聚晶金刚石复合片热残余应力分布规律实验研究

利用改进的应力释放法、X射线衍射法以及Raman光谱,对平面界面结构金刚石复合片表面热残余应力分别进行了实验研究,得到了金刚石层表面热残余应力值及其分布规律,同时得到了基体厚度与热残余应力的相关关系.研究结果表明,采用应力释放法、X射线衍射法及Raman光谱法测试PDC表面热残余应力,其测试结果均与有限元分析结果相吻合,证明了这三种方法的有效性.其中,X射线衍射法测试结果的误差最大,应力释放法其次,Raman光谱法最为精确.由于应力释放法应变片尺寸及X射线衍射法光斑照射范围的限制,无法在试样表面上取较多的测试点,因此难以得到理想的热残余应力分布曲线.而Raman光谱法中所采用的激光光斑仅5μm,可以取更多的测试点,因此其结果更能真实的反映金刚石层表面热残余应力的分布规律.本文的研究结果为精确测试PDC热残余应力,从而为优化PDC界面结构、提高PDC使用性能提供了理论和实验依据.     

U型钢板桩的X射线法表面残余应力研究

由于对尺寸要求较为严格,因此钢板桩内部的残余应力会对其产品总体质量产生较大影响.采用X射线方法对U型钢板桩二分之一长度和四分之一长度位置的表面残余应力进行了测试.详细说明了X射线残余应力测试原理,试验设备和测试过程,给出了钢板桩应力分布状况.采用全释放法测试了对应点位的残余应力值,比较了X射线法和释放法之间的差距.结果表明X射线方法和全释放法所测数值较为接近,两个位置上的应力分布状态基本一致,钢板桩中部腹板位置呈现压应力,而两边板应力较小.     

高压气瓶工艺残余应力测试和分析

用X射线及磁记忆两种方法对压缩天然气的高压气瓶应力状态进行了系统分析,对一个气瓶整体制造工艺中的残余应力变化用X射线法进行了跟踪检测。考察了气瓶锻造后、淬火后及回火后外表面的残余应力状况,对相同测点进行了三次应力测试。为准确找到测点位置并寻求两种方法之间关系,在每次应力测试之前,均用金属磁记忆方法进行了先期检测。结果表明:锻造后应力水平不高,但磁记忆曲线有小幅波动,显示应力不均匀;淬火后表面具有较大压应力,最大达到0.86σS,且磁场亦有较大变化,个别点有明显应力集中;回火处理有效地消除了淬火残余应力,最大值小于0.17σS,应力均匀化,磁记忆曲线几乎无波动,效果良好。而从定量角度,残余应力和磁记忆两者之间没有明确的对应关系。对于磁记忆所显示的磁场强度变化处,用X射线法进行残余应力测试,结果并没有显示出较高的应力水平。说明两种方法不可互相替代,但以其各自的特点和优势可做互相补充。     

无损残余应力测量及其新技术

简述及比较了主要的残余应力无损测量技术，重点为磁力法，并介绍一台新的磁力仪MAPS，且对MAPS及传统磁力仪作了比较，同时以X射线及中子衍射得到的结果验证了MAPS的可靠性，也介绍了文献上较少见的火车钢轨残余应力分布图。     

冷拔无缝钢管残余应力测量的杂交实验方法

提出了一种数值模拟和实验杂交的实验方法,测量了钢管内表面的残余应力。采用非线性有限元法模拟了冷拔钢管的成型过程,得到了钢管脱模以后的残余应力,通过释放切口处单元的刚度模拟了含有残余应力钢管的切割过程,研究了切割方法对残余应力的影响,数值计算和实验结果表明切割方法对二次残余应力有很大影响。采用X射线测量仪测量了钢管内表面的残余应力。研究结果表明,计算结果基本符合实验结果,误差可以被工程接受。     

残余应力的超声测量方法

1.前言无损地测定实际构件的残余应力,对于预测构件疲劳强度储备情况,检查热处理及表面强化处理工艺效果,控制构件切削加工工艺及检查消除应力工艺的效果等具有很大意义。目前,绝大多数残余应力测定方法对工件均有一定损伤,甚至完全破坏,只有X射线法、磁性法和超声法能无损测定残余应力。X射线法虽然理论较完善,但因仪器复杂,价格昂贵,对人体有伤害且穿透深度有限,仅能无损测定表面应力,其应用受到很大限制。磁性法和超声法测残余应力的有关问题各国正在大力研究中。尤其是超声法,由于具有无损、对人体无      

钻孔法测量残余应力中几个问题的探讨

本文针对钻孔法测量残余应力中一些不能用“释放”理论解释的问题,通过对钻孔法基本测量原理的分析和与其它传统电测方法对比,认为常用于测量残余应力的电测方法中钻孔法应定义为“干扰法”,切条法和套孔法为“释放法”,Sach＇s镗削法则为“干扰-释放法”.根据实验结果推荐公式=(λ-1)~(1/2)为预测钻孔深度的经验公式.同时应用“干扰”理论分析了压痕法测量残余应力的基本特性,提出压痕法与电测法结合将发展成为一种近似无损的测量残余应力的新方法.     

膨胀管残余应力测试

膨胀管残余应力是影响膨胀管抗外挤、内压强度的重要因素之一。确定膨胀管的残余应力,测试方法至关重要。在常用测试方法中,机械测量法中的盲孔法体现出测试的优越性。应用盲孔法测试J55、K55两种规格膨胀管的残余应力,并根据实际测试的应力水平和实验误差,采用应变释放系数分级法对试验结果进行修正,以提高测试结果的精度。实验结果表明,膨胀管膨胀后存在环向、轴向的残余应力,且外表面总是压残余应力。将实验结果与仿真结果对比,误差满足工程要求,说明盲孔法测试膨胀管残余应力方便、快捷、准确、有效。     

缺口根部和裂纹尖端残余应力的X射线法测定

X射线法用于缺口根部和裂纹尖端等徽区的残余应力测试的先决条件是解决缩小光束直径、提高衍射束的强度和准确设置试样等技术问题.在X射线衍射仪上借助于自行设计制造的限束对光装置和侧倾对中附件,成功地测定了缺口根部半径为1mm的喷丸残余应力场和板形试样压-压周期载荷下裂纹尖端的残余拉应力场.     

用激光散斑剪切干涉法及钻孔释放法测定残余应力

本文用激光散斑剪切干涉法及钻孔释放法直接测取释放应变,进而计算残余应力.用模拟铝合金试件测取残余应力,条纹清晰,试验结果与理论解一致性较好。     

Residual Stress State Characterization of Machined Components by X-ray Diffraction and Multiparameter Micromagnetic Methods

Machining induced residual stress states have been identified to affect the distortion of parts during following heat treatments. Thus, ideally a complete characterization of the components residual stress state is required. Magnetic and micromagnetic analysis of residual stresses can represent an important gain of time compared to X-ray diffraction. Investigations with these two methods were performed on different components with various and inhomogeneous residual stress states: cylindrical and tapered ball bearing rings made from AISI52100 steel and a disc made from AISI5210 steel. Reliable results and good agreement between X-ray diffraction data and residual stresses obtained from the magnetic and micromagnetic analysis can be obtained with the use of a calibration for each single component. An important gain of time can be achieved with the combined use of X-ray diffraction analysis for the calibration and the micromagnetic technique. However, local residual stress variations in zones smaller than the sensor size may not be detected. A global calibration of the micromagnetic equipment with one calibration file for several parts still needs optimization.     

基于DIC方法的残余应力快速测量系统

结合数字图像相关(Digital Image Correlation,DIC)方法与钻孔法,开发了残余应力快速测量系统。该系统可分为两部分:适用于现场测量的便携式机械系统与针对残余应力测量而改进的基于DIC算法的程序。在四点弯曲加载平台上对工件进行载荷释放前后的残余应力测量试验,通过与应变片测量结果进行对比,该残余应力测量系统的精度达到了应变片测量的同等精度。同时,该测量系统解决了传统应变片测量系统对心误差大、操作繁琐、效率低和测量结果稳定性差等问题,具有较高的工程应用价值。     

Mapping Multiple Components of the Residual Stress Tensor in a Large P91 Steel Pipe Girth Weld Using a Single Contour Cut

The contour method is applied in an innovative manner to measure the distribution of hoop residual stress in a large martensitic-ferritic steel pipe containing a multi-pass girth weld. First, a novel one-step wire electro-discharge machining cut is conducted to divide the pipe lengthways into two halves. The deformation of the cut halves is then measured and analysed in a way that simultaneously gives maps of hoop stress across the wall thickness on both sides of the pipe and automatically accounts for through-thickness hoop bending effects and how they may vary along the pipe. Finally the contour method results are combined with X-ray diffraction residual stress measurements using the principle of superposition to determine the distribution of the axial and radial residual stresses in the pipe. It is thereby demonstrated how the distribution of three direct components of the residual stress tensor in a welded pipe can be readily determined using a “hybrid” contour measurement approach.     

结构动态应力计算方法研究

复杂结构动态应力的准确计算是一个没有圆满解决的问题。本文以最小余能原理为基础，提出了计算结构动态应力的最小伤痛有法。该方法采用二次分析思想，首先采用常规有限元对结构进行适当离散，计算输出结构所需应力区域的有限元结点位移和加速度动力时程反应，再应用最小余能法计算所求部位的动态应力值。这种方法的优点是它可以与现有的有限元程序有机结合，方便使用；动应力在区域内的分布规律可以由计算者根据具体情况而确定，一般情况下，可以选用二次曲线来逼近动应力在区域内的实际分布，避免了常规有限元法计算结构动应力时必须对单元形函数求导的做法，从而提高了动应力计算精度。计算结果表明：本文方法计算结构动态应力结果较常规有限元法的计算结果有明显改进，特别是当结构变化剧烈时，改进效果更为明显。     

Evaluation of Errors Associated with Cutting-Induced Plasticity in Residual Stress Measurements Using the Contour Method

Cutting-induced plasticity can lead to elevated uncertainties in residual stress measurements made by the contour method. In this study plasticity-induced stress errors are numerically evaluated for a benchmark edge-welded beam to understand the underlying mechanism. Welding and cutting are sequentially simulated by finite element models which have been validated by previous experimental results. It is found that a cutting direction normal to the symmetry plane of the residual stress distribution can lead to a substantially asymmetrical back-calculated stress distribution, owing to cutting-induced plasticity. In general, the stresses at sample edges are most susceptible to error, particularly when the sample is restrained during cutting. Inadequate clamping (far from the plane of cut) can lead to highly concentrated plastic deformation in local regions, and consequently the back-calculated stresses have exceptionally high values and gradients at these locations. Furthermore, the overall stress distribution is skewed towards the end-of-cut side. Adequate clamping (close to the plane of cut) minimises errors in back-calculated stress which becomes insensitive to the cutting direction. For minimal constraint (i.e. solely preventing rigid body motion), the plastic deformation is relatively smoothly distributed, and an optimal cutting direction (i.e. cutting from the base material towards the weld region in a direction that falls within the residual stress symmetry plane) is identified by evaluating the magnitude of stress errors. These findings suggest that cutting process information is important for the evaluation of potential plasticity-induced errors in contour method results, and that the cutting direction and clamping strategy can be optimised with an understanding of their effects on plasticity and hence the back-calculated stresses.     

双折射材料初应力的定量研究相移等达因技术的应用

文章提出两种用相移等达因技术对存在于双折射材料内部的初始应力进行定量分析的方法，并以两种常用的双折射材料Ｐ６和Ｈｏｍａｌｉｔｅ１００为例进行了内部初应力的实验研究，给出了材料内部初应力的分布。以上研究说明双折射内部初始应力不容忽视，数字相移等达因技术是双折射材料内部初始应力进行定量分析的有力手段     

Repeatability of the Contour Method for Residual Stress Measurement

This paper describes the results of a residual stress measurement repeatability study using the contour method. The test specimen is an aluminum bar (cut from plate), with cross sectional dimensions of 50.8 mm?×?76.2 mm (2 in?×?3 in) with a length of 609.6 mm (24 in). There are two bars, one bar with high residual stresses and one bar with low residual stresses. The high residual stress configuration (±150 MPa) is in a quenched and over-aged condition (Al 7050-T74) and the low residual stress configuration (±20 MPa) is stress relieved by stretching (Al 7050-T7451). Five contour measurements were performed on each aluminum bar at the mid-length of successively smaller pieces. Typical contour method procedures are employed with careful clamping of the specimen, wire electric discharge machining (EDM) for the cut, laser surface profiling of the cut faces, surface profile fitting, and linear elastic stress analysis. The measurement results provide repeatability data for the contour method, and the difference in repeatability when measuring high or low magnitude stresses. The results show similar repeatability standard deviation for both samples, being less than 10 MPa over most of the cross section and somewhat larger, around 20 MPa, near the cross section edges. A comparison with published repeatability data for other residual stress measurement techniques (x-ray diffraction, incremental hole drilling, and slitting) shows that the contour method has a level of repeatability that is similar to, or better than, other techniques.     

Inverse Eigenstrain Analysis of the Effect of Non-uniform Sample Shape on the Residual Stress Due to Shot Peening

This paper deals with the analysis of elastic strain and eigenstrain in non-uniformly shaped shot-peened 17-4PH stainless steel samples. Based on residual strain measurements by synchrotron X-ray diffraction, the finite element (FE) models are established for the inverse problem of eigenstrain analysis in slice conical sample. The eigenstrains obtained in the slice are then implemented into the FE model of the solid conical sample. It is found that the dependence of elastic strain distributions on the peening intensity and sample shape/thickness could be elucidated via the understanding of underlying permanent strain, or eigenstrain. The effect of the peening process is therefore best described in terms of the induced eigenstrain. The proposed framework is useful for the predictive modelling of residual stresses in non-uniformly shaped shot-peened materials, in that it allows efficient reconstruction of complete residual stress states. In addition, it provides an excellent basis for developing predictive tools for in service performance and design optimisation.     

Comparison Between Surface and Near-Surface Residual Stress Measurement Techniques Using a Standard Four-Point-Bend Specimen

Background

Determination of near-surface residual stresses is challenging for the available measurement techniques due to their limitations. These are often either beyond reach or associated with significant uncertainties.

Objective

This study describes a critical comparison between three methods of surface and near-surface residual stress measurements, including x-ray diffraction (XRD) and two incremental central hole-drilling techniques one based on strain-gauge rosette and the other based on electronic speckle pattern interferometry (ESPI).

Methods

These measurements were performed on standard four-point-bend beams of steel loaded to known nominal stresses, according to the ASTM standard. These were to evaluate the sensitivity of different techniques to the variation in the nominal stress, and their associated uncertainties.

Results

The XRD data showed very good correlations with the surface nominal stress, and with superb repeatability and small uncertainties. The results of the ESPI based hole-drilling technique were also in a good agreement with the XRD data and the expected nominal stress. However, those obtained by the strain gauge rosette based hole-drilling technique were not matching well with the data obtained by the other techniques nor with the nominal stress. This was found to be due to the generation of extensive compressive residual stress during surface preparation for strain gauge installation.

Conclusion

The ESPI method is proven to be the most suitable hole-drilling technique for measuring near-surface residual stresses within distances close to the surface that are beyond the penetration depth of x-ray and below the resolution of the strain gauge rosette based hole-drilling method.

     

X-ray residual stress measurement on mechanical components with high curvature

In this paper we deal with the definition of an appropriate X-ray diffraction procedure for residual stress determination on samples with high curvature radius. We choose as the application high-strength hot worked coil springs for car suspensions (wire diameterd=12 mm). Different methods of X-ray measurement area limitation are compared, taking into account the measurement errors, for the determination of stress in one and in three directions. After the identification of the irradiated area limits for plane samples, further limits are identified due to the sample curvature (torsion bar). We describe loading devices purposely designed, constructed and calibrated. In each case, the sample is loaded so that the stress state is determined at the same time both by strain gages and by X-ray measurement.