depend on the fabrication method. The main problem in the fabrication of MMCs is wettability between reinforcing particles and molten alloy. Al206/5 vol% alumina_p cast composites were fabricated by the addition of reinforcing particles into molten Al alloy, semi-solid and liquid states, in two different forms: (1) as-received alumina (nano/micro) particles and (2) pre-synthesized composite reinforcement prepared via ball milling of alumina (nano/micro) with Al and Mg powders (master metal matrix composite). The effects of powder addition techniques, alumina/matrix interfacial bonding strength, and morphological characteristics of alumina particles on wear behavior were investigated. A new combination parameter, called alumina particle appearance (APA) index, was introduced. APA index approximates the collective effects of morphological characteristics of alumina particles on wear behavior. It is suggested that samples with lower APA index have superior wear properties. Microscopic examinations of the composite and matrix alloy and alumina/matrix interface were studied by scanning electron microscopy and transmission electron microscopy. It was found that wear resistance was increased in the composites fabricated by the addition of pre-synthesized reinforcing particles into molten alloy in the semi-solid state. Improvement in wear resistance is attributed to higher bonding strength of matrix/reinforcement as well lower APA index compared to those prepared via as-received alumina particles.     

Influence of reinforcement particles on the mechanism of the blasting erosion arc machining of SiC/Al composites

Electrical arc machining has shown its remarkable efficiency in processing difficult-to-cut materials, especially high-temperature alloys and metal-based composites. Despite several studies about the material removal mechanisms of the electrical arc machining of metal alloys, few of these reports relate to the mechanism of machining composites with electrical arcing. Considering that reinforcements such as SiC particles have different thermal and electrical properties with metal alloys, research on the influence of SiC reinforcement on the electrical arc machining process is important and necessary. Based on comparison experiments using 20 and 50 vol.% SiC/Al composites, this research focused on the influence of SiC particles on the machining performance and material removal mechanism of blasting erosion arc machining (BEAM), and further analyzed the influence of reinforcements on composite material removal mechanisms. Analysis revealed that the molten material expelling mechanism is also influenced by the SiC fraction difference. For the BEAM of lower SiC fraction composites, both the SiC particles and the molten aluminum are mainly pumped and ejected by the flushing dielectric. In greater SiC fraction composites, most SiC particles are directly sublimed by heat. In addition, the mechanism of BEAM in the material removal and tool wear of SiC/Al composites was discussed based on heat transfer simulation and observation. Furthermore, the results disclosed that many chemical reactions take place during machining that have an obvious influence on the tool wear rate.     

Ejection of molten material produced by pulsed electron and laser beams

Crater formation in electron and laser beam drilling is mainly due to molten material removal. In this process, there are two different modes of removal: ejection outside the target and transport of material which remains around the crater on the target surface. Measurement of these removal modes was carried out. The diameters of molten particles ejected from the targets were obtained. Characteristic particle diameters were determined for each material and each drilling condition. The volume of solidified material remaining around the crater was also obtained. From these results, the proportion of molten material ejected from the target was determined. Most of the molten material remained around the crater for iron and tungsten, but was ejected outside the target for aluminium and alumina ceramics.     

Research on formation and stability of keyhole in stationary laser welding on aluminum MMCs reinforced with particles

The formation and stability of keyhole in stationary laser welding on aluminum metal matrix composites reinforced with particles are studied using a numerical simulation. The interaction between molten pool and reinforcement particles is evaluated by using the particle–fluid coupling model in the numerical simulation. In order to study the effect of different volume fractions of particles on the keyhole stability and fluid flow inside the molten pool, keyhole formation process, variation of free surface, temperature distribution, and fluid flow are calculated numerically, respectively. The calculation results show that the keyhole is stable at the beginning under different conditions and then the protrusion occurs inside the keyhole with increasing calculation time. The flow behavior of molten pool affected by particles and forces acting on the surface could explain the forming of humps inside the keyhole, which directly cause the variation of the keyhole. As the volume fraction of TiB₂ particles increases, the keyhole is more likely to be instable and the oscillation occurs at an earlier time. Fluctuations of the surface tension and recoil pressure due to the uneven distribution play an important role in the instability of the keyhole.     

Analysis of impact energy factors in ductile materials using single particle impact tests on gas gun

Wear is surface damage that involves progressive material loss due to relative motion between the contacting surfaces. Removal of material by action of impacting particles is known as erosion. Single particle impact tests were conducted using small particles (95-100 μm) and impact velocity 90 ms⁻¹. A new technique has been developed to measure the impact crater using Laser Scanning Confocal Microscope (LSCM). Depth of craters was calculated based on the impact parameters and the material properties and compared with measured values. The variations are discussed with the high strain-rate deformation and energy loss in the material through strain energy and heating.     

Numerical simulation of solid particle impacts on Al6061-T6 Part II: Materials removal mechanisms for impact of multiple angular particles

In the accompanying paper (M. Takaffoli, M. Papini, Numerical simulation of solid particle impacts on Al6061-T6 Part I: Three dimensional representation of angular particles), it was demonstrated that realistic 3D models of angular particles could be generated and used with a smoothed particle hydrodynamics model to simulate the damage done to an Al6061-T6 target due to many non-overlapping particle impacts. In this paper, the same methodology was used to simulate overlapping impacts, and thus the material removal mechanisms associated with the solid particle erosion of this material. The evolution of the topography of the blasted surface was simulated, and the surface ripple patterns that typically form during the erosion of aluminum alloys were observed. The predicted volumetric erosion rates at different impact angles were, on average, within 7% of those measured in erosion experiments. An investigation of the simulated trajectory of the impacting particles revealed the cooperative contribution of overlapping impacts to material loss, and solid particle erosion mechanisms such as the micromachining of chips, the ploughing of craters, and the formation, forging and knocking off of crater lips. The results indicate that numerical simulation of the solid particle erosion of ductile metals by realistic angular particles is possible.     

基于电感式传感器的金属颗粒材质识别及粒径估计

传统的电感式颗粒传感器输出的是电感或电压幅值的脉冲信号,本质为标量信号。可通过脉冲信号的正负性区分金属颗粒是磁性或非磁性,且只能在已知颗粒材质的情况下估计颗粒的粒径。但在含有多种金属颗粒的油液中,基于标量信号的颗粒识别方法将失效。为此,本文采用了一种双锁相放大电路,将颗粒产生的复数域信号转化为一对直流信号。提出一种基于模糊隶属度函数的信号处理方法,实现了在噪音干扰下多种颗粒的材质识别和粒径估计。本文搭建了三线圈传感器实验系统。利用五种金属颗粒构建了隶属度函数,并进行系统标定。最后选取两种颗粒对标定后的系统进行了验证。结果表明系统对颗粒材质的识别准确,粒径估计误差小于2%。     

A two stage mechanism of ductile erosion

Photographic and metallographic evidence has shown that erosion of ductile materials can occur in two stages. The first stage is when the impacting particle strikes the surface to produce an indentation and possibly remove a chip of metal. The second stage is when the particle breaks up and fragments are projected radially from the primary site. The fragments can produce secondary damage. The processes have been expressed numerically and the resulting estimates gave good correlation with experimental data. The influence of velocity, particle size and angle of impact can be explained by consideration of the relative contributions of the two stages under different conditions.