Initial residual stress experiment and simulation of thin-walled parts for layer removal method

Thin-walled parts have low stiffness characteristic. Initial residual stress of thin-walled blanks is an important influence factor on machining stability. The present work is to verify the feasibility of an initial residual stress measurement of layer removal method. According to initial residual stress experiment for casting ZL205 A aluminum alloy tapered thin-walled blank by a common method,namely hole-drilling method,three finite element models with initial residual stress are established to simulate the layer removal method in ABAQUS and ANSYS software. By analyzing the results of simulation and experiments,the cutting residual stress inlayer removal process has a significant effect on measurement results. Reducing cutting residual stress is helpful to improve accuracy of layer removal method.

Effects of Carburized Parts on Residual Stresses of Thin-Rimmed Spur Gears with Symmetric Web Arrangements Due to Case-Carburizing

This paper presents a study on effects of carburized parts on residual stresses of thin-rimmed spur gears with symmetric web arrangements due to the case-carburizing. The carbon content of each element of the FEM gear model due to carburizing was obtained according to Vickers hardness Hv - carbon content C% and C% - d (distance from surface) charts. A heat conduction analysis and an elastic-plastic stress analysis during the case-carburizing process of thin-rimmed spur gears with symmetric web arrangements were carried out for various case-carburizing conditions by using the three-dimensional finite element method (3D-FEM) program developed by authors, and then residual stresses were obtained. The effects of the carburized part, the web structure, and the rim thickness on the residual stress were determined.

Numerical simulation of the crustal stress field by using data of deep geophysical exploration in the northern part of North China

DSS data of the last twenty years and more in the northern part of North China are further interpreted, and combined with other geological and geophysical data, the crustal model for the 3 D finite element method is built after straticulate crustal structure and elastic mechanics parameters are obtained. Referring to regional tectonic stress field and taking the effect of gravity into account, the paper constrains properly the model boundary and then computes the displacement of each nodal point and the strain and stress of each element by using the program from the 3 D linear elastic finite method. The relationship between the distribution feature of the crustal stress field and seismicity is discussed on the basis of analyzing contour maps of maximum principal compressive stress in the upper, middle and lower crusts.

Machining Deformation Prediction of Thin-Walled Part Based on Finite Element Analysis

For the problems of machining distortion and the low accepted product during milling process of aluminum alloy thin-walled part,this paper starts from the analysis of initial stress state in material preparation process,the change process of residual stress within aluminum alloy pre-stretching plate is researched,and the distribution law of residual stress is indirectly obtained by delamination measurement methods,so the effect of internal residual stress on machining distortion is considered before finite element simulation. Considering the coupling effects of residual stress,dynamic milling force and clamping force on machining distortion,a threedimensional dynamic finite element simulation model is established,and the whole cutting process is simulated from the blank material to finished product,a novel prediction method is proposed,which can availably predict the machining distortion accurately. The machining distortion state of the thin-walled part is achieved at different processing steps,the machining distortion of the thin-walled part is detected with three coordinate measuring machine tools,show that the simulation results are in good agreement with experimental data.

Computer Simulation of the Process of Quenching Large-Size Parts in Water and Aqueous Solutions

The article presents results of the computer simulation of quenching large-size parts in water and aqueous solutions. It has been shown that the main attention should be paid to eliminating film boiling and providing uniform cooling at the surface of the part to be quenched. Simplified formulas for calculating the optimal time of cooling large-size steel parts are presented.

大跨越架空输电导线铝部应力分布试验

为了掌握大跨越架空输电导线铝部应力空间分布特性,以JLHA1/G6A-500/280型特强钢芯铝合金导线为研究对象,采用铝股丝表面激光刻槽,内嵌高灵敏、超大复用容量超弱光纤光栅,搭建了大跨越输电导线铝部应力试验平台,研究了不同张力条件下大跨越架空输电导线铝部应力分布规律,建立了大跨越导线实体有限元模型,分析了铝股应力分布特征,并验证了试验结果的正确性。结果表明:导线承受张力作用时,外层铝股和次外层铝股应力不同,外层铝股应力小于次外层铝股应力,导线同层铝股应力基本相同;铝股应力随导线张力的增大呈线性增大趋势,张力每增大1%,铝股应力增大约10%。不同导线张力作用时钢股和铝股应力均呈现环状分层特性,铝股平均应力小于钢股平均应力,铝部和钢股应力比约为3∶7;外层和次外层铝合金股丝应力沿圆周向分布不均匀,建议大跨越导线线型设计时考虑铝股丝分层特性。

Effects of effective stress and temperature on permeability of sandstone from CO2-plume geothermal reservoir

Rock is generally complex and heterogeneous,therefore the heterogeneity effects of effective stress and temperature on permeability should be taken into account.In this study,two-part Hooke’s model（TPHM） is introduced to understand the influences of effective stress and temperature on permeability of soft and hard parts（two parts） of rock based on coupling thermo-hydro-mechanical tests.Under a fixed temperature level（25 ℃.35 ℃.50 ℃.65 ℃.80 ℃.90 ℃ and 95 ℃）.the tests were carried out in a conventional triaxial system whereas the confining pressure was remained at 50 MPa.and the pore pressure was increased to the specified levels step by step.i.e.8 MPa,18 MPa.28 MPa.38 MPa.41 MPa,44 MPa.46 MPa and 48 MPa.The temperature-dependent relationships for two parts permeabilities are proposed on the basis of the initial test results.We point out that temperature of 65 ℃-90 ℃ is the threshold for the development of CO2-plume geothermal（CPC） reservoir sandstone cracking under low effective stress（2-9 MPa） based on the relationship between temperature and soft part permeability.Furthermore,we discuss the effect of temperature on the two parts in the rock.The results indicate that as the temperature increases from 25 ℃ to 65 ℃.the flow channel in the hard part has a stronger response to temperature than that in the soft part at a fixed effective stress level,which is opposite to the situation of effective stress.Considering that natural rock is generally heterogeneous with non-uniform pore structure,we suggest a physical interpretation of the phenomenon that before the thermal cracking threshold the two parts have different responses to temperature.

基于应力等效关系的汽车零部件疲劳寿命预测模型

对于预测多级应力加载下的汽车零部件疲劳寿命,已有的相关非线性模型通常需要依赖大量的试验数据,或者较难选取合适的基准值,使得疲劳可靠性理论在汽车领域的应用存在一定局限性。针对此问题,基于材料疲劳寿命特性曲线,通过分析两级应力之间疲劳损伤转化过程,建立了一种考虑相邻载荷作用的等效转化关系,推导了两级、三级及更高应力等级情况下相邻应力之间的疲劳累积损伤等效公式和剩余疲劳寿命的表达式,进而提出了一种基于应力等效关系的疲劳寿命预测模型。该模型的计算过程仅需不低于两级应力的材料疲劳寿命试验结果。采用二级、三级、四级及五级应力加载试验数据,分别计算并对比了Miner模型、Manson模型、Subramanyan模型、Hashin模型及新模型的相对误差平均值和最大值,进一步汇总了两级至五级应力下各模型疲劳累积损伤与疲劳累积寿命的预测结果、各模型预测疲劳损伤与试验疲劳损伤之差的分布。结果表明,基于相邻载荷作用等效转化的新模型在疲劳寿命的整体预测结果优于Miner模型、Manson模型、Subramanyan模型及Hashin模型,可更为准确地应用于材料多级应力下的疲劳寿命/损伤预测。

基于Weibull分布的缺口件多轴疲劳寿命建模

针对多轴缺口件,引入Weibull分布建立考虑应力梯度效应的疲劳寿命预测方法.首先,将最大应变能密度定义为损伤参量,并结合坐标变换确定能反映裂纹萌生和扩展的临界面位置;其次,利用有限元方法提取临界面特定路径的应力分布,并对其进行归一化处理得到多轴等效应力梯度因子,进而基于GSP应变能密度模型得出应变能密度与实验寿命的线性关系;最后,结合等效应力梯度因子、应变能密度模型和Weibull分布,基于Von-Mises准则提出了新的疲劳寿命预测方法,并利用该方法分别求出失效概率10%、50%和90%对应的疲劳寿命.为验证该方法,将计算结果与SWT模型、FS模型和Manson-Coffin方程的计算结果进行对比,结果表明该方法的预测精度较高.

基于数值模拟的钛合金锥形件激光辅助铲旋成形研究

针对中部带法兰锥形件采用传统“锻造+机加工”制备时材料利用率低、强度及韧性不足的问题,提出采用激光辅助铲旋成形工艺来实现钛合金中部带法兰锥形件的完整近净成形。根据铲旋成形原理,选取合适的激光热源模型,并基于Simufact Forming软件平台建立激光辅助铲旋有限元模型,研究了铲旋成形过程中的中部法兰变形区温度、变形行为及等效塑性应力和等效塑性应变分布规律。结果表明,采用坯料整体预热+激光辅助补热的方式,可实现坯料基体表层温度高、内层温度低,既有利于表面金属材料铲旋成形出法兰,又可避免锥壁翘起;铲旋成形时变形区材料轴向流动较多,径向流动较少,法兰形状呈“倒水滴”状;旋轮接触区等效塑性应力值较大,但法兰主体部分等效塑性应力值较小且分布均匀;基体主要变形区等效塑性应变值最大,达9~11,沿厚度方向逐渐减小,具有局部大塑性变形且变形不均匀的特点。

太阳辐射作用下大型预埋件温度效应分析

在结构施工过程中,因温度变化导致钢结构变形的情况较为普遍,尤其是大型钢结构。为此,以大型钢结构预埋件为研究对象,考虑预埋件单元迎光面与背光面的换热面间温差,建立了太阳辐射作用下预埋件的表面温度计算方法。结合预埋件表面温度实测数据,采用MIDAS Gen软件分析了预埋件的温度场分布和变形规律,发现天气晴朗情况下,预埋件单元温度场具有较强的非均匀性,迎光面测点温度较背光面高5~10℃;多云天气和阴天的情况下,由于傍晚或天气转阴时太阳辐射较弱,结构温度场的非均匀性变弱;减小预埋件纵向长度可以有效减小预埋件的温度变形;此外,可以采用不同施工措施以减小其温度变形,改变钢结构表面涂料种类、颜色的措施最有效,采用隔热板效果次之,改变钢构件截面尺寸效果最差。

薄壁结构件毛坯去应力分析与铣削加工变形有限元模拟研究

薄壁件在航空航天领域应用广泛,其制造精度直接决定了装备的服役性能。然而,由于热处理的影响,导致薄壁件在加工之前存在残余应力。如果控制不当极易导致零件超差。因此,本文以7075铝合金板材为研究对象,分析了残余应力在板料淬火与预拉伸时产生的原理。进一步,采用有限元方法作为工具,对7075毛坯在淬火和预拉伸法过程中残余应力的产生进行了模拟。通过模拟发现,当毛坯件被拉伸约3%,塑性应变量约为2.4%时,淬火残余应力消除可达91.2%。在降低残余应力的基础上,本文建立了薄壁结构件铣削加工仿真模型,模拟了多因素耦合作用下的铣削加工变形,并通过铣削实验验证了仿真结果的正确性。

大型7085铝合金筒形件淬火残余应力及其消减工艺研究

以大型7085铝合金筒形件为研究对象,研究了在最大程度保证铝合金大锻件性能的同时尽可能减小其淬火残余应力的方法。基于Abaqus平台,分别建立了大型筒形件淬火有限元模型和淬火后冷胀形有限元模型,考虑了淬火工艺和冷胀形工艺间的数据继承关系,分析了工艺参数对锻件性能及残余应力的影响规律。针对大型7085铝合金筒形件的淬火过程,将7085铝合金的等温转变曲线和时间-温度-性能曲线写入Abaqus用户子程序USDFLD中,计算了大型筒形件在不同淬火工艺条件下的析出相含量和分布、对应的硬度变化以及残余应力分布,获得了35℃的淬火水温是最优的选择。在消减淬火残余应力的冷胀形工艺中,基于不同的淬火水温条件开展了胀形量、胀形道次和每道次之间环转动角度的正交模拟实验,结果显示胀形量对残余应力消减的影响最显著,胀形量为4.5%时大型7085铝合金筒形件的应变均匀性最好且残余应力消减最充分。将仿真获得的优化淬火工艺和胀形方案应用于生产试制,所获得的大型筒形件各项力学性能达到设计要求,其残余应力实测结果与仿真结果对比具有较好的一致性。

煤矿刮板运输机关键部位应力分析与结构优化设计

基于轻量化设计思想,介绍了一种适用于煤矿刮板运输机关键部位的结构优化方案。具体结构优化过程主要包括基于有限元模型的关键部位应力分析和关键部位结构优化设计两个环节,其中关键部位应力分析可用于确认煤矿刮板运输机关键部位受力薄弱点,以此为基础开展关键部位结构优化设计。将关键部位结构优化设计应用于工程实践,检验结构优化设计可行性和应用价值。

金属结构件焊接失效的原因及预防措施

焊接是金属结构件使用时常见的连接技术,受各方面因素影响,结构件容易出现焊接失效问题,降低其使用寿命。首先对金属结构件焊接失效的条件进行分析,然后从塑性断裂、脆性断裂、疲劳断裂三个层面详细介绍了焊接失效的原因,最后针对三种常见的失效形式提出了针对性的预防措施。对于提升金属结构件的焊接质量,降低焊接失效概率具有一定的意义。

基于有限元法的某深孔件模锻成形工艺研究

某深孔件是船用低速柴油机中的关键构件,由于其特殊的工作环境,该工件的制造技术有着极高的要求。精密模锻是一种可以改进锻件整体质量及提高产品性能的工艺,因此可以通过模锻工艺来加工该深孔件。本文采用有限元模拟软件对该深孔件在压力机上模锻成形过程进行了数值模拟仿真,分析了锻件的温度场及应力场的分布特征,从而指导该深孔件的实际生产。

现代机械制造工艺及精密加工技术的应用

铝合金复杂薄壁件在加工过程中,受到铣刀和夹具的作用力,容易出现较大的变形,降低了工件的加工精度。为了解决该问题,研究过程以薄壁铝合金导轨为分析对象,建立铝合金材料切削时的应力计算模型,借助有限元仿真技术模拟最佳的装夹方式、装夹作用力以及机械加工参数。结果显示,此类构件宜采用底部设置压板、两侧设置支撑点的装夹方式,通过合理控制装夹作用力和加工参数,可将变形量和内应力降至较低的水平,从而实现精密加工。

TC4钛合金薄壁件低温铣削变形研究

钛合金薄壁件刚性差、导热系数小,在加工过程中易产生回弹变形,直接影响其加工精度和性能。基于冰固持铣削实验和ABAQUS软件二维铣削及回弹变形有限元仿真,在温度区间[20℃,-80℃]内研究了工件温度、刀具角度和装夹方式对TC4钛合金薄壁件回弹变形的影响规律,得到不同条件下变形量、残余应力、切削力和刀具温度变化曲线。结果表明:铣削与回弹仿真可以有效预测实际加工。当工件温度从20℃降到-8℃时,TC4钛合金薄壁件的回弹变形量和残余应力分别减小了5.97%和48.61%,切削力在整个温度阶段增长了4%。当刀具角度为9°时,工件变形量最大;当刀具角度从3°增大到15°时,切削力和刀具温度分别下降了14.6%和27%。与点接触相比,面接触能够有效抑制工件变形。

智能电能表可靠性预计技术

智能电能表可靠性预计是提高智能电能表固有可靠性的重要技术手段,开展预计的关键是选择合适的预计手册。分析了各预计手册的特点和局限性,结合智能电能表的固有特征及其可靠性预计的需求,指出Telcordia SR-332是目前预计智能电能表可靠性最实用的预计手册,具有重要的理论价值和工程应用价值。在选择预计手册之后,对多款智能电能表的预计结果进行对比分析,并总结出提高智能电能表可靠性的措施。

高速铁路提篮拱桥拱脚应力分析

沪宁线提篮拱桥是我国设计研究的第一座高速铁路大跨度预应力混凝土系杆拱桥。该桥拱脚的端横梁与相邻的拱座、拱肋、箱梁、支座承台的连接构造复杂。本文介绍应用 Super SAP软件的 8结点等参单元 ,对拱脚进行空间分析 。