60Si2Mn螺旋弹簧的压缩应力松弛行为与贮存寿命预测

为评价60Si2Mn螺旋压缩弹簧的室温松弛特性,利用InstronE3000K8953型小吨位电子动静态疲劳试验机,对其在不同温度和初始应力水平条件下进行了高温压缩加速应力松弛试验,研究了环境温度、初始应力水平对松弛行为的影响.基于粘弹性体模型,揭示了应力松弛过程中弹性应变向塑性应变的转化特性与塑性应变随松弛时间的变化规律.在对应力松弛前后弹簧丝材金相和TEM微结构进行对比分析的基础上,探讨了应力松弛的微观机制.结果表明,环境温度与初始应力水平对松弛速率具有显著影响.基于应力松弛过程的热激活特性,建立了60Si2Mn螺旋压缩弹簧的贮存寿命预测方程,并对不同应力水平下弹簧的室温和高温贮存寿命进行了合理预测.     

An Exact Solution of Torsion Problem for an Incomplete Torus with Application to Helical Springs

An exact analytical solution for the torsion problem of an incomplete torus with a particular form of non-circular cross-section has been found. The solution extends for the close-coiled helical spring the known solution of the torsion problems for straight cylinders with circular and elliptical cross-sections. The pitch of helix is ignored. The hollow cross-sections of the particular form also demonstrate a closed form of analytical solution. The solution can be used for analysis of helical springs with non-circular wire profile.     

Delayed presetting of helical springs

Abstract

This article establishes the calculation of remaining deformation and residual stress for helical springs after long-lasting presetting process. The article extends the model for the immediate presetting process accounting the creep deformation of the spring. The method is based on plasticity theory for the instant flow overexposed by the relaxation over the long-term presetting. In this article, the following method is used. The plastic deformation of the helical spring with the circular cross section occurs instantly. If the shortening of the spring in the tool holder persists, the relaxation of stresses occurs and the force of the spring reduces. As the consequence, after the elastic unloading of the long-time presetting, the residual stresses spring reduce gradually with the squeezing time as well. The final length of the springs considerably shortens with the increasing preset duration. The advantage of the discovered closed form solutions is the calculation without the necessity of complex finite-element simulation of spring length loss and residual stresses after presetting process. The analytical expressions are proposed and the exact calibration applied for evaluation of factors for presetting processes.     

Photoelastic analysis of the stress field surrounding a fatigue crack

A photelastic analysis was carried out on plane polyester specimens containing a fatigue crack, in order to study the effect of plastic yielding around the crack tip on the elastic stress distribution in the vicinity of the crack. In general, results were in good agreement with values calculated for the case of a sharp-tipped crack. However, very near the crack tip, principal stresses obtained experimentally were slightly lower than calculated stresses, probably due to the bluntness of the fatigue crack. Also lines of constant stress tended to move behind the crack tip, in contrast with the calculated stresses, which occurred further forward over the field of investigation.     

Finite element method for the stress analysis of isotropic cylindrical helical spring

This paper presents an efficient two nodes finite element with six degrees of freedom per node, capable to model the total behaviour of a helical spring. The formulation, which includes the shear deformation effects, is based on the assumed forces hybrid approach. The resultant forces approximation verifies exactly the resultant equilibrium equations. The developed model proves its accuracy compared with other elements. This element permits to get the distribution of different stresses along the spring and through the wire surface by only one element.     

Fatigue crack propagation in a quasi-one-dimensional elasto-plastic model

Fatigue crack advance induced by the application of cyclic quasistatic loads is investigated both numerically and analytically using a lattice spring model. The system has a quasi-one-dimensional geometry, and consists in two symmetrical chains that are pulled apart, thus breaking springs which connect them, and producing the advance of a crack. Quasistatic crack advance occurs as a consequence of the plasticity included in the springs which form the chains, and that implies a history dependent stress–strain curve for each spring. The continuous limit of the model allows a detailed analytical treatment that gives physical insight of the propagation mechanism. This simple model captures key features that cause well known phenomenology in fatigue crack propagation, in particular a Paris-like law of crack advance under cyclic loading, and the overload retardation effect.     

Modeling and dynamics analysis of helical spring under compression using a curved beam element with consideration on contact between its coils

Helical springs are indispensable elements in mechanical engineering. This paper investigates helical springs subjected to axial loads under different dynamic conditions. The mechanical system, composed of a helical spring and two blocks, is considered and analyzed. Multibody system dynamics theory is applied to model the system, where the spring is modeled by Euler–Bernoulli curved beam elements based on an absolute nodal coordinate formulation. Compared with previous studies, contact between the coils of spring is considered here. A three-dimensional beam-to-beam contact model is presented to describe the interaction between the spring coils. Numerical analysis provides details such as spring stiffness, static and dynamic stress for helical spring under compression. All these results are available in design of helical springs.     

随机超载对疲劳裂纹扩展迟滞效应的模拟

考虑超载的迟滞效应,对随机超载作用下的疲劳裂纹扩展进行了模拟计算．载荷谱为在基本恒幅循环载荷基础上加入一以泊松流发生的随机超载序列,超载的大小为均匀分布．采用裂纹闭合模型考虑超载的迟滞效应,认为裂纹张开应力在超载引起的塑性区内按线性规律衰减．循环续循环模拟计算出裂纹从初始长度一直到疲劳破坏的扩展曲线．据此,计算了各种超载发生强度和大小下的疲劳裂纹扩展寿命的平均值与标准差。     

考虑微动磨损的钢丝微动疲劳裂纹扩展寿命预测研究

微动疲劳是矿井提升钢丝绳主要失效形式之一,在钢丝微动疲劳过程中,微动磨损严重影响钢丝微动疲劳裂纹扩展特性,进而制约钢丝微动疲劳断裂机制,故开展考虑微动磨损的钢丝微动疲劳裂纹扩展寿命预测研究至关重要. 运用自制钢丝微动疲劳试验机开展钢丝微动疲劳试验和拉伸断裂试验,通过高速度数码显微系统揭示微动疲劳过程中钢丝微动磨损演化、裂纹萌生和扩展及断裂特性,基于摩擦学和断裂力学理论,运用有限元法、循环迭代法和虚拟裂纹闭合技术建立了考虑微动磨损的钢丝微动疲劳裂纹扩展寿命预测模型,并进行试验验证. 结果表明:采用微动疲劳过程稳定阶段磨损系数预测钢丝微动磨损演化可保证预测正确性,微动疲劳过程中钢丝主要为I型裂纹扩展模式,考虑微动磨损的钢丝微动疲劳裂纹扩展寿命预测值和试验值吻合较好,验证了预测模型正确性.      

The Role of Residual Stresses in the Performance and Durability of Prestressing Steel Wires

Residual stresses developed during wire drawing influence the mechanical behavior and durability of steel wires used for prestressed concrete structures, particularly the shape of the stress–strain curve, stress relaxation losses, fatigue life, and environmental cracking susceptibility. The availability of general purpose finite element analysis tools and powerful diffraction techniques (X-rays and neutrons) has made it possible to predict and measure accurately residual stress fields in cold-drawn steel wires. Work carried out in this field in the past decade, shows the prospects and limitations of residual stress measurement, how the stress relaxation losses and environmentally-assisted cracking are correlated with the profile of residual stresses and how the performance of steel wires can be improved by modifying such a stress profile.     

螺旋压缩弹簧应力松弛特性试验分析及其应用

本文通过应力松弛试验、理论推导及数值模拟研究了高温下螺旋压缩弹簧的应力松弛规律,并利用加速模型对工况下弹簧应力松弛服役寿命做出预测。首先,根据螺旋压缩弹簧的结构特点搭建了弹簧应力松弛连续动态测试装置,该装置不仅避免了传统测试方法存在的缺陷,而且能够保证试验过程中位移载荷恒定,并实时监测载荷变化。本文以某飞机舱门单锁机构中的螺旋压缩弹簧为试验对象进行了不同温度条件下的应力松弛试验,得到其松弛动力学曲线,并基于Arrhenius模型建立了弹簧在工况下的应力松弛服役寿命预测模型;其次,基于应力松弛和蠕变在本质上的一致性,结合金属材料蠕变规律并根据试验弹簧的受力特点,推导出用于描述试验材料松弛行为的蠕变本构方程,由试验结果获得该本构方程的材料常数;最后,通过该本构方程及材料常数,在ANSYS软件中对试验弹簧的松弛过程进行模拟,结果表明,模拟结果与试验结果误差不大于4%。因此,通过本文方法所建立的蠕变方程对弹簧在不同载荷条件下的应力松弛规律进行仿真分析具有一定的可行性与准确性。     

基于SWT方法的钢绞线索微动疲劳特性分析

为得到钢绞线索丝间接触区的应力场分布并预测微动疲劳裂纹萌生位置和微动疲劳寿命，本文利用参数化方法建立了精细化的钢绞线拉索有限元模型，包括整索模型和不同层丝间接触区域的局部精细化子模型．分析了钢绞线索在两种交变荷载工况下的应力场变化情况，并基于多轴疲劳SWT(Smith-Watson-Topper)临界平面法进行了疲劳特性分析和疲劳寿命预测．主要结论如下：钢绞线索内接触区边缘处的微动幅值较大，中心处几乎没有相对滑动，微动疲劳的初始裂纹萌生点位于接触区域边缘；经不同区域子模型分析比较，在轴向循环荷载作用下，外层钢丝的接触区域比内层钢丝更易发生微动疲劳损伤；在横向位移循环荷载作用下，同层钢丝因位置角度不同而产生了较大的疲劳特性差异，且相比轴向循环拉伸，该工况下最不利单丝的微动疲劳寿命更低；与非接触区域相比，接触区的疲劳寿命大幅降低，微动现象对钢绞线索的抗疲劳性能有明显降低作用．     

Stress distribution about a slowly growing crack determined by photoelastic-coating method

An experimental stress-analysis technique using a birefringent coating is reported for determining the stress distribution about a slowly growing crack. The maximum error of the test method for a large strain gradient is found to be less than 10 percent. For a plate with an internal crack, the experimentally determined stress distribution compares favorably with two numerical solutions. Comparison of stresses about an internal or double-edge crack to those about a single-edge crack indicates that the isochromatics bend over to about 45 deg with the plane of the crack in the former and are inclined at about 60 deg in the latter. Also, the stresses for a single-crack tip vary as the inverse square root of the radius, while the stresses for a double-crack tip follow anr ^?1/4 law more closely.     

弹塑性疲劳微弯裂纹尖端塑性区问题

主要研究疲劳载荷作用下弹塑性裂纹弯曲延伸扩展问题.通过分析论证,比较精确地研究了疲劳载荷作用下弯曲延伸裂纹尖端塑性区域边界上交变应力的分布状况.综合考虑了疲劳作用应力,塑性区域交变应力,利用二阶摄动方法,研究计算了弯曲延伸裂纹尖端塑性区域的范围,并预测了疲劳载荷作用下弹塑性裂纹扩展路径.     

缺口件疲劳寿命分布预测的有效应力法

本文提出了一种由光滑件疲劳寿命试验数据预测缺口件疲劳寿命分布的有效应力法。该方法中缺口件的裂纹可能萌生表面被分解成一个个微元,整个表面可看成是这些微元组成的一个串联模型,按照串联概率失效模型,缺口件的疲劳强度失效概率就可以由各微元的疲劳强度失效概率计算得到,其中微元的疲劳强度失效概率是由光滑件的疲劳强度失效概率通过最弱环节理论计算得到的。在缺口件的疲劳强度失效概率表达式中,引入了有效应力的概念,用它查取光滑件的疲劳寿命试验数据就可以直接得到缺口件的疲劳寿命分布。该方法可以同时考虑到应力梯度和试件尺寸对缺口件疲劳寿命分布的影响。进行了材料LY12CZ的带中心孔缺口件的寿命算例分析,预测结果和试验结果吻合良好,表明该方法是有效的。     

含缺口试件疲劳全寿命预测一种建议的方法

传统的研究含缺口构件的疲劳的方法是将疲劳启裂和疲劳裂纹扩展两个过程完全独立起来,用不同的方法来模拟,相互间并没有定量的关系。本文是基于最新发展的多轴疲劳损伤理论,建立了一种适用于各种载荷条件下的疲劳启裂和裂纹扩展的普适方法。根据从弹塑性分析中得到的应力应变,确定疲劳损伤模型,建立能够预测疲劳启裂、裂纹扩展速率和扩展方向的新方法。整个模拟可以分为两步:弹-塑性应力分析得到材料的应力应变分布;再运用一个通用的疲劳准则预测疲劳裂纹启裂和裂纹扩展。通过对1070号钢含缺口试件的疲劳全寿命预测,得到了与实验非常吻合的模拟结果。     

Three-dimensional structure optimal design for extending fatigue life by using biological algorithm

This paper presents some applications of a new structural shape optimization procedure for maximizing fatigue life or inspection intervals for damage tolerant structures. In this approach, a new and simple method, which we termed FAST (Failure Analysis of Structures), for estimating the stress intensity factor for cracks at a notch, as well as an extension of the biological algorithm was employed to study the problem of optimization with fatigue life as the design objective. Research by the authors has demonstrated that the optimum shape for minimizing stress is not necessarily the optimum shape for static strength or fatigue life of a damage tolerant structure. The examples are presented that highlight this difference. The optimal shapes for stress are compared with optimized shapes found for static strength with different crack lengths. These are also compared with optimized shapes found for maximum fatigue life. The choice of initial crack size was found to have a significant effect on the optimal shapes for the structures presented.     

Influence of Residual Stresses Introduced by Shot Peening Upon the Fatigue Life of Materials

Strain hardening by shot peening is an operation which broadly increases the fatigue resistance of a mechanical part. This increase is particularly due to the compressive residual stresses induced in the surface layers of the material. This article demonstrates the resulting improved fatigue resistance of three types of mechanical parts (helical springs, chain links, and lifting hooks.     

The torsional fatigue properties of titanium-alloy spring wire

The absence of any torsional fatigue-test data on currently used titanium-alloy spring wire along with inconsistent fatigue-test data derived from earlier test programs prompted this investigation. The torsional fatigue testing was performed on straight lengths of 13V?11Cr?3Al titanium-alloy spring wire in diameters of 0.148 in. (0.376 cm), 0.225 in. (0.572 cm) and 0.374 in. (0.950 cm) considered as representative. A second material selected as a possible alternate for 13V?11Cr?3Al spring was 3Al?8V?6Cr?4Mo?4Zr which was tested in diameters of 0.225 in. (0.572 cm) and 0.376 in. (0.955 cm). Testing as straight-wire lengths eliminated the manufacturing variables introduced by fabricating a helical-spring geometry. Two methods were considered for improving fatigue life, namely abrasive cleaning and shot peening. At a torsional stress of 100 ksi (689.5 MPa), the test data indicate that an improvement in fatigue life of at least one order of magnitude may be realized by shot peening 0.225-in. (0.572-cm)-diam 13V?11Cr?3Al wire to an intensity of 0.015A. A similar improvement of fatigue life may be gained by shot peening 0.148-in. (0.376-cm)-diam wire to a similar intensity. A substantial fatigue-life improvement was obtained by an obrasive-cleaning operation on all wire diameters tested. The fatigue life of the 3Al?8V?6Cr?4Mo?4Zr titanium-alloy wire in the cold-worked and aged condition was lower at all stress levels and diameters tested than for similar diameters of 13V?11Cr?3Al titanium-alloy wire.