一种提高冷镦件模具寿命的设计方法

针对采用整模结构的冷镦模具疲劳寿命极低的现状,提出以三层圆筒组合模具结构替代整体模具, 改变模具受力方式,使冷镦件模具达到较高寿命的设计方法．以螺栓圆头的冷镦试验结果为依据,以力学的应力分析方法为基础,应用力学理论,导出了生产实践中实用的组合模具设计原理与经验公式,并举例说明了该方法的应用．     

冷热组合凹模的最优化设计理论

通常组合凹模的设计是根据经验公式确定直径及过盈量,往往不是最优值.本文根据工作状态的内压力及模具的材料屈服强度,用弹塑性理论及热的传导理论及多元函数偏微分求极值的方法得出组合凹模各直径及过盈量的最优设计值,最大地增加模具承受的内压力,从而提高模具寿命.用此方法进行设计,已在我厂生产实践中收到良好效果.     

海上固定式导管架平台疲劳寿命评估及程序系统

本文使用疲劳分析与断裂力为结合的方法，对海上固定式导管架平台结构的疲劳裂纹，从形成到扩展至其损伤容限或贯穿管壁厚的整个过程，进行了分析评估。在４８６微机上构造了一个计算机分析程序系统，该系统除了具有通常的平台静，动强度计算外，可对平台的疲劳寿命，剩余寿命进行计算，当与平台在线裂纹监测系统组合后，可实施对平台结构剩余服役寿命的适时预报。     

微观加工形貌对三维线接触Stribeck曲线与疲劳寿命的影响

齿轮的传递效率和寿命与齿面成形方式紧密相关,针对圆柱齿轮常见的剃削、磨削、珩磨、抛光四种加工方式,采用三维线接触混合润滑分析模型,结合Zaretsky接触疲劳寿命计算方法,系统分析了高速到极低速工况下,界面摩擦系数对接触疲劳寿命的影响,以及不同微观加工形貌作用下三维线接触Stribeck曲线与疲劳寿命的变化规律.研究表明:全膜润滑状态下,界面摩擦对疲劳寿命的影响较小,各类组合表面的摩擦系数基本一致,但各组合表面疲劳寿命差异较大,抛光组合表面的疲劳寿命最优;在混合润滑状态下,各类组合表面的摩擦系数变化差异明显,而相对疲劳寿命差异明显减小,其中,磨削组合表面摩擦系数较大,抛光组合表面摩擦系数最小;值得注意的是,研究表明界面摩擦系数和疲劳寿命不是表面粗糙度的简单函数,不随界面粗糙度值的大小变化而单调变化.     

针对注塑成型随形冷却的流热力耦合拓扑优化方法研究

注塑成型在塑料工业生产中占据重要地位,注塑模具的散热能力影响着塑料制品的生产效率以及产品质量.本文基于变密度拓扑优化方法,以最小化结构平均温度为目标,研究了注塑模具冷却管道的拓扑优化问题.由于在注塑成型过程中模具会受到注塑机施加的克服塑件胀模力的巨大锁模力,故本文还将模具结构承载性能作为优化的评价指标.最终基于开源平台OpenFOAM对此三维流-热-力耦合拓扑优化问题进行求解,得到了具有制造可行性的冷却管道设计.     

结构疲劳寿命估计的集合理论模型

对于材料性质和载荷具有不确定性结构进行疲劳寿命估计时,结构疲劳寿命往往是这些不确定性变量的函数.以凸分析和区间数学为理论基础,将这些不确定变量用椭球和区间定量化,基于Taylor级数展开,提出了近似估计结构疲劳寿命的非概率集合理论模型—凸模型方法和区间分析方法.它们克服了概率方法需要预先知道不确定变量的概率分布密度或大量统计数据的局限性,并且计算量小.通过数值算例,将凸模型方法、区间分析方法与概率方法进行了比较研究,数值计算结果表明了这两种非概率方法对线性及非线性形式的结构寿命估计均能提供令人相当满意的精度.     

基于修正的局部应力应变法估算连接件疲劳寿命

飞机机体结构疲劳裂纹的萌生与扩展几乎都发生在紧固件连接处,预测结构连接件的疲劳寿命具有重要意义.为了准确计算连接件疲劳寿命,提出了一种修正的局部应力应变法,该方法首先采用应力严重系数法和修正Neuber法分析连接件高应力区的应力、应变,然后利用Manson-Coffin方程计算疲劳寿命,此外考虑到在中、高周疲劳里表面加工和尺寸因素的影响是不能忽略的,对应变-寿命曲线的弹性段作了修正以使其同时适用于高、低周疲劳寿命的估算.以搭接件为算例进行疲劳寿命计算,并使用MTS Landmark试验机对搭接件进行疲劳试验.结果表明,采用此方法估算的连接件疲劳寿命与试验结果相比误差小于16％,证明了此方法的有效性.     

结构疲劳寿命的区间估计

对材料性质和载荷具有不确定性的结构进行了疲劳寿命估计．结构的疲劳寿命往往是这些不确定性因素的函数．以区间数学为基础，将这些不确定性因素用区间进行定量化，借助一阶Taylor级数，提出了近似估计结构疲劳寿命的区间分析方法．区间分析方法克服了概率分析方法需要预先知道大量统计数据的缺点，且计算量小．通过典型数值算例将区间分析方法和概率分析方法进行了比较，结果表明了区间分析方法对线性和非线性形式的结构寿命估计在小不确定度情况下均能提供足够的精度．     

考虑日历环境影响的结构日历寿命研究

为科学地确定飞机结构的日历寿命，本文认为飞机结构的损伤历程是地面停放环境和空中疲劳载荷协同作用的结果，并提出以动态的S－N曲线为基础，采用传统的名义应力法和Miner累积损伤理论来估算结构日历寿命的方法。     

腐蚀条件下飞机结构疲劳寿命评定技术的试验验证

一般环境下飞机结构疲劳寿命评定技术已相对成熟,而建立在模拟试验基础上的腐蚀条件下飞机结构疲劳寿命评定技术目前尚不完善.本文通过退役飞机全尺寸结构疲劳试验结果与对应的关键部位腐蚀条件下疲劳寿命评定结果的对比分析方法,验证腐蚀条件下飞机结构疲劳寿命评定方法,同时提出了用已服役多年飞机全尺寸结构疲劳试验结果修正地面停放腐蚀修正系数曲线及加速环境谱当量加速关系的方法.     

Effect of Cold Working on Crack Growth from Holes in Fiber Metal Laminates

Cold expansion has proven to be an effective technique for extending the fatigue life of monolithic materials. Although fiber metal laminate materials show improved fatigue performance compared to their monolithic counterparts, the nucleation and growth of small cracks tends to occur early on in the fatigue life of the material, making acceptance of fiber metal laminates in aerospace more difficult. This work examined whether cold expansion could delay this process in fiber metal laminates and increase the fatigue life of these materials at the same time. The results showed that significant differences existed in the residual strain field between the mandrel exit and entry faces resulting in slower fatigue crack growth on the exit face, which also had higher residual strains in the region surrounding the cold expanded hole. Overall, cold expansion is effective at increasing the fatigue life of fiber metal laminate materials, but is less effective at delaying nucleation and growth of small cracks on the entry face.     

Simultaneous transfer of heat and mass occurring in casting process

Studied in this paper is simultaneous transfer of heat and water vapor which takes place in a green sand mold in a very short period of time after pouring a molten metal in its cavity. Governing equations describing heat and mass transfer in a mold are solved by finite difference method and the results are compared with the actually measured values to examine the validity of the calculated results. The effect of thermal properties and permeability of the mold, the amount of water contained, the heating temperature (i.e., temperature of casting metal) and other factors on the heat transfer rate at the interface between the molten metal and the mold, the pressure rise in the mold and the development of dried zone around the casting are investigated to propose some empirical relations available for predicting those transfer phenomena by using dimensionless parameters presented.     

Simulation of fiber reinforced composite materials mold filling process and mechanical properties analysis

A dynamic simulation of fiber reinforced composite materials mold filling process with double inlets is presented based on the gas–solid–liquid model proposed by Yang et al. [B.X. Yang, J. Ouyang, J. Tao, C.T. Liu, Modeling and simulation of fiber reinforced polymer mold filling process by level set method, CMES – Computer Modeling in Engineering and Sciences 63 (3) (2010) 191–222]. Numerical results show that the fibers far away from the melt interface are in skin-core-skin structure, while those near the interface are almost parallel to the arc of the interface. When the two streams of melts meet, the weld line will be formed, where the orientation of fibers is perpendicular to the flow direction. The orientation of fibers of the numerical result shows well agreement with the experimental results. Finally, the mechanical properties of fiber reinforced composite materials are analyzed. The composite materials with skin-core-skin structure are regarded as laminated orthogonal plywood and the elastic modulus, the shear modulus and Poisson’s ratio are predicted under different slenderness ratios and fiber volume fractions.     

薄板坯连铸结晶器中铸坯凝固壳应力发展的有限元分析

对薄板坯连铸结晶中铸坯凝固壳应力的发展过程建立了有限元分析模型。在计算铸坯温度场和凝壳厚度分布的基础上用热弹粘性模型数值模拟了凝固壳中的应力发展过程，同时得到了凝壳断面从结晶器液池顶面到结晶器出口处的移支过程中各部位裂纹产生倾向的大小。模型中考虑了钢水静压力的作用和结晶器锥度，计算结果合理。     

用代数应力模型模化型腔充填过程中的紊流流动

针对型腔充填过程中的紊流流动，用代数应力模型研究紊流流动现象．成功地将代数应力模型引入ＰＨＯＥＮＩＣＳ软件中，完成了恒温流体充填过程三维时均速度和自由表面的计算模拟．与实验结果相比说明，本文基于ＰＨＯＥＮＩＣＳ软件开发的充填模拟具备了对复杂型腔充填过程的数值计算．     

基于应力集中分析的钻杆内加厚过渡结构设计

通过讨论钻杆内加厚过渡带结构参数对其应力集中系数的影响,提出了实现钻杆内加厚过渡部位低应力集中设计的基本条件,并用钻杆实物疲劳试验对上述分析结果进行了验证,这一工作为改进钻杆内加厚过渡带结构设计提供了重要依据。     

Numerical simulation of the interface molten metal air in the shot sleeve chambre and mold cavity of a die casting machine

The objective of this study relates to the numerical simulation of the free surface during the two-dimensional flow and solidification of aluminum in the horizontal cylinder and mold cavity of the high pressure die casting HPDC machine with cold chamber. The flow is governed by the Navier–Stokes equations (the mass and the momentum conservations) and solved in the two phase’s liquid aluminum and air. The tracking of the free surface is ensured by the VOF method. The equivalent specific heat method is used to solve the phase change heat transfer problem in the solidification process. Considering the displacement of the plunger, the geometry of the problem is variable and the numerical resolution uses a dynamic grid. The study examines the influence of the plunger speed on the evolution of the interface aluminum liquid–air profile, the mass of air imprisoned and the stream function contours versus time. Filling of a mold is an essential part of HPDC process and affects significantly the heat transfer and solidification of the melt. For this reason, accurate prediction of the temperature field in the system can be achieved only by including simulation of filling in the analysis.     

Flow disturbance in polymer melt behind an obstacle

In polymer processing weld-lines occur when a polymer melt is separated and then reunited. The internal structure of a weld-line region is determined by the rheological state of the reunited melt streams. An experimental investigation of the region of interest within the mold is almost impossible. Thus, computer simulation is necessary to examine weld-lines. This paper presents a detailed analysis of the flow behavior at a weld-line interface which was caused by a flow obstacle. The results show a gradual increase of the velocity within a short distance behind the obstacle which coincides with a short weld-line determined by the advancement of the flow fronts obtained from conventional mold filling studies. However, based on the residence time history of the melt there is a weld-line over the full length of the part. Its formation mechanism was additionally described by experimental filling studies by the sandwich injection molding technique. In conclusion, the formation of the weld-line should be determined not only by the flow fronts, but also by the thermo-rheological history of the reunited melt streams. Received: 18 September 1997 Accepted: 3 March 1998     

Tribological Characterization of Gradient-density Polyacrylamide Hydrogel Surfaces

Experimental Mechanics - The contact and frictional response of a hydrogel is dependent on the polymer structure at the gel surface. Recent work has shown that different mold materials in contact...