基于红外光谱大型筒类锻件热处理过程中温度场检测方法研究

为了实时掌握热处理过程中锻件温度场的变化情况,提出一种基于红外光谱大型筒类锻件温度场检测方法。在传热学的基础上,运用分离变量法建立了大型筒类锻件热处理过程中的温度场检测模型;利用红外光谱构建了基于三级干涉滤光器的大型锻件红外光谱测温系统;结合红外光谱测温系统测量的温度数据和锻件温度场检测模型,实现了锻件热处理过程中温度场的检测;最后通过仿真实验验证了本文提出方法的可行性,实现了热处理过程中锻件温度场的检测,为热处理工艺的正确实施提供了理论依据。     

选区激光烧结瞬态温度场模拟与测试方法研究

采用有限元方法,考虑实际的边界条件和热物性参量的变化,对Al2O3覆膜陶瓷粉末的选区激光烧结过程瞬态三维温度场进行动态模拟.通过比色测温法对红外热成像系统的发射系数进行修正后,对选区激光烧结过程瞬态温度场进行测试.数值模拟和实测结果显示,两者吻合较好.     

激光烧结石墨烯铜复合材料温度场有限元模拟

在激光烧结石墨烯增强铜基复合材料的过程中,了解瞬时温度场分布对优化工艺参数、控制烧结质量有重要作用。建立了激光烧结预涂在42CrMo基板上的石墨烯铜的混合粉末的有限元模型。研究了激光烧结过程温度场分布,熔池的几何参数以及烧结层与基体的冶金结合宽度。为了验证模拟结果,使用与模拟相同的参数进行了单道激光烧结的实验。研究表明,热传导、热辐射和相变潜热在激光烧结过程的温度场分布中起重要作用。实验结果与模拟结果较为一致。所以可以依据模拟结果预测实验的温度场分布和熔池几何参数,同时也可以据此优化激光烧结参数。     

激光熔覆中同轴粉末流温度场的数值模拟

在激光同轴送粉熔覆中,由于激光与粉末流相互作用,粉末流整体温度分布直接影响激光熔覆的质量.基于非预混燃烧模型,将激光相处理为连续性介质,粉末颗粒相看作离散相物质,建立了激光作用下粉末流的质量、动量和能量方程.用Fluent软件进行了不同激光功率和粉末流速度条件下粉末流整体温度场数值模拟,讨论了各种参数对温度场分布的影响.为了验证该模型的准确度,利用CCD比色测温方法测量了粉末流整体温度场分布.结果表明,数值模拟与CCD检测结果具有良好的一致性,数值模拟结果对激光熔覆具有指导意义.     

基于ANSYS的脉冲激光辐照石英玻璃的温度场数值模拟

采用有限元仿真软件ANSYS 12.0对脉冲功率激光辐照石英玻璃建立了热力学模型,对其表面温度场进行了数值模拟,得到了在不同激光功率密度下的瞬态温度场分布,并对模拟结果进行了分析和研究,为激光辐照石英玻璃实验提供依据.     

基于量热法的高功率激光功率测试技术

针对高功率激光功率的测试,尤其是高功率激光器烤机时的长时间测量需求,设计了基于水冷却的激光功率测量方法。利用热敏电阻测量冷却水进水口和出水口的温差计算激光功率。利用有限元仿真软件建立了吸收腔热路结构的三维有限元模型,并对不同口径的冷却水路进行模拟仿真。测试结果表明,用该方法测试高功率激光功率,测量相对误差可以保证在1.6%以内。     

真空环境下激光与固体靶冲量耦合的机理分析和数值模拟

在准真空环境下，采用高功率密度的调Q-Nd:YAG激光照射固体铝靶表面，测量了不同入射激光强度下气化靶物质对靶的冲量.通过分析不同情况下激光与固态靶、气化物质的作用机理，采用流体力学理论和三维有限差分的计算方法，对不同激光强度情况下气化物质对靶产生冲量的过程进行了数值模拟，将模拟计算所得结果与实验测量结果进行了比较和分析，进而对实验结果进行了解释.由数值模拟结果与实验结果的一致性可见，本文采用的模型能反映激光作用下固体靶力学响应的物理过程.     

激光辐照下红外测温的误差补偿方法研究

为了提高激光辐照下加热点处红外测温精度,建立了多变量测温补偿模型,研究了测量距离、测量角度与测量精度的关系。采用单一变量与正交变量结合的方法,建立关于测量距离与测量角度的二元变量补偿模型,并进行误差补偿模型验证实验。结果表明:补偿模型与实际测量结果可以较好地匹配,补偿后测量误差为±1.25%,与补偿之前相比测量精度提高64.25%,验证了补偿模型的正确性,为激光辐照下加热点温度红外测量提供理论指导。     

火焰烟黑三维温度场和浓度场同时重建实验研究

利用电荷耦合器件摄像机采用烟黑温度场和浓度场同时重建模型对自由火焰烟黑的三维温度场和浓度场进行了同时重建实验研究,所利用的重建模型是基于区域重建的方法.将重建的烟黑温度场和浓度场与文献结果进行了对比,而且还将重建温度场与热电偶所测量的温度场进行了对比.结果表明,重建的烟黑温度场和浓度场与文献结果趋势相一致,重建温度值与热电偶测量值符合较好.因此,同时重建模型可以较好地重建出火焰烟黑的三维温度场和浓度场. 关键词： 火焰烟黑 温度场 浓度场 三维同时重建     

基于3D-DIC对爆炸作用下碳纤维层合板的变形研究

针对3种不同铺层的碳纤维复合材料层合板,设计了开放式爆炸加载实验,研究不同的炸药质量和爆炸距离下层合板的动态力学行为。基于两台高速相机,搭建了高速三维变形场的实验测量系统,记录层合板在爆炸作用下动态变形过程。通过三维数字图像相关方法(3D-DIC)软件计算得到层合板在冲击波作用下的动态位移场和应变场。研究发现:层合板在弱冲击波作用下只发生弹性变形,正交铺层和准均质铺层均表现出良好的抗冲击能力;在强冲击波作用下层合板会产生分层、基体开裂、纤维断裂等形式的损伤,铺层顺序对损伤形式有很大影响。     

Investigation of Portevin-Le Chatelier effect in 5456 Al-based alloy using digital image correlation

A variety of experimental methods have been proposed for Portevin-Le Chatelier (PLC) effect. They mainly focused on the in-plane deformation. In order to achieve the high-accuracy measurement, three-dimensional digital image correlation (3D-DIC) was employed in this work to investigate the PLC effect in 5456 Al-based alloy. The temporal and spatial evolutions of deformation in the full field of specimen surface were observed. The large deformation of localized necking was determined experimentally. The distributions of out-of-plane displacement over the loading procedure were also obtained. Furthermore, a comparison of measurement accuracy between two-dimensional digital image correlation (2D-DIC) and 3D-DIC was also performed. Due to the theoretical restriction, the measurement accuracy of 2D-DIC decreases with the increase of deformation. A maximum discrepancy of about 20% with 3D-DIC was observed in this work. Therefore, 3D-DIC is actually more essential for the high-accuracy investigation of PLC effect.     

A novel technique for measuring 3D deformation of adhesively bonded single lap joint

An easy-to-implement yet practical single-camera microscopic stereo-digital image correlation(stereo-DIC) technique is proposed for surface three-dimensional(3D) deformation measurement of singe lap joint(SLJ) samples subjected to mechanical loads. The basic principles, optical configurations and implementation procedures of the proposed technique are described in detail. Compared with existing single-camera 2D-DIC technique, which has been regularly used for in-plane deformation measurement of a SLJ specimen, the proposed technique offers the special merit of simultaneously determining all the three displacement components by simply adding two additional optical elements to existing single-camera 2D-DIC systems. The accuracy and effectiveness of the proposed technique is demonstrated by measuring the 3D deformation of a SLJ specimen subjected to quasi-static tensile loads.     

High-efficiency and high-accuracy digital image correlation for three-dimensional measurement

The computational efficiency and measurement accuracy of the digital image correlation (DIC) have become more and more important in recent years. For the three-dimensional DIC (3D-DIC), these issues are much more serious. First, there are two cameras employed which increases the computational amount several times. Second, because of the differences in view angles, the must-do stereo correspondence between the left and right images is equivalently a non-uniform deformation, and cannot be weakened by increasing the sampling frequency of digital cameras. This work mainly focuses on the efficiency and accuracy of 3D-DIC. The inverse compositional Gauss–Newton algorithm (IC-GN²) with the second-order shape function is firstly proposed. Because it contains the second-order displacement gradient terms, the measurement accuracy for the non-uniform deformation thus can be improved significantly, which is typically one order higher than the first-order shape function combined with the IC-GN algorithm (IC-GN¹), and 2 times faster than the second-order shape function combined with the forward additive Gauss–Newton algorithm (FA-GN²). Then, based on the features of the IC-GN¹ and IC-GN² algorithms, a high-efficiency and high-accuracy measurement strategy for 3D-DIC is proposed in the end.     

Bonding energy of Sylgard on fused quartz: an experimental investigation

The bonding energy between the polymer Sylgard and fused quartz is determined experimentally using a miniature bulge test combined with three-dimensional digital image correlation (3D-DIC). Based on the experimental observation, Mindlin plate theory is used to compute the bonding energy (adhesive energy or surface energy) between the Sylgard and the fused quartz. The experimental results demonstrate that the combination of the miniature bulge test and the 3D-DIC provides a viable tool to directly measure interfacial and bonding properties.     

Whole-field thickness strain measurement using multiple camera digital image correlation system

Three Dimensional digital image correlation(3D-DIC) has been widely used by industry, especially for strain measurement. The traditional 3D-DIC system can accurately obtain the whole-field 3D deformation. However, the conventional 3D-DIC system can only acquire the displacement field on a single surface, thus lacking information in the depth direction. Therefore, the strain in the thickness direction cannot be measured. In recent years, multiple camera DIC (multi-camera DIC) systems have become a new research topic, which provides much more measurement possibility compared to the conventional 3D-DIC system. In this paper, a multi-camera DIC system used to measure the whole-field thickness strain is introduced in detail. Four cameras are used in the system. two of them are placed at the front side of the object, and the other two cameras are placed at the back side. Each pair of cameras constitutes a sub stereo-vision system and measures the whole-field 3D deformation on one side of the object. A special calibration plate is used to calibrate the system, and the information from these two subsystems is linked by the calibration result. Whole-field thickness strain can be measured using the information obtained from both sides of the object. Additionally, the major and minor strain on the object surface are obtained simultaneously, and a whole-field quasi 3D strain history is acquired. The theory derivation for the system, experimental process, and application of determining the thinning strain limit based on the obtained whole-field thickness strain history are introduced in detail.     

Digital image correlation for large deformation applied in Ti alloy compression and tension test

In this paper, digital speckle correlation is used in the measurement of Ti alloy compression and tension test. The key technologies applied in the measurement are discussed in detail, including camera calibration with telephoto lens and digital image correlation in large deformation. Single camera self-calibration algorithm based on photogrammetry is proposed. In the algorithm, the interior parameters of camera are estimated without calibrated object, using the bundle adjustment technique, so the 3-D coordinates of calibration target points are not needed in advance to get a reliable camera calibration result. An updating reference image scheme could be employed to deal with large deformation situation. A large deformation measurement scheme, updating reference image scheme, is proposed in this paper. The un-deformed image is used as reference in correlation at first. Only for extremely large deformation field, in which iteration of correlation is not convergent, the reference image is updated to the image of previous deformed stage. Using this method, not only extremely large deformation can be measured successfully but also the accumulated error could be controlled. The 75 mm lens is calibrated in the measurement and compared the result with extensometer and un-calibrated image. Experimental results show that up to 150% tensile deformation and 50% compression deformation can be measured successfully.     

An experimental method for eliminating effect of rigid out-of-plane motion on 2D-DIC

The out-of-plane motion is one of the most important factors that affect the precision of two-dimensional digital image correlation (2D-DIC). In this paper, a novel solution is presented to improve conventional 2D-DIC by eliminating the effect of out-of-plane motion, including translation and rotation. Firstly, an experimental technique using two projected laser strips is proposed to measure the out-of-plane motion of a planar specimen. A theoretical model is then established to predict the pseudostrains caused by out-of-plane motion based on the pin-hole imaging model. Using the measured out-of-plane displacement, the captured deformed images used in 2D-DIC are amended to eliminate the effect of out-of-plane motion by the theoretical model. Finally, two experiments were conducted to validate the effectiveness of the proposed method. Results indicate that application of the proposed method can effectively eliminate the errors caused by out-of-plane motion.     

A comparison of 2D and 3D digital image correlation for a membrane under inflation

Three-dimensional (3D) digital image correlation (DIC) is becoming widely used to characterize the behavior of structures undergoing 3D deformations. However, the use of 3D-DIC can be challenging under certain conditions, such as high magnification, and therefore small depth of field, or a highly controlled environment with limited access for two-angled cameras. The purpose of this study is to compare 2D-DIC and 3D-DIC for the same inflation experiment and evaluate whether 2D-DIC can be used when conditions discourage the use of a stereo-vision system. A latex membrane was inflated vertically to 5.41 kPa (reference pressure), then to 7.87 kPa (deformed pressure). A two-camera stereo-vision system acquired top-down images of the membrane, while a single camera system simultaneously recorded images of the membrane in profile. 2D-DIC and 3D-DIC were used to calculate horizontal (in the membrane plane) and vertical (out of the membrane plane) displacements, and meridional strain. Under static conditions, the baseline uncertainty in horizontal displacement and strain were smaller for 3D-DIC than 2D-DIC. However, the opposite was observed for the vertical displacement, for which 2D-DIC had a smaller baseline uncertainty. The baseline absolute error in vertical displacement and strain were similar for both DIC methods, but it was larger for 2D-DIC than 3D-DIC for the horizontal displacement. Under inflation, the variability in the measurements were larger than under static conditions for both DIC methods. 2D-DIC showed a smaller variability in displacements than 3D-DIC, especially for the vertical displacement, but a similar strain uncertainty. The absolute difference in the average displacements and strain between 3D-DIC and 2D-DIC were in the range of the 3D-DIC variability. Those findings suggest that 2D-DIC might be used as an alternative to 3D-DIC to study the inflation response of materials under certain conditions.     

散斑面内形变场检测系统设计

数字散斑测量是一种非接触、全场测量的高精度光测方法。该系统由散斑生成装置、数据采集装置和数据处理装置三部分组成。散斑生成装置将扩散的激光束投射到待测物体上,用接收屏接收物体散射生成的散斑图像。数据采集装置主要由CCD和数字采集卡组成,CCD拍摄散斑图像,并将其传输给数字采集卡,经采集卡转换成数字图像,以矩阵形式输入到数据处理装置。数据处理装置根据光学相关识别技术设计的检测程序对采集到的数字图像进行相关运算,通过对相关峰的准确定位来获取物体的形变信息。     

高精度数字图像相关测量系统及其技术研究

研制双CCD长距显微数字图像相关测量系统,它融合光电子、数字图像相关方法和散斑技术于一体,具有非接触式、高精度、宽量程、准实时、测试方法简便等优点,它可用于材料力学性能(特别是柔性高分子材料力学性能)测量、低膨胀系数新型材料线胀系数等的测量。若将其用于应变测量,灵敏度优于1με,而传统数字图像相关方法测量应变的理论灵敏度为20με。利用列阵光学元件解决了0.05 mm高衬比度微小标记的方便设置;提出消除了数字图像灰度噪声的时间平均法,使相关测量精度稳定地达到0.01 pixel。还给出金属材料拉应变的测量结果,实验结果与经典理论值相当接近。此外,还阐述数字图像相关测量技术是一种超光学系统衍射极限分辨力的测量技术。