表面机械研磨处理对纯铜棘轮行为的影响:宏微观试验与本构模拟

目的 通过金属表面纳米化试验机制备出梯度结构纯铜,提升纯铜材料的疲劳寿命,并揭示其背后的机理。方法 通过系统的宏观力学性能测试、微观组织表征以及本构模拟探究了表面机械研磨处理(Surface Mechanical Attrition Treatment,SMAT)对T2纯铜棘轮行为的影响。结果 循环变形试验结果表明SMAT纯铜样品的循环失效圈数明显多于未处理纯铜样品的循环圈数,且SMAT纯铜样品在循环过程中的累积塑性变形明显小于未处理纯铜样品的累积塑性变形,即棘轮应变明显小于未处理纯铜样品的棘轮应变。电子背散射衍射(Electron Back Scattered Diffraction,EBSD)和X射线衍射分析(X-Ray Diffraction,XRD)表征发现:经过SMAT后,材料的晶粒尺寸均呈现由处理表面到材料芯部逐渐减小的梯度分布。且SMAT时间越长,样品的总位错密度越大。此外,基于应变梯度塑性理论模型对SMAT前后纯铜的单拉及循环变形响应进行了有限元模拟,模拟结果显示累积塑性应变沿深度方向(SMAT冲击方向)呈梯度分布,最大几何必需位错密度以及最大等效应力均出现在模型的次表层。同时,当模拟的循环圈数相同时,代表SMAT样品的梯度结构模型的棘轮应变明显低于代表未处理样品的均匀模型的棘轮应变。结论 循环变形试验结果表明SMAT对于T2纯铜的棘轮应变有抑制作用,有限元模拟进一步揭示了SMAT对于棘轮应变的抑制效应以及背后的机理。     

合金钢的高温单轴棘轮效应实验研究1.25Cr0.5Mo

利用MTS810电液伺服试验机在300℃温度下对1.25Cr0.5Mo合金钢进行了单轴棘轮效应实验研究,探讨了温度、应力幅值、应力峰值、平均应力以及加载历史对材料棘轮效应的影响.以0.1%/s及0.2%/s两种不同的应变加载速率分别对材料进行单轴拉伸实验,结果表明1.25Cr0.5Mo合金钢在所研究的温度范围内的变形行为是率无关的;在0.4%应变幅值下进行了单轴应变循环实验,响应应力幅值随循环次数几乎没有变化,可视为循环稳定材料;单轴棘轮效应实验表明棘轮应变速率随平均应力、应力幅值及温度的升高而增大;棘轮变形依赖于加载历史,先前较大的循环应力对后继较小的循环应力下的棘轮变形起抑制作用.     

Lateral earth pressure behind an integral abutment

Integral abutment bridges have gained increasing attention in the past few decades. They provide a cost-effective solution to the high maintenance expenses associated with the joints and bearings found in conventional bridges. This paper describes the observed behaviour of granular soil backfill retained behind an integral abutment subjected to cyclic loading. Significant pressure build-up was observed in the soil behind the abutment in most locations. The pressure build-up is attributed to several mechanisms such as sand particle flow and densification due to cyclic loading, and the shearing of dense sand during bridge expansion. Therefore, the applicability of using a linear soil pressure distribution assumed by the classical theories in designing the integral abutment system is discussed. Furthermore, the vertical and lateral distribution of the soil pressure behind the abutment has also been analysed. Results from the data measured show that bridge skew resulted in bigger soil pressures at the obtuse side of the abutment compared to the acute. The conclusions of this paper highlight several new design aspects, which are usually overlooked by the common design methodologies of integral abutments, that more accurately predict the vertical and lateral variation in the soil pressure behind abutments.     

Adhesive Layer Shrinkage in Bonds Subjected to Thermal Cycling

Residual stress states within certain classes of polymeric adhesives andcoatings subjected to cyclic temperature conditions can becomeincreasingly tensile with exposure to cyclic temperature conditions.Under some conditions, these tensile stresses are believed to beresponsible for initiating debonds which may eventually propagatethroughout the bond. In certain potting-type applications in which thepolymer is constrained in a particular fashion, these debonded layerscan shrink extensively. In an industrial application, this shrinkage hasreached as much as 15%, nearly two orders of magnitude larger thanexpected based on simple thermal contraction. This paper provides athermal racheting explanation for this dramatic shrinkage. Numericalstudies have confirmed the explanation, and provide additional insightsinto the effects of temperature range, coefficient of friction betweenthe adhesive and substrates, and the viscoelastic nature of theadhesive. Based on the hysteretic nature of the normal forces whichaffect the frictional forces, the proposed mechanism usesfriction hysteresis under cyclic thermal conditions to explain observedshrinkage.     

Ratcheting and fatigue-led wear in rail–wheel contact

A computer model, which simulates the ratcheting wear of a ductile material subject to repeated loading, is presented and discussed in detail. Variation of material properties is a feature of the model, failure by ductility exhaustion occurring at isolated points or extending regions of failure. Such regions form crack‐like features. Mechanisms for removal of weakened material from the surface as wear debris are described. The wear process causes a degree of surface roughness. The simplicity of the model enables simulation of millions of load cycles in only a few hours' computer time. The computer model is used to study the effect of partial slip on wear rate. When creepage is relatively low, the wear rate increases sharply with creepage. When creepage is relatively high, the wear rate is largely insensitive to the creepage.     

Effect of stress parameters on ratcheting deformation stages of polycrystalline OFHC copper

Engineering stress‐controlled ratcheting tests under different sets of stress amplitudes and mean stresses show that ratcheting deformation in polycrystalline OFHC copper occurs in three different stages. A plateau region with almost no accumulation of inelastic strain follows general ratcheting deformation during initial loading cycles. With breakdown of the plateau region inelastic ratcheting deformation occurs at an increasingly rapid rate. The effect of the stress amplitude on the ratcheting process is found to be more than mean stress effect. Reconstruction of the ratcheting curves clearly separates the conditions for stress‐controlled low cycle fatigue with zero mean stress and ratcheting with tensile mean stress.     

An integrated thermal and mechanical investigation of molten-salt thermocline energy storage

Thermal ratcheting is a critical phenomenon associated with the cyclic operation of dual-medium thermocline tanks in solar energy applications. Although thermal ratcheting poses a serious impediment to thermocline operation, this failure mode in dual-medium thermocline tanks is not yet well understood. To study the potential for the occurrence of ratcheting, a comprehensive model of a thermocline tank that includes both the heterogeneous filler region as well as the composite tank wall is formulated. The filler region consists of a rock bed with interstitial molten salt, while the tank wall is composed of a steel shell with two layers of insulation (firebrick and ceramic). The model accounts separately for the rock and molten-salt regions in view of their different thermal properties. Various heat loss conditions are applied at the external tank surface to evaluate the effect of energy losses to the surroundings. Hoop stresses, which are governed by the magnitude of temperature fluctuations, are determined through both a detailed finite-element analysis and simple strain relations. The two methods are found to yield almost identical results. Temperature fluctuations are damped by heat losses to the surroundings, leading to a reduction in hoop stresses with increased heat losses. Failure is prevented when the peak hoop stress is less than the material yield strength of the steel shell. To avoid ratcheting without incurring excessive energy loss, insulation between the steel shell and the filler region should be maximized.     

Optimization of Preventive Grinding of Backup Roll against Contact Fatigue Cracking

Continuouslyvariablecrown(CVC)system, developedbySMSSchloemann Siemag,hasbeen widelyusedforshapecontrolataminimumcost[1,2]. BackuprollsareimportantcomponentsoftheCVC rollingmillsandtheirconsumptionratewillsoaras soonasmacro rollingcontactfatigue(RCF)occur…