COUPLED THERMO MECHANICAL FEM ANALYSIS OF TWIST COMPRESSION DEFORMATION PROCESS

3-D rigid-viscoplastic FEM of compressible materials was applied to analyze the deformation behavior during twist compression forming of axisymmetrical body at high temperatures. When calculating the temperature fields, considering the thermo mechanical coupling effect between temperature and deformation, 2-D FEM and CNG methods were adopted, and the up winding technique was used to avoid the influences of numerical instability on calculated results.

Effects of coil length on tube compression in electromagnetic forming

The effects of the length of solenoid coil on tube compression in electromagnetic forming were investigated either by theory analysis or through sequential coupling numerical simulation. The details of the electromagnetic and the mechanical models in the simulation were described. The results show that the amplitude of coil current waveform and the current frequency decrease with the increase of the coil length. And the peak value of magnetic pressure is inversely proportional to the coil length. The distribution of the magnetic force acting on the tube is inhomogeneous while the tube is longer than the coil. The shortened coil length causes the increases of the maximum deformation and energy efficiency. The numerically calculated result and the experimental one of the final tube profile are in good agreement.

Research on flow stress of spray formed 70Si30Al alloy under hot compression deformation

The flow stress of spray formed 70Si30Al alloy was studied by hot compression on a Gleeble- 1500 test machine. The experimental results indicated that the flow stress depends on the strain rate and the deformation temperature. The flow stress increases with an increase in strain rate at a given deformation temperature. The flow stress decreases with the deformation temperature increasing at a given strain rate. The relational expression among the flow stress, the swain rate, and the deformation temperature satisfies the Arrhenius equation. The deformation activation energy of 70Si30Al alloy during hot deformation is 866.27 kJ/mol from the Arrhenius equation.

Deformation mechanism of the spray formed 70Si30Al alloy during hot compression

The deformation mechanism of the spray formed 70Si30Al alloy was studied by hot compression on a Gleeble-1500 test machine. It is shown that hot deformation of the spray formed 70Si30Al alloy is achieved by liquid flow due to isostatic pressure and movement of solid particles due to shear force. Deformation condition depends on the nucleation rate and closure rate of the cavities. The flow stress slightly varies when the difference between the nucleation rate and closure rate of the cavities is small; however, it decreases when the nucleation rate of the cavities is greater than the closure rate of the cavities.

Failure mechanism and forming limit of tube axial compressive process

Based on minimum energy principle for plastic forming, tearing and buckling failures mechanisms are explored and criteria for them are developed by theoretical analysis and experiment. Combined with finite element software developed forming limit and effects of process parameters on failures are investigated and proper parameters for stable forming are determined. The results show that: 1) The failures and forming limit are mainly determined by geometry and materials parameters of tube blank, fillet radius or half conical angle of die. For the process under fillet die, there exists a maximum fillet radius within which no tearing failure happens, and a maximum radius and a minimum radius range within which no buckling failure happens. For the process under conical die, there exists a maximum and minimum half conical angle range within which no tearing and buckling failures occur. 2) For both forming processes, the higher the value of material strain hardening exponent or the lower the value of relative thickness, the more impossible for tearing and buckling failures to occur, and the larger the ranges of fillet radius and half conical angle. The experiment results verify the reliability and practicability of this research.

Effect of Extrusion Forming on Compressive Strength of Al_(18)B_4O_(33)w/Mg Composites

The aluminum borate whisker reinforced magnesium matrix composites (Al18B4O33w/Mg) were fabricated by pressure infiltration technique and extrusion-vacuum infiltration technique respectively to study the effect of extrusion forming on their mechanical behaviors. The microstructure of the composites was observed by scanning electron microscopy. The compressive strength was investigated and compared with that of the matrix alloy AZ91D. The results show that the extrusion forming could cause fracture of the whisker, but reduce the holes in the composite during impregnation and improve the interfacial bonding between the whisker and the matrix alloy. Compared with that of the matrix as-cast alloy AZ91D, the compressive strength of Al18B4O33w/Mg by the pressure infiltration technique was increased by 22%, while that of Al18B4O33w/Mg by the extrusion-vacuum infiltration technique was increased by 120 %.

Effect of Deformation Condition on Axial Compressive Precision Forming Process of Tube with Curling Die

The effect of the deformation condition on the axial compressive precision forming process of tube with curling die was investigated by using a rigid-plastic FEM. The results show that the forming accuracy depends mainly on geometric condition rp/d0, little on tube material properties and friction condition; the relative gap △/2rp of double-walled tubes obtained decreases with Increasing rp/d0, and there is a parameter k for a given to/do or rp/t0, when rp/d0 >k, △/2rp< 1, otherwise △/2rp>1.

Flow characteristics of aluminum coated boron steel in hot press forming

The flow characteristics of aluminum coated boron steel in hot press forming were investigated.Furthermore,the effects of aluminum coated layer on press forming were analyzed during deep drawing.The results show that aluminum coated boron steel exhibits a high sensitivity on temperature and strain rate.Aluminum coating layer appears in surface flaking in a temperature range of 700-800 ℃,but smooth surface is formed above 900 ℃.

Simulation and Analysis of Ring Compression Using RP/RVP Meshless Method

To avoid mesh distortion and iterative remeshing in mesh-based numerical analysis,a meshless approach based on element free Galerkin (EFG) method is applied to the metal forming analysis of ring compression. Discrete equations are formulated upon the moving least-squares (MLS) approximation and modified Markov variational principles for rigid-plastic/ rigid-viscoplastic (RP/RVP) material models. The penalty function is used for the incompressible condition without volumetric locking. Based on the axisymmetric mechanical model,ring tests with different friction coefficients are studied. The deformed nodal configurations and shaded contours of equivalent strains are shown by developed meshless post processor. The comparison of meshless and finite element (FE) results validates the feasibility and accuracy for meshless method to simulate metal forming process.

Basin-and Mountain-Building Dynamic Model of “Ramping-Detachment-Compression” in the West Kunlun-Southern Tarim Basin Margin

Analysis of the deformation structures in the West Kunlun-Tarim basin-range junction belt indicates that sediments in the southwestern Tarim depression were mainly derived from the West Kunlun Mountains and that with time the region of sedimentation extended progressivdy toward the north. Three north-underthrusting （subducting）, steep-dipping, high-velocity zones （bodies） are recognized at depths, which correspond to the central West Kunlun junction belt （bounded by the Kiida-Kaxtax fault on the north and Bulungkol-Kangxiwar fault on the south）, Quanshuigou fault belt （whose eastward extension is the Jinshajiang fault belt） and Bangong Co-Nujiang fault belt. The geodynamic process of the basin-range junction belt generally proceeded as follows： centering around the magma source region （which largely corresponds with the Karatag terrane at the surface）, the deep-seated material flowed and extended from below upward and to all sides, resulting in strong deformation （mainly extension） in the overlying lithosphere and even the upper mantle, appearance of extensional stress perpendicular to the strike of the orogenic belt in the thermal uplift region or at the top of the mantle diapir and localized thickening of the sedimentary cover （thermal subsidence in the upper crust）. Three stages of the basin- and mountain-forming processes in the West Kunlun-southern Tarim basin margin may be summarized： （1） the stage of Late Jurassic-Early Cretaceous rampingrapid uplift and rapid subsidence, when north-directed thrust propagation and south-directed intracontinental subduction, was the dominant mechanism for basin- and mountain-building processes; （2） the stage of Late Cretaceous-Paleogene deep-level detachment-slow uplift and homogeneous subsidence, when the dominant mechanism for the basin- and mountain-forming processes was detachment （subhorizontal north-directed deep-level ductile shear） and its resulting lateral propagation of deep material; and （3） the stage of Neogene-present compression-rapid uplift and strong subsidence, when the basin- and mountain-forming processes were simultaneously controlled by north-vergent thrust propagation and compression. The authors summarize the processes as the “ramping-detachment-compression basin- and mountain-forming dynamic model”. The basin-range tectonics was initiated in the Late Jurassic, the Miocene-Pliocene were a major transition period for the basin- and mountain-forming mechanism and the terminal early Pleistocene tectonic movement in the main laid a foundation for the basin-and-mountain tectonic framework in the West Kunlun-southern Tarim basin margin.

Study on Temperature Distribution of Specimens Tested on the Gleeble 3800 at Hot Forming Conditions

Taking Ti-6Al-4V specimens into consideration, the coupled thermal-electrical finite element model has been developed in Abaqus/Explicit to simulate the heating process in Gleeble 3800 and to study the temperature history and distribution in the specimen. In order to verify the finite element （FE） results, thermal tests are carried out on Gleeble 3800 for a Ti-6Al-4V specimen with a slot to in the centre of the specimen. The effects of the specimen size, heating rate, and air convection on the temperature distribution over the specimen have been investigated. The conclusions can be drawn as： the temperature gradient of the specimen decreases as the specimen size, heating rate, and vacuuming decrease.

围压和裂隙倾角对花岗岩力学行为的影响研究

含裂隙围岩的力学行为对高放废物地质处置库的长期稳定和安全至关重要。为研究围压和裂隙倾角对花岗岩围岩力学行为的影响,以完整花岗岩和含不同倾角贯通单裂隙的花岗岩为研究对象,开展了单轴压缩和三轴压缩试验研究。结果表明:0~10 MPa围压范围内,倾角30°和60°裂隙花岗岩分别发生了穿裂隙面破坏和沿裂隙面滑移破坏;随围压升高,倾角45°裂隙花岗岩由复合破坏转变为穿裂隙面破坏,后又在10 MPa围压条件下再次转变为倾斜“Z”字型裂纹的复合破坏。围压的存在制约了预制裂隙面的劣化作用。三轴压缩条件下低倾角裂隙花岗岩的抗压强度及变形发展曲线与完整花岗岩的结果相近,试样峰值破坏时的轴向应变在围压0,2,5,10MPa条件下分别约为0.38%,0.49%,0.59%和0.75%。沿裂隙面滑移破坏试样的抗压强度以及峰值破坏时的轴向应变均显著低于穿裂隙面破坏试样的相关结果,且其抗压强度与试验前后裂隙面的分形维数差值符合幂函数增长关系。

侧向约束下含拱玄武岩试样单轴压缩破坏行为研究

玄武岩作为岩浆岩的一种,广泛存在于人类活动的工程地质环境中。为研究含拱玄武岩的力学特征,本次试验运用水刀切割技术制作具有不同高跨比的含拱玄武岩试样,随后在刚性伺服机上对其进行侧限条件下的单轴压缩试验。分析了不同高跨比试样的峰值强度、破坏形态、裂隙类型和局部应变变化情况,以及拱的高跨比对含拱玄武岩试样裂纹扩展的影响。试验结果表明:随着拱高跨比的增加,试样峰值强度整体呈下降趋势,由于侧向约束的存在,试样峰值强度整体下降幅度较小,当拱的高度超过试样高度的1/2时,峰值强度降幅最大;拱的高跨比影响着裂纹的扩展方向,随着拱高跨比的增加,拱两侧破坏裂隙逐渐向中部靠拢,形成类倒漏斗形状,且试样中部的变形以微拉变形为主转变为以微压变形为主;试样的破坏过程总是由两侧的拱脚开始,逐渐出现岩屑剥落和裂纹起裂现象,随着加载的继续,拱脚处微裂纹逐渐向顶部扩展并贯通,导致试样最终完全破坏。

新型粉煤灰泡沫混凝土墙体轴心受压性能试验研究

利用工业固废粉煤灰制备节能与承重一体的新型墙体,对无冷弯薄壁C型钢外包内置钢丝网片固废粉煤灰泡沫混凝土墙体FW、外包1mm厚冷弯薄壁C型钢内置钢丝网片固废粉煤灰泡沫混凝土墙体CW1、外包2mm厚冷弯薄壁C型钢内置钢丝网片固废粉煤灰泡沫混凝土墙体CW2分别在轴压作用下的破坏形态、荷载-位移曲线及墙体极限承载力进行试验研究。研究结果表明:从破坏形态度角度,FW、CW1及CW2在破坏时,冷拔钢丝、冷弯薄壁C型钢发生屈服,泡沫混凝土破裂;FW大面积泡沫混凝土挤压破碎剥落,破坏严重;CW2破坏时完整性优于FW、CW1。从变形角度,CW1、CW2外包的C型钢能够对墙体内部的泡沫混凝土起到约束作用,墙体的刚度得到提升。从承载力角度,CW2较CW1提升了17.4%,较FW提升了23.7%。对墙体的轴压承载力进行理论计算,与墙体轴心受压试验的实测值相比,二者误差在10%以内且小于实测值,满足国家现行规范、行业技术标准相关要求。

基于火-储联合循环的冷热电三联供系统多运行模式热力性能分析

综合考虑绝热压缩空气储能及火电机组的特点和不足,该文从能量转化及利用机理出发,提出将二者耦合集成的火-储联合循环概念以及一种基于该循环的新型冷热电多能联供系统,并对该系统进行性能评估和特性分析。基于构建的热力模型,分别研究纯电及热电、冷电联产3种典型场景下热能综合利用方式对重要参数及性能的影响规律。结果显示,在最优集成方案下,储能系统的循环效率可提高2.61%。在热电和冷电模式下,循环效率可进一步提升至77%及70.13%。火-储集成能够显著提高能源综合利用水平,在多能联产模式下性能提升更为明显。此外,通过敏感性分析得到典型运行模式下热能利用的合理方式。该文结果能够指导火-储耦合集成系统优化设计及运行,可为火电机组与压缩空气-储能高效发展提供一种新思路。

节点约束对单面连接角钢受压承载力影响试验研究

为了研究节点约束对单面连接角钢受压承载力的影响,设计了一种弹簧支座刀口铰,通过试验研究了120根等边角钢的偏心受压稳定承载力。分析了其最小轴、平行轴布置时的破坏模式、承载力及变形形态,研究了不同节点约束、构造形式对其承载力的影响,并与国内规范进行了比较。研究结果表明:最小轴布置时,构件的失效模式为弯曲失稳,旋转轴介于最小轴和平行轴之间;平行轴布置时,构件失效模式为绕与刀口铰平行的主轴的弯曲失稳;构件长细比小于120时,其承载力主要受偏心控制,偏心越大,承载力越低;构件长细比大于120时,其承载力主要受约束刚度控制,约束刚度越大,承载力越高;采用A、C类连接时,在不同长细比下二者各具优势,但采用B类连接时构件的承载力始终低于采用A、C类连接时的承载力;与规范的对比表明,规范GB 50017—2017和DL/T 5486—2020均未考虑节点构造形式对斜材受压承载力的影响,计算结果存在一定的局限性,研究结论对于工程设计具有一定的指导意义。

海底管线管全流程成形过程中残余应力演化

为了研究海底管线管全流程成形过程中残余应力的演化,考虑成形工序中应力的继承,采用ABAQUS软件开展了管线管JCO、焊接和多向缩径校准全流程成形过程有限元模拟。首先进行了JCO成形过程模拟,然后基于高斯面热源子程序对JCO成形后的管线管进行了焊接过程模拟,最后对焊接后的管线管进行了多向缩径校准成形过程模拟,探讨了多向缩径校准成形工艺参数对管线管残余应力的影响。模拟结果表明:多向缩径校准可以实现管线管几何形状和残余应力的双重调控;相对传统的2瓣模具缩径,采用4瓣模具和8瓣模具校准后的管线管残余应力分布更加均匀;摩擦因数对残余应力的影响不明显;采用4瓣模具、 0.04摩擦因数和1.6%缩径率校准后的管线管椭圆度可达0.05%,除焊接热影响区,管线管内外表面的最大周向残余应力分别为28和-45 MPa,截面Mises残余应力均值为(120±20) MPa,焊缝区和非焊缝区的Mises残余应力均值分别降低了79%和30%。

T形橡胶密封圈压缩模优化设计

飞机起落架T形橡胶密封圈模压成型过程中,分型面选择不合理导致飞边去除困难,且易伤及密封圈密封面;溢料槽距离型腔较远,余料不能全部流出,导致尺寸超差;料室、柱塞张角太大,浪费原料。通过分析T形橡胶密封圈使用功能,优化后将模具分型面设计在密封圈R0.5mm圆弧与直边转接处;溢料槽设计成等腰梯形,且边缘距离型腔1 mm;模具采用小角度锥面定位,定位精度高,保证同轴度;调整模具各型腔制造公差。模压成型的零件表面质量高,尺寸稳定性好,飞边去除简单方便,零件合格率达98%以上。

基于掺氢燃气轮机的综合能源系统热经济学性能研究

为实现燃驱天然气场站的低碳高效运行,构建了一种新型综合能源系统架构,采用蒸汽循环回收燃气轮机的余热,电能用于驱动固体氧化物电解制氢技术产生氢气,进而将氢气通入燃气轮机中实现掺氢燃烧,同时利用压缩空气储能技术将可再生能源转化成稳定的电能输出。计算结果表明,系统在设计工况下的能量效率、(火用)效率和平准化单位能量成本分别为85.66%、41.37%和294.70元/(MW·h)。敏感性分析表明,燃气轮机压比和掺氢比例、蒸汽循环低压锅炉压力和抽汽系数、压缩空气储能技术释能功率对系统热力学性能影响显著,而燃气轮机压比和掺氢比例、蒸汽循环抽汽系数对系统经济学性能影响显著。多目标优化结果表明,系统的最优(火用)效率和平准化单位能量成本分别为42.31%和284.33元/(MW·h)。

纤维素基粘结剂对型煤成型的影响研究

粘结剂成分及配比对型煤的成型过程、强度、成本控制等方面具有至关重要的作用。文章基于冷压成型工艺,改变无机粘结剂、复合纤维素基粘结剂、添加水量的配比,探究了这3种因素对颗粒强度的影响规律及机理。结果表明:影响成型的最关键因素是水分添加量,其次是粘结剂的种类及用量;复合纤维素基和无机成分混合后,增强了成型过程中的机械与物理化学结合力,显著增强了颗粒抗压强度;纤维素Ⅰ(8%)+纤维素Ⅱ(16%)+黄陶土(6%)+水分(20%)配比下的型煤冷、热强度分别达到1320.16和132.97 N,其成型最为理想,可以指导工业化应用及理论发展。