超声滚压金属材料的疲劳性能研究进展

超声滚压(ultrasonic surface rolling, USR)技术结合高能冲击和静载滚压的特点,处理后工件具有表面光洁度高、变形层深、残余压应力大和晶粒细化明显等优势;可通过适当的工艺参数设计,极大提高金属材料的疲劳强度,因而在制造业得到了广泛应用。自该技术应用至今,国内外学者做了大量有关USR工艺及性能方面的研究,并在多种重要金属材料及关键零部件中应用。截至目前,关于USR工艺参数对材料表面完整性和疲劳性能的研究,比较零散,缺乏系统总结。研究首先简要介绍了USR的工作原理和可控性;然后总结了不同USR工艺参数诱导的残余应力和微观组织,以及残余应力在疲劳加载过程中的释放规律;分析了不同工艺USR诱导的表面完整性对疲劳性能的影响及其潜在机理;阐述了与USR相关的复合强化方法的最新进展,并展望了USR金属材料的应用前景。     

30CrMnSiNi2A超高强度钢孔挤压强化残余应力场的模拟

利用有限元软件ANSYS建立了30CrMnSiNi2A超高强度钢孔挤压强化残余应力场的三维有限元模型,分别模拟分析了不同孔径、过盈量、厚度和孔边距比下30CrMnSiNi2A超高强度钢构件孔挤压强化的三维残余应力场分布.模拟结果表明,残余应力沿厚度在中层和出口处随着孔径的增大而增大,且残余拉应力的增加幅度也大;随着过盈量的增大,残余压应力增大,但达到一定程度后过盈量的增量所引起的有利残余压应力的增量减小;随着厚度的增加,残余压应力在入口表面的孔周处先减小后增大;孔边距的减小,对残余压应力影响较小,而对残余拉应力的影响很大.     

非稳态纯滚动接触弹塑性分析

建立了二维弹塑性非稳态循环纯滚动接触有限元模型.材料本构采用一种较好的循环塑性模型,并通过材料用户子程序在通用有限元软件ABAQUS中自定义该本构模型.通过在弹塑性无限半空间表面上重复移动随时间按简谐规律变化的赫兹法向载荷来模拟非稳态循环纯滚动接触过程.通过数值模拟,得到接触表面附近的残余累积变形、应变和残余应力.不同的最大赫兹接触压力对残余应力和残余应变影响较大.在简谐变化的法向接触载荷作用下接触表面的变形呈波浪形,随着滚动次数的增加,该波状表面沿载荷移动相反方向逐渐移动,但移动速率要衰减.波状表面波谷处的残余应力、应变和变形大于波峰处.随滚动次数的增加,残余应力增大但很快趋于稳定,残余应变也增大但增大速率衰减.     

基于弹性理论的残余应力反演和变形计算

毛坯在制造过程中,材料力学性能的非均匀性导致其内部产生残余应力.残余应力会造成结构破坏,在工件的切削去除过程中,残余应力会逐渐释放并引起变形.采用有限元的“生死单元”技术模拟材料的切削去除过程,并转化为残余应力的释放,基于板壳理论、小变形理论、弹性理论和叠加原理,将径向基函数插值法与几何方程、物理方程相结合,开发出一种新的解析方法,反演残余应力场并计算变形.结果表明解析方法的理论解与有限元解高度吻合,能够用于判断残余应力分布并计算残余应力弹性释放引起的变形.     

航空薄壁弧形结构件喷丸强化变形预测

喷丸强化是一种有效提高工件抗疲劳性能的表面处理工艺，经喷丸强化处理后的航空薄壁弧形结构件发生变形是航空制造领域的共性难题．本文基于变截面曲梁平面弯曲理论，建立了弧形件喷丸诱导应力与变形方程，将得到的构件最大变形与有限元方法计算结果进行对比，所建立理论模型能有效预测弧形件喷丸强化后的变形．讨论了喷丸压力和喷丸区域对喷丸变形的影响，结果表明：喷丸强化工艺仅作用于弧形件腹板表面时，弧形件变形以径向收缩为主；喷丸强化工艺仅作用于弧形件筋板表面时，弧形件变形以径向扩张为主；与局部喷丸相比，对弧形件所有表面喷丸强化时，弧形件弯曲变形减小，轴向伸长增大．     

氮离子注入GCrl5轴承钢的摩擦磨损性能研究

作者利用多种表面测试手段对不同条件下的氮离子注入GCr15轴承钢的摩擦学性能进行了研究,发现其表面形貌、表层残余应力、显微硬度、微观组织结构和摩擦磨损性能均与未注入材料的不同。并且指出,由于离子注入引起了表面粗糙度的降低,表层残余应力的增大和表面显微硬度的提高,以及注入层氮化物的形成,所以摩擦磨损机理也发生了变化。试验结果表明,摩擦力和磨损量的降低最高分别可达67％和83％。     

切削加工过程数值模拟的研究进展

近年来,有限元方法在切削加工模拟中得到了越来越广泛的应 用,在研究切削工艺参数及切屑成形机理方面有着不可替代的作用。 本文介绍了国外切削加工过程有限元数值模拟的研究进展,阐述了切 削过程有限元模拟的关键技术,包括切屑形成、切削加工中的热力耦 合、工件与刀具接触和摩擦、切屑分离和断裂准则以及工件残余应力、 残余应变的模拟等技术;最后,还对切削工艺有限元数值模拟的发展 方向作了探讨。     

表面纳米化对316L不锈钢低周疲劳性能的影响

超声喷丸(USSP)处理工艺在316L不锈钢表面制备出了纳米表面晶层,对表面纳米化后和未表面纳米化的316L不锈钢试样进行对比拉拉低周疲劳试验,运用数理统计学的方法分析研究了表面纳米化处理对316L不锈钢的低周疲劳性能的影响,并就表面纳米化对疲劳性能的影响机理进行了初步分析探讨.研究结果表明,超声喷丸表面纳米化处理可以有效地提高316L不锈钢的低周疲劳寿命;超声喷丸处理在表面所形成的残余压应力、晶粒细化的纳米强化表层是疲劳寿命提高的主要原因.     

高温MEMS剪应力传感器残余应力分析

采用理论分析与数值模拟相结合的方法,研究了残余应力对静电反馈式MEMS高温剪应力传感器的结构设计的影响.研究表明:在电极宽度和间距不变的情况下,增加电极数和减小电极长度可有效地减小由静电力引起的应力和变形;残余应力对结构应力和变形的影响远大于静电力.     

搅拌摩擦焊接残余应力及残余变形数值分析

建立了搅拌摩擦焊接顺序热力耦合有限元模型,用移动热源模拟搅拌头的作用,对搅拌摩擦焊接进行数值模拟.瞬态温度场及残余应力场与试验结果吻合良好,从而验证了该模型的正确性.本文研究了焊接过程中应力变化过程,指出应力场的不均匀分布引起板的弯曲变形.建立了不同尺寸有限元模型,研究板的尺寸对残余变形的影响.板的宽度对纵向残余变形曲率影响较大,长度对变形曲率影响较小.当焊接长度足够长,模型宽度相同时,不同模型远离端部区域纵向弯曲曲率相同.板的横向残余变形主要由焊缝区域变形引起,远离焊缝区域几乎没有弯曲变形发生,且板的尺寸对变形曲率影响很小.     

Modelling and simulation of process-integrated powder coating by radial axial rolling of rings

In this paper, we present finite element (FE) process simulations of a new production method used to coat ring-shaped work pieces with functional layers. Similarly to the conventionally applied hot isostatic pressing (HIP), this new coating method is based on powder metallurgy. It is expected to overcome some important drawbacks by integrating the consolidation of the powdery layer material into the hot rolling of the substrate ring. This makes HIP dispensable. Nevertheless several difficulties arise through the process integration. E.g., the presence of the compactable layer requires a different handling of the rolling stage compared with classical ring rolling. FE simulations shall support the design of this new process in order to investigate critical process parameters. For this purpose, new finite element modules have to be developed. A crucial point is the adequate modelling of the layer material. In this regard, we present a rate-dependent finite strain material model that describes the consolidation of the layer material in a thermodynamically consistent way. Moreover, FE process simulations of the new production method are presented and compared with experimental results.     

A plasticity model describing yield-point phenomena of steels and its application to FE simulation of temper rolling

To describe the yield-point phenomena of steels, an extended version of the first author’s model (Yoshida, F., 2000. A constitutive model of cyclic plasticity. International Journal of Plasticity 16, 359–380) is proposed on the premise that the material behavior of sharp yield point and the subsequent abrupt yield drop result from a rapid dislocation multiplication and the stress-dependence of dislocation velocity. A specific feature of this model is that it describes well a high upper yield point, the rate-dependent Lüders strain at the yield plateau and the subsequent workhardening, as well as cyclic plasticity characteristics, such as the Bauschinger effect and rate-dependent ratcheting. Using this model, an FE simulation of temper rolling process is conducted in order to clarify its role for the elimination of the yield point of steel sheets. Particularly, the effect of upper yield point on the deformation characteristics in the process is discussed.     

Measurement of deformation gradients in hot rolling of AA3004

In this paper we describe an experimental technique developed to measure the deformation gradients and temperature in a single hot rolling pass of an AA3004 sample that was fitted with an insert. The insert had been previously hand engraved with a 1×1 mm grid pitch, and the analysis of the data digitally captured from the image of the deformed grid enabled the calculation of the components of the deformation gradient tensor. Four steel pins prevented relative motion between the insert and the rest of the sample. No detachment was observed between insert and sample after rolling. The temperature was measured during rolling using two embedded thermocouples, one close to the surface and the other in the centerline. The commercial finite element code ABAQUS was used to create a three-dimensional model of the rolling process. The recorded temperature was compared to the numerical values evaluated after tuning the heat transfer coefficient. The shape of the grid after rolling was checked against the deformed mesh using different fricition coefficients in order to obtain the optimum match. The unusually large length of the insert enabled the rolling process to be stopped halfway so that a picture of the roll-gap area could be obtained. This provided a partially deformed grid that represented the transient state during rolling. The experimentaily determined deformation gradient in this area as well as in the steady-state area agreed well with the finite element oredictions.     

Pitting formation under rolling contact

The mechanism of pitting caused by rolling contact is analyzed using the fracture mechanics approach. The governing factors are the initial crack length, crack angle, contact force, friction, strain hardened layer, and the hydraulic pressure of trapped fluid acting on the crack surface. Mode I and II stress intensity and the strain energy density factors are calculated by application of the two-dimensional finite element method. The strain energy density criterion is applied to show that shallow angle crack under small rolling contact force and friction enhances the probability of pitting under the roller’s running surface. The presence of a strain hardened surface layer also tends to affect the fracture behavior. The analytical results agree well with the experimental observations.     

薄膜多层滚压的表面粗糙度晶体学分析

提出了晶体学模型来研究多层薄膜滚压的表面粗糙度。研究了单层滚压模型，提出滚压的三维模型和二维模型（平面应变），讨论了晶粒大小和应力状态的影响。把单个单层滚压和多层滚压模型、三维模型和平面应变模型进行了比较，发现对于所涉及的二维和三维模型来说，单层滚压和多层滚压模型并无明显的差别。因此在这些情况下，可以用单个单层滚压模型来代替多层滚压模型从而节省CPU时间。     

Spray and jet cooling in steel rolling

Prediction and control of roll and strip cooling are necessary in modern steel mills because they not only affect the process efficiency but also strongly influence the quality of rolled products. In this article, relationships among metallurgy, heat transfer, and control of the cooling system in steel rolling are first discussed. Heat transfer characteristics associated with the water spray and jet cooling used in rolling processes are then studied. The effects of important convective heat transfer parameters on cooling perormance for both stationary and moving surfaces are examined. Results indicate that local heat fluxes up to 20 × 10⁶ W/m² are observed in the nucleate boiling regime. The present results are compared with typical boiling heat transfer studies in terms of heat fluxes, heat transfer coefficients, spray rate, and cooling efficiency. The effect of surface motion is found to increase the cooling efficiency of roll and strip cooling. Finally, implementation of the present finding in roll and strip cooling to thermomechanical processing in steel rolling is proposed.     

A novel analytical model based on arc tangent velocity field for prediction of rolling force in strip rolling

Accurate prediction of rolling force is an effective method to improve strip quality in rolling process. To achieve this goal, a novel arc tangent velocity field model based on the upper bound method is proposed to evaluate the rolling force. The mathematical expression of rolling force is derived from the virtual work principle and maximum plastic work principle. Comparing the experimental results with the proposed analytical model prediction, it has been found that this model is good for estimation of rolling force. Meanwhile, the finite element method is also used to simulate the rolling process to verify the validity of the analytical model. It is shown that this model can be used for prediction of rolling force in practice.

     

Tractive rolling contact mechanics of graded coatings

In this study, the tractive rolling contact problem between a rigid cylinder and a graded coating is investigated. The main objective of this study is to investigate the effect of the stiffness ratio, the coefficient of friction and the coating thickness on the surface contact tractions, the surface in-plane stress, the stick zone length and the creep ratio parameter that may have a bearing on the fatigue life of the component. Assuming that the shear modulus varies exponentially through the thickness of the coating, the governing integral equations associated with the rolling contact problem are constructed. Furthermore, it is supposed that the contact patch is controlled by a central stick zone accompanied by two slip zones. The conventional Goodman approximation is employed in order to decouple the governing singular integral equations. Finally, the numerical solution of the integral equations is obtained by applying the Gauss–Chebyshev integration method.     

Qualitative analysis of a rolling hoop with mass unbalance

The dynamical behavior of a rolling hoop with an unbalanced point mass under the influence of gravity is discussed. The whole process from rolling to hopping of the hoop is analyzed qualitatively. The conditions of slipping, hopping and touching down of the hoop are obtained. It is shown that the hoop cannot maintain a pure rolling before hopping up, and the slippage is unavoidable. The hoop has neither vertical velocity nor vertical acceleration at the moment when the normal constraint force vanishes. The hopping motion of the hoop can occur only when the derivative of the vertical acceleration with respect to time is positive. It requires that the angular velocity of the hoop should be larger than a critical value, and the mass point should be located in the fourth quadrant of the hoop circle at the moment of hopping. The whole process of the pure rolling, rolling with slipping, hopping and falling motions of the hoop is shown in the phase plane, and the physical explanation of the hopping motion is given.