PREDICTION OF FLOW STRESS OF HIGH-SPEED STEEL DURING HOT DEFORMATION BY USING BP ARTIFICIAL NEURAL NETWORK

The hot deformation behavior of TI (18W-4Cr-1V) high-speed steel was investigated by means of continuous compression tests performed on Gleeble 1500 thermomechan- ical simulator in a wide range of tempemtures (950℃-1150℃) with strain rotes of 0.001s-1-10s-1 and true strains of 0-0. 7. The flow stress at the above hot defor- mation conditions is predicted by using BP artificial neural network. The architecture of network includes there are three input parameters:strain rate,temperature T and true strain , and just one output parameter, the flow stress ,2 hidden layers are adopted, the first hidden layer includes 9 neurons and second 10 negroes. It has been verified that BP artificial neural network with 3-9-10-1 architecture can predict flow stress of high-speed steel during hot deformation very well. Compared with the prediction method of flow stress by using Zaped-Holloman parumeter and hyperbolic sine stress function, the prediction method by using BP artificial neurul network has higher efficiency and accuracy.

Evaluation of Residual Stresses Induced by High Speed Milling Using an Indentation Method

In this work, a recently developed method based on the change of distance between collinear indents is used to evaluate different states of residual stress, which were generated in samples of AA 6082-T6 and AA 7075-T6 aluminium alloys milled at high speed. One of the advantages of this method, which needs a universal measuring machine, is not requiring neither the use of specific equipment nor highly skilled operators. Also, by integrating an indentation device to the mentioned machine, the absolute error of measurement can be reduced. In results obtained in samples subjected to different cutting conditions it is observed a correlation between the stress values and the depth of cut, showing the AA 6082-T6 alloy higher susceptibility to be stressed. Furthermore, the high sensitivity of the method allowed detecting very small differences in the values reached by different normal components in the zones corresponding to climb and conventional cutting. It is important to note that these differences were similar for both evaluated alloys. Finally, the directions associated with the principal components of residual stress, where maximum local plastic stretching occurs, were found to be strongly dependent on the rolling direction prior to machining.

Methodology to Evaluate Fatigue Damage of High-Speed Train Welded Bogie Frames Based on On-Track Dynamic Stress Test Data

The current method of estimating the fatigue life of railway structures is to calculating the equivalent stress amplitude based on the measured stress data. However, the random of the measured data is not considered. In this paper, a new method was established to compute the equivalent stress amplitude to evaluate the fatigue damage based on the measurable randomness, since the equivalent stress is the key parameter for assessment of structure fatigue life and load derivation. The equivalent stress amplitude of a high-speed train welded bogie frame was found to obey normal distribution under uniform operation route that verified by on-track dynamic stress data, and the proposed model is, in effect, an improved version of the mathematical model used to calculate the equivalent stress amplitude. The data of a long-term, on-track dynamic stress test program was analyzed to find that the normal distribution parameters of equivalent stress amplitude values differ across different operation route. Thus, the fatigue damage of the high-speed train welded bogie frame can be evaluated by the proposed method if the running schedule of the train is known a priori. The results also showed that the equivalent stress amplitude of the region connected to the power system is more random than in other regions of the bogie frame.

Techniques for improving computational speed in numerical simulation of casting thermal stress based on finite difference method

Finite difference method (FDM) was applied to simulate thermal stress recently, which normally needs a long computational time and big computer storage. This study presents two techniques for improving computational speed in numerical simulation of casting thermal stress based on FDM, one for handling of nonconstant material properties and the other for dealing with the various coefficients in discretization equations. The use of the two techniques has been discussed and an application in wave-guide casting is given. The results show that the computational speed is almost tripled and the computer storage needed is reduced nearly half compared with those of the original method without the new technologies. The stress results for the casting domain obtained by both methods that set the temperature steps to 0.1 ℃ and 10 ℃, respectively are nearly the same and in good agreement with actual casting situation. It can be concluded that both handling the material properties as an assumption of stepwise profile and eliminating the repeated calculation are reliable and effective to improve computational speed, and applicable in heat transfer and fluid flow simulation.

Effect of Increasing Speed on Stress of Biaxial Bogie Frames

Increasing the trains’ speed has always been one of the goals of any railway industry and train manufacturers. Also, the influence of the train speed on bogie’s dynamics has an immense importance. Therefore, it is important to analyze the effect of train speed on the stress distribution in different parts of train structure. In this study the result of the increasing speed on the applied stresses of a biaxial bogie frame has been examined. For this purpose, a biaxial bogie frame has been modeled using finite element analysis. Static and dynamic forces applied on the bogie with biaxial frame have been obtained for different speeds and rail roughness. The Von Mises stresses are adopted as equivalent stresses in the strength calculation. The results show that maximum stress always has been induced in the bogie bowl also the increase in bogie’s speed has remarkable effect on the increment of applied stresses in the bogie frame.

Analysis of stress and natural frequencies of high-speed spatial parallel mechanism

In order to grasp the dynamic behaviors of 4-UPS-UPU high-speed spatial parallel mechanism, the stress of driving limbs and natural frequencies of parallel mechanism were investigated. Based on flexible multi-body dynamics theory, the dynamics model of 4-UPS-UPU high-speed spatial parallel mechanism without considering geometric nonlinearity was derived. The stress of driving limbs and natural frequencies of 4-UPS-UPU parallel mechanism with specific parameters were analyzed. The relationship between the basic parameters of parallel mechanism and its dynamic behaviors, such as stress of driving limbs and natural frequencies of parallel mechanism, were discussed. The numerical simulation results show that the stress and natural frequencies are relatively sensitive to the section parameters of driving limbs, the characteristic parameters of material on driving limbs, and the mass of moving platform. The researches can provide important theoretical base of the analysis of dynamic behaviors and optimal design for high-speed spatial parallel mechanism.

波形钢腹板梁焊接残余应力分布及试验验证

为研究波形钢腹板梁焊接残余应力的分布规律,通过有限元软件建立其三维热弹塑性模型,利用热-力耦合分析技术对其焊接温度场和应力场进行有限元数值仿真,采用双椭球体热源和修改单元材料属性的方法实现能量输入和焊缝填充,并将模拟计算结果与实测值进行对比分析.结果表明:有限元预测的波形钢腹板梁残余应力分布与实测结果具有相同趋势,在波形钢腹板梁焊缝的弯折角处,残余应力发生一定幅度的连续应力波动;底板和腹板的残余应力峰值均出现在焊缝中心区域,其值分别为材料屈服强度的1.30倍和1.26倍;底板纵向残余拉应力在焊缝中心线两侧78 mm范围内急速下降后缓慢过渡为压应力,在底板较窄一侧压应力线性增大,最大值约为材料屈服强度的0.61倍;在底板较宽一侧压应力线性减小,并在边缘处转化为拉应力;焊接速度对残余应力分布扰动不大,而对残余应力峰值影响较显著;当焊接速度从150 mm/min增加至250 mm/min时,横向和纵向的残余应力最大值分别增加了27.11%和5.88%.

采空区场地高速铁路路基动力响应离散元数值模拟分析

目的高速铁路穿越采空区场地存在重大安全隐患,为探讨采空区场地高速铁路路基的动力响应规律,方法利用3DEC离散元软件建立17组采空区场地高速铁路路基数值模型,分析不同列车荷载作用下路基内部的沉降变形和动应力分布规律,对比分析无砟轨道和有砟轨道路基内部动力响应的分布差异,分析采空区开采宽度、厚度对动力响应分布规律的影响。结果与无砟轨道相比,有砟轨道路基内部的动应力幅值明显更高,但其动应力的衰减速率也更高;动应力、动位移的时程曲线沿着路基深度方向出现不断增大的相位差;路基内部动位移幅值随着荷载作用时间增加而逐渐增大,但增大的速度不断降低,动应力幅值基本保持不变;动应力、动位移幅值与列车轴重存在明显的线性关系,随着轴重增加而线性增大;采空区开采宽度、厚度越大,列车荷载造成的动位移幅值也越大,但当开采宽度大于一定数值后,动位移幅值反而出现减小趋势。结论列车荷载、路基轨道类型和采空区场地的差异都会对路基内部的动力响应分布情况产生影响,研究结果可为采空区场地高速铁路的安全运行提供理论参考。

波形钢腹板梁T形接头焊接仿真分析与试验研究

为了解决波形钢腹板梁焊接温度场和残余应力分布尚不明确的问题,本文基于Simufact Welding软件建立三维有限元模型,对其T形接头的焊接温度场和残余应力进行了预测,并对模拟结果进行了试验验证。波形钢腹板梁的焊接温度场分布与熔池中心距离有关,距离熔池中心越近,温度梯度越大;焊接残余应力以纵向残余拉应力为主,而横向残余应力的应力水平相对较低,拉压应力共存;焊接速度和底板厚度的改变只会影响残余应力的峰值大小,不会影响残余应力的分布规律。结果表明:数值模拟结果和试验实测值吻合良好,数值模拟可靠。

锥面分段开孔高速刀柄的设计方法

根据高速刀柄在不同过盈量下的联接性能分析结果与不同转速下的锥面接触应力分布规律,提出了一种锥面分段开孔高速刀柄的设计方法,即对刀柄定位锥面按照锥体素线长度均等分成前、中、后三段,并在各段的中等分处周向均布一组盲孔,通过调控盲孔的数量与尺寸使刀柄锥面达到一定的柔度。文章阐述了盲孔开设参数对锥面接触应力、柔度的影响规律和参数确定原则,给出了以HSK-E50为原型的锥面分段开孔设计案例,采用有限元分析其极限转速和锥面接触应力分布情况。结果表明,锥面分段开孔刀柄与原型刀柄相比,极限转速提高了约10.79%,锥面接触应力分布显著均匀。

航空铝合金激光焊接关键工艺参数与应力场关系

激光焊接工艺参数不仅影响铝合金结构件的残余应力,而且影响其服役性能,探究参数与应力场的关系对提高焊接结构件的质量具有重要的意义。采用圆锥热源模型对厚度为5 mm的7075-T7351铝合金板材进行激光焊接数值模拟,分析焊接速度和激光能量两个关键参数对焊接残余应力场的影响规律,并借助实验验证模拟结果的准确性,揭示7075铝合金激光焊接工艺参数与应力场的关系。研究结果表明:残余应力会随着焊接速度的增加而不断增大,但当焊速超过一定值后焊核区应力不再增加,最大应力逐渐向两侧扩展;激光能量越大,导致残余应力降低且最大残余应力分布区域逐渐扩大;获得7075铝合金激光焊的最佳工艺窗口,焊接速度5~7 mm/s,激光焊接能量70~100 J/mm。所得研究成果在7075铝合金激光焊接工艺优化的周期缩短和成本降低方面具有一定的价值和意义。

插入道岔施工对运营高速道岔锁定轨温变化影响试验

为研究插入道岔施工(Turnout Inserting Construction,TIC)对既有高速道岔锁定轨温(StressFree Rail Temperature of Existing high-speed Turnout,SFRTET)的影响,提出基于双向应变法的锁定轨温变化测试方案,推导不同因素影响下的锁定轨温变化测量原理,确定监测数据的处理方法,并开展道岔锁定轨温变化现场试验研究.研究结果表明:基于锁定轨温变化监测方法确定的传感器安装时轨温与实测数据差异仅1.4%,验证了测试方案的合理性和数据处理方法的正确性;高速道岔的锁定轨温会受插入道岔各工序施工的影响,其在轨道结构拆除、轨道结构施工、道岔形位精调和工电联调3个工序中表现出显著的动态变化特征,即锁定轨温经历多次循环变化才达到稳定状态;既有高速道岔锁定轨温受侧股钢轨重新焊接施工影响最为显著,尤其是靠近焊接位置的侧股钢轨,其锁定轨温变化达12.87℃,建议侧股钢轨重新焊接工序尽可能选择在轨温接近既有道岔原锁定轨温时开展.

高速铁路接触网弹性吊索疲劳仿真研究

为研究弹性吊索的服役状态与疲劳寿命,对高铁接触网出现的弹性吊索断线现象进行调研并开展疲劳研究。基于武广高铁的线路设计参数构建了弓网动态仿真模型,对300 km/h速度下的弹性吊索振动状态进行分析。由于受电弓运行通过时对接触悬挂的抬升作用,弹性吊索主要沿竖直方向振动,并在线夹位置不断承受交变弯曲载荷。在UG软件中建立了弹性吊索绞线(1×7)及其线夹的实体模型并将其导入到LS-DYNA软件中进行了应力载荷计算;其应力集中位置位于弹性吊索与其线夹连接处。将应力历程数据导入到ANSYS nCode DesignLife软件中分析弹性吊索在指定载荷下的疲劳寿命。最后,根据Miner累积损伤原则计算了300 km/h运行速度下武广高铁弹性吊索的疲劳寿命为4.58×10~6弓架次;当运行速度增加至350 km/h时,疲劳寿命为1.17×10~6弓架次;当运行速度增加至400 km/h时,疲劳寿命为4.80×10~5弓架次。

浅层取换套修井作业的井口切割装置设计与分析

在油井下井过程中,套管钳会对套管的连接螺纹产生损伤,套管在井中也容易受到腐蚀,导致取换过程中套管卸扣困难,需要对套管进行迅速的切割处理。然而,由于井口作业的空间有限,现有的套管取换方法费用高、周期长、动力紧张且油田生产现场不能出现明火。基于此,设计一种包括扶正机构、切割机构、传动机构、切割刀具四部分的浅层取换套修井作业的井口切割装置。通过ANSYS等软件对主要零部件进行分析,结果表明:该装置具有体积小、安装方便、切割工作安全可靠、切割效率高等优点,可实现快速切割套管的功能,从而提高作业效率,降低成本。

风电机组结构动力响应研究

针对风电机组动力响应引起的稳定性问题,文章研究了不同风速下的叶片与塔架一体化风力机数值响应情况。基于SolidWorks建立风力机三维结构模型,提取叶根和叶尖质点,利用有限元分析法,分析不同风速变化情况下的应力及位移变化趋势。对风力机摆振方向与挥舞方向的风速衰减进行研究,探讨了叶片表面附近流场剪应力分布。结果表明:在不同风速下,叶尖、叶根应力及位移变化呈现一定的规律性;在自然风经过风力机时,风能被有效捕获,进而呈现规律性衰减。研究结果为风力机运行动力学提供了参考。

冲击荷载下充填节理岩体Ⅰ型裂纹动态扩展特性研究

为研究冲击荷载作用下充填节理岩体Ⅰ型裂纹动态扩展特性,利用分离式霍普金森杆(split Hopkinson pressure bar,简称SHPB)试验系统及裂纹扩展测试系统,对石膏、水泥及云石胶3种充填节理的侧开三角形单边裂纹(singlecleavage triangle,简称SCT)岩体试件进行动态冲击压缩试验,对比分析裂纹动态扩展过程及冲击破坏模式,并通过试验-数值法研究了Ⅰ型裂纹动态扩展过程中的应力强度因子及能量释放率的变化规律。研究表明:充填节理岩体主要有3种破坏模式,分别为预制裂纹扩展贯穿整个试件、裂纹贯穿后发生充填节理破坏、充填节理先破坏并阻滞裂纹贯穿;节理充填体的破坏与充填体强度、胶结力及应变率等相关;裂纹扩展速度自起裂处振荡增长,并在贯穿充填节理前某个位置达到最大,而应力强度因子及能量释放率在节理附近达到最大;充填节理刚度退化会抑制裂纹的扩展,并造成能量释放率的急剧增大;岩性组合差异加剧岩体试件材料属性的失配,导致应力强度因子及能量释放率随裂纹穿过节理后出现不同程度降低。

闸墙长廊道侧支孔船闸阀门运行方式优化试验研究

船闸阀门开启时间对闸室通航效率、输水廊道压力和闸室停泊条件等产生影响,针对阀门运行方式优化问题,采用物理模型试验对船闸进水口水位、阀门段输水廊道压力特性、闸室和下引航道内船舶系缆力等水力特性进行分析,结果表明:闸室和下引航道内前横、后横和纵向3个方向的船舶系缆力均随阀门开启时间增大而减小,且纵向船舶系缆力大于横向船舶系缆力。随着阀门开启时间增加,充水时阀门段输水廊道压力先减小后增大,泄水时则逐渐增大。综合考虑当阀门开启时间为6 min时船闸整体运行效果较好,该成果可为实际船闸运行提供技术支撑。

高速精密压力机多杆机构弹性动力学研究

高速精密压力机机构运动精度是冲压产品质量关键影响因素,机构弹性动力学研究对提高冲压机构运动精度有重要意义。以高速压力机双滑块六杆机构为研究对象,基于弹性动力学理论建立多杆机构弹性变形分析数学模型,提出考虑弹性变形冲压机构运动精度求解方法。以梁单元作为等效单元,综合考虑了横向位移、纵向位移、转角位移以及曲率的影响,建立机构运动微分方程,利用实振型叠加法进行求解。最终确定构件弹性变形及其导致的下死点精度误差,同时获得弹性构件最大动应力。分析结果表明弹性变形是精密冲压机械运动精度主要影响因素,高速精密压力机弹性动力学研究对运动精度设计具有理论指导意义。

基于声流的非接触超声电机理论分析与试验研究

针对传统超声电机存在严重的摩擦磨损及难以长时间连续工作的问题,本文中基于声流原理设计了1种新型的非接触式超声电机.建立电机定子谐响应有限元分析模型,获得其工作频率及结构振型,并对悬浮间隙内的声流场进行建模,采用雷诺应力法求解声流场驱动力,分析不同激励电压下转子转速以及驱动力的变化规律.为验证模型的合理性,搭建试验测试系统并进行性能测试对比分析.结果表明,该电机在声流驱动下能够稳定地运转,转速随着电压的升高而单调上升,驱动电压为1430 V时,转子转速可以达到28 r/min.理论结果与试验结果具有较好的一致性,验证了模型的合理性.