Study on Plasticity Modification for Measuring High Residual Stress by Hole-Drilling Method

Hole-drilling method is a commonly used method for measuring residual stress. The calibration coefficients in ASTM E837-13 a would cause large errors due to the plasticity deformation of materials. In the study, calibration coefficients were modified in the plasticity deformation stage based on the distortion energy theory. The calibration experiment of calibration coefficients was simulated by the finite element model, and the plasticity modification formulas of 7075 aluminum alloy were obtained. From the results of uniaxial tensile loading test, the measuring errors of high residual stress are significantly reduced from-4.071%～53.440% to-5.140% ～ 0.609% after the plasticity modification. This work provides an effective way to expand the application of hole-drilling method.

Use of Plastic Correction Formula to Improve Accuracy of Welding Residual Stress Test with Blind-Hole Method

The blind-hole method is the most widely used approach to experimentally determine the distribution of residual stress. This paper aims to improve test accuracy of welding residual stress and conducts an experimental study on the strain release factors involved when using the blind-hole method for Q235 and Q345, two steels commonly used in building structures. The ranges of strain release factors A and B in the elastic stage, the effects of strain release factors on residual stress calculated values, and the plastic corrected strain release factors are analyzed considering of the effect of plastic deformation around the blind hole on measurement accuracy. Finally, a simplified calculation formula to determine strain release factors is proposed for use with the blind-hole method. Results show that in the elastic stage, strain release factor A for Q235 and Q345 ranges from-0.399 to-0.525 and strain release factor B from-0.791 to-0.960. Changing the strain release factors A and B shows that calculated residual tensile stress varies in relation to a decrease in both factor values. However, there is a increase in calculated residual compressive stress with a decrease in the strain release factor A value, but there is an decrease with a decrease in strain release factor B value. Calculated residual stress applied to elastic strain release factors is compared with that applied to amended plastic strain release factors for Q235 steel. The maximum deviation between calculated residual stress and test stress is reduced from 21.1 to 1.0%,and for Q345 steel from 26.5 to 1.2%. It is thus evident that the plastic correction formula proposed in this paper can be used in calculations when conducting a residual stress test.

Butt-welding Residual Stress of Heat Treatable Aluminum Alloys

This study, taking three types of aluminum alloys 2024-T351, 6061-T6 and 7075-T6 as experimental materials, conducted single V-groove GTAW （gas tungsten arc welding） butt-welding to analyze and compare the magnitude and differences of residual stress in the three aluminum alloys at different single V-groove angles and in restrained or unrestrained conditions. The results show that the larger the grooving angle of butt joint, the higher the residual tensile stress. Too small grooving angle will lead to dramatic differences due to the amount of welding bead filler metal and pre-set joint geometry. Therefore, only an appropriate grooving angle can reduce residual stress. While welding, weldment in restrained condition will lead to a larger residual stress. Also, a residual stress will arise from the restraint position. The ultimate residual stress of weldment is determined by material yield strength at equilibrium temperature. The higher the yield strength at equilibrium temperature, the higher the material residual stress. Because of its larger thermal conductivity, aluminum alloy test specimens have small temperature differential. Therefore, the residual tensile stress of all materials is lower than their yield strength.

Residual stress evolution regularity in thermal barrier coatings under thermal shock loading

Residual stress evolution regularity in thermal barrier ceramic coatings （TBCs） under different cycles of thermal shock loading of 1 100℃ was investi- gated by the microscopic digital image correlation （DIC） and micro-Raman spec- troscopy, respectively. The obtained results showed that, as the cycle number of the thermal shock loading increases, the evolution of the residual stress under- goes three distinct stages： a sharp increase, a gradual change, and a reduction. The extension stress near the TBC surface is fast transformed to compressive one through just one thermal cycle. After different thermal shock cycles with peak temperature of 1 100℃, phase transformation in TBC does not happen, whereas the generation, development, evolution of the thermally grown oxide （TGO） layer and micro-cracks are the main reasons causing the evolution regularity of the residual stress.

能量配比对6 mm 7A52铝合金板材VPPA-MIG复合焊接残余应力分布的影响

VPPA-MIG复合焊接的热源由VPPA和MIG两种电弧热源混合而成,该焊接方法集合了MIG焊接效率高、参数区间宽以及VPPA焊接能量集中、穿透深度大等优点,能够实现不同厚度铝合金板材的高效率和高质量焊接。在铝合金板材VPPA-MIG复合焊接过程中,VPPA与MIG两种电弧不同能量配比会影响焊后接头的残余应力分布。以6 mm厚7A52铝合金板材为试验材料,设置VPPA电弧能量配比不同的焊接参数进行VPPA-MIG复合焊接试验,焊后采用钻孔法测试并分析了接头残余应力分布及峰值大小。结果表明,复合焊接接头的熔合区和热影响区出现拉应力,母材区出现压应力。在复合焊接热源总能量不变的情况下,残余应力峰值随VPPA电弧能量配比的增加而增大,且当VPPA电弧能量配比从35%增大至40%时,可以获得成形效果良好的复合焊缝,横向残余应力峰值不超过73 MPa,纵向残余应力峰值不超过232 MPa,不会出现过大的残余应力峰值。与单MIG焊接相比,VPPA-MIG复合焊的残余应力峰值比单MIG焊大,而高应力区要比单MIG焊窄。

钢板残余应力检测方法的实验比较

为验证自主研制的透射式励磁感应钢板内应力无损检测系统的测量效果,在工厂生产线上切取了2种材质、不同板形的4块钢板作为残余应力测量试样,分别使用自研系统、X射线衍射法、超声法和盲孔法进行残余应力测量及比较。取样测量实验发现,4种方法的残余应力测量结果相差明显,同一被测点的测量结果也相差较大,在个别被测点出现残余应力测量值符号相反的现象。针对测量结果数据及其存在的差异,从4种方法的检测原理出发,定性分析了产生差异的原因,概括出4种方法的技术特点,并针对每种方法提出若干使用建议。

四种典型球墨铸铁应变释放系数及其塑性修正研究

盲孔法是工程中测量残余应力最普遍的方法,其中材料的应变释放系数是该方法中的关键参数,目前国内外对球墨铸铁的应变释放系数研究相对较少。本文采用盲孔法对四种常用球墨铸铁QT450-10、QT550-6、QT600-3和QT700-4的应变释放系数进行了标定,得到应变释放系数与应力的关系曲线,发现低牌号的球墨铸铁由于铁素体含量多,对应力集中更为敏感,在标定试验中易产生局部的塑性变形。使用基于形状改变比能S的修正方法对四种球墨铸铁的应变释放系数进行修正,发现和其他均质金属材料不同,球墨铸铁应变释放系数与■之间存在良好的线性关系,因此提出了球墨铸铁应变释放系数关于■的修正公式,可直接应用于盲孔法测量球墨铸铁的残余应力。

非均匀残余应力的钻孔法测量原理及应用

工件近表面的残余应力,尤其是表面大约1mm深度范围内的残余应力分布时常是一些制造行业关注的重点,而常见的残余应力测量方法,由于种种原因,在实测这一深度的非均匀分布残余应力时候会遇到困难。高速钻孔法残余应力测量技术采用分层钻孔的方法,可以较好地表征这一深度范围内的残余应力分布,在这一测量领域有独特的优势,但国内由于测试设备和技术的原因,采用这种技术并不普及。本文以喷丸处理的铝合金残余应力测量为例,结合相关国标和ASTM标准,详细介绍了该测量技术的实施过程和特点,阐述了高速钻孔法非均匀残余应力分析的计算方法,分析了分层钻孔法在进行非均匀残余应力场测量中的难点,并就解决方案进行了分析和讨论。

残余应力检测技术及其应用

随着我国工业水平的不断提升,残余应力问题日益受到重视。准确测试和控制残余应力可以实现改善材料性能、提升尺寸精度、延长寿命等目的,进而提升关键工程构件的安全性和可靠性。因此,残余应力检测技术在航空航天、核电、船舶等领域发挥着重要作用,为工程构件力学性能研究和安全评估提供关键数据支持。总结了目前常用的残余应力检测技术的原理、适用范围、优缺点等,讨论了选择残余应力检测技术时需考虑的主要因素,指出了残余应力检测技术在科研和应用领域的发展趋势。

盲孔法测试膨胀管残余应力研究

膨胀管在膨胀作业结束后,会残留分布不均的残余应力,残余应力将会影响膨胀管胀后抗外挤强度、抗腐蚀强度等关键性能。为此,采用盲孔法测试膨胀管外表面轴向残余应力与环向残余应力水平及变化情况,通过有限元法获得残余应力整体分布情况并加以验证。研究结果表明:膨胀管的胀后残余应力近外壁面2 mm内平均环向和轴向残余应力测试值分别为-352.5与-589.0 MPa,与有限元模拟值误差小于10%;环向残余应力的中性面在沿壁厚方向距内壁面约70%厚度处,轴向残余应力的中性面在沿壁厚方向距内壁面约64%厚度处;膨胀管胀后并经过多天存放,轴向残余应力降幅为18.7%,环向残余应力降幅为12.8%。所得结论可为膨胀管性能评价研究提供技术参考。

SMA490BW耐候钢TIG焊接接头残余应力分析

【目的】旨在进行SMA490BW耐候钢TIG焊接接头疲劳寿命的评估。【方法】采用盲孔法、X射线法、有限元分析3种方法对SMA490BW耐候钢TIG焊接接头进行了焊接残余应力分析,并对切割小试样引起的残余应力变化进行分析。【结果】结果表明,SMA490BW耐候钢纵向残余应力在焊缝拉应力峰值接近材料屈服强度,远离焊缝中心残余应力迅速降低并进一步转变为压应力,此分布规律为典型的纵向残余应力分布特征。在整体试板上采用线切割出用于疲劳试验的足尺寸小试样,小试样上纵向残余应力的峰值接近230 MPa,约为屈服强度的70%,纵向残余应力在横向分布规律保持不变。【结论】该部分所建立的有限元模型分析结果与测试数据吻合很好,证实模型的热源模型、力学边界条件均与实际工艺接近,采用该计算模型的精度和正确性可以保障。

预应力混凝土管桩施工技术选择与应用

针对锦绣华庭项目复杂的地质条件,通过现场分别进行静压沉桩法与锤击沉桩法沉桩试验,总结分析两种不同沉桩方式的优缺点。通过考虑施工工艺的适用性和可改进性,以及工期、经济及社会效益等方面,最终选择更适合本项目施工的锤击沉桩法。但锤击沉桩法施工噪声和振动非常大,而项目位于古遗址、古文物区域及城区居民区,对施工振动、噪声控制等文明施工要求很严格。因此,对锤击沉桩施工方法进行了改进,以减少噪声和降低振动,同时达到了速沉桩、成桩率高的目的,并且克服了传统植桩法在复杂地基施工过程中遇到的难题,为以后相近条件的项目施工提供参考。

淬火介质参数对铝合金板材残余应力水平的影响研究

文章采用钻孔法测试不同淬火介质、不同水温以及不同浓度PAG溶液的淬火残余应力,分析淬火介质对残余应力水平与分布的影响规律,为淬火介质的选择提供试验依据。结果表明:淬火介质参数对淬火残余应力的影响规律为:随着水温的升高,淬火残余应力逐渐降低,与20℃水淬相比,80℃水淬后残余应力降低比例约60%;随着PAG浓度的升高,淬火残余应力逐渐降低,与20℃水淬相比,15%PAG淬火后残余应力降低比例最大达72.9%;在各淬火介质参数下7055铝合金厚板淬火残余应力水平为10%NaCl+KNO_(3)溶液>20℃水>5%PAG溶液,其中10%NaCl+KNO_(3)溶液淬火后应力水平较20℃水淬提升约20%。

基于盲孔法的X7001挤压L型铝材残余应力测试研究

采用盲孔法对3种截面规格的X7001铝合金挤压L型截面型材的纵向残余应力进行试验测量,基于试验结果分析了L型铝材的残余应力分布特点,给出了其残余应力分布建议图。结果表明:L型截面铝材残余应力分布呈对称模式;残余拉应力峰值略大于残余压应力峰值,且均不超过屈服强度的15%;生产工艺对构件残余应力分布模式有一定影响;残余应力系数β与构件宽厚比有关,建议普通L型截面X7001挤压型铝材的残余应力系数β的绝对值取值范围为0.08~0.15。

RECENT PROGRESS IN RESIDUAL STRESS MEASUREMENT TECHNIQUES

Residual stress measurement is of critical significance to in-service security and the reliability of engineering components, and has been an active area of scientific interest. This paper offers a review o[ several prominent mechanical release methods for residual stress measurement and recent developments, focusing on the hole-drilling method combined with advanced optical sensing. Some promising trends for mechanical release methods are also analyzed.

Residual Stress Measurement in Electron Beam Welded Joints of 50mm Thick Titanium Alloy

For researching the residual stress distribution characteristics of the different large thickness titanium alloy joints by electron beam welding,under heat treatment or non-heat treatment conditions,the changes in residual stress distribution characteristics of electron beam welding joints,which thickness is 50 mm,were measured using blind-hole method with local layer-by-layer removal.Effect of post-welding heat treatment on the residual stress distribution also studied.The results show that blind-hole method with local layer-by-layer removal is suitable to measure residual stresses in thick plate,and good to reflect the welded residual stress distribution of large gradient.Residual stress of the test samples in the weld and heat affected zone has high stress level,and internal stress dramatic changes with thickness in this areas.After heat treatment,the samples' stress distributions were significantly reduced.The samples' transverse and longitudinal residual stress are basically the same.Homogenization is obvious.

聚乙烯管材残余应力的定性和定量评价

研究了冷却速度、挤出速度和拉伸比等不同挤出工艺对管材物理性能及残余应力的影响,结果表明,随着冷却和挤出速度的增加,PE管材纵向回缩率增大,静液压和SCG破坏时间逐渐降低。通过盲孔应变法研究了不同挤出工艺对管材内外层的释放应变和残余应力分布的影响,研究表明,采用理想化的均匀分布模型不适用于残余应力的定量评价,采用非均匀应力分布模型计算得到的管材外层的残余应力随着冷却和挤出速度的增加而增大,而管材内层的残余应力变化较小,由于管材沿壁厚方向冷却速度的不均匀,内外层残余应力分布存在差异。最终,通过对管材内中外层分别进行拉伸、密度和结晶度等物理性能试验,进一步证明了盲孔法定量评价残余应力的有效性。同时试验发现,当挤出拉伸比太高时,分子链取向严重,管材纵向回缩率增大,静液压和耐SCG性能下降,管材外层残余应力的最大值为14.6 MPa,与材料拉伸屈服强度相比,提高了50%。

35kV C-GIS环氧树脂外锥套管残余应力检测研究

环氧树脂浇注外锥套管在柜式气体绝缘开关设备中发挥载流导体和高压对地绝缘与支撑的关键作用,但工件内部残余应力与复杂的机械载荷叠加使外锥套管在运行工况下频繁发生开裂、击穿甚至解体等绝缘故障,严重威胁变配电系统安全稳定运行。文中以35 kV柜式开关设备外锥套管为研究对象,对比研究了超声法与钻孔法对其残余应力的检测效果,利用局部放电与抗弯试验验证了残余应力对工件运行可靠性的影响。主要结论如下:基于声弹性效应的残余应力检测方法发现环氧树脂外锥套管残余应力分布在-50~20 MPa。钻孔法检测结果表明外锥套管次表面残余应力分布为-7.5~7.6 MPa,与超声纵波法检测的残余应力检测位点一致,但是受钻孔深度影响,该方法具有一定限制。残余应力的存在使环氧树脂绝缘件机械重载运行后的局部放电量有所增加,使其机械强度大幅下降。因此需要严格控制环氧树脂绝缘件浇注工艺并开发残余应力检测方法。

Q235钢墙板-Q460高强钢立柱结构体系残余应力分布试验研究

在箱式钢结构中起主要承载作用的侧面墙板-立柱结构体系中,受墙板蒙皮支撑作用的高强钢立柱,其残余应力分布受与墙板焊接连接过程影响,与独立工作焊接H形截面构件有较大差异。为研究Q235钢墙板—Q460高强钢立柱结构体系的残余应力分布规律,采用盲孔法对6个结构体系试件和2个独立Q460高强钢焊接H形截面试件进行了试验研究。基于测量数据,得到了所有试件的全截面残余应力分布,分析了墙板与立柱焊接连接、截面尺寸等因素对残余应力分布的影响,并研究了截面各板件间残余应力的相互影响及自平衡性。结果表明:立柱与墙板的焊接在一定程度上降低了立柱后翼缘中部的最大残余拉应力,减小了后翼缘残余压应力的分布范围,对前翼缘和腹板无明显影响;残余拉应力幅值与截面尺寸无直接关系,残余压应力随着板件宽厚比的增大而减小;各板件间残余应力存在相互影响作用,前翼缘、腹板以及后翼缘与墙板组合板件这3部分分别满足自平衡。提出了适用于Q235钢墙板—Q460高强钢立柱结构体系的较为准确和安全的残余应力分布数学模型,为后续研究受墙板蒙皮支撑的高强钢立柱稳定性奠定基础。

基于弹簧刚度法的螺栓分布研究

螺栓组载荷分布不均是齿轮齿条钻机产生振动甚至损坏的重要原因之一。工程中,螺栓连接点常常会受到复杂的时变低速重载,螺栓组容易因载荷分布不均而发生断裂,从而影响钻机的稳定性。为研究不同螺栓分布情况下螺栓组所受应力情况,通过建立多螺栓连接的力学模型对螺栓载荷分布情况进行分析,并在此基础上考虑结构复杂的连接件提出一种多螺栓连接载荷计算方法。设计并进行了试验研究和有限元分析,通过对比其结果,验证了计算方法的准确性。基于提出的理论计算方法,给出载荷作用下螺栓剪切应力的分布规律,对比了螺栓均匀分布模型和非均匀分布模型的剪切应力分布特点,结果发现非均匀螺栓分布的承载分布均匀性要优于均匀分布的螺栓。