金属切屑塑性流动的稳定性

对金属正交切削过程中切屑形成机制和材料塑性流动行为进行实验研究和理论分析.通过对4种常用金属材料正交切削过程的实验研究和切屑形貌的微观观察,确定了连续切屑转变成锯齿切屑的临界速度.结果表明该临界速度与材料性能相关.在实验观察基础上,提出描述材料正交切削过程的二维分析模型.该模型假设切屑形成区为包括主剪切区和次剪切区的一个平行四边形.载荷有主剪切区中的剪应力和次剪切区中的正压力;通过量纲分析得到描述材料正交切削过程的无量纲主控参数和无量纲形式的基本控制方程;应用线性稳定性分析方法建立平面应变状态下评价材料塑性流动稳定性的普遍准则;求得切屑形成区内材料塑性变形的速度和应力近似解.讨论切屑形成、形貌转变以及相关的塑性失稳机制.分析结果表明,表征材料惯性与阻尼之比的无量纲参数—雷诺数可以作为主控参数描述金属切削过程以及切屑材料塑性流动的稳定性.     

纳米尺度下切削过程的准连续介质力学模拟

采用准连续介质力学方法模拟了镍单晶体刀具在单晶铜工件上的切削过程,深入分析了切削过程中的能量演化?应力场变化和原子位移情况等因素.结合切削过程中位错滑移等塑性行为和原子径向分布理论,揭示了切屑产生的机理,证实了切削过程中已加工表面和体相晶体结构的非晶态变化是切屑产生的主要原因.通过对纳米切削过程不同阶段的模拟表明:刀具的耕犁作用下剪切带的形成和扩展是切屑形成的初始阶段;变质层的产生是纳米切削的中间阶段并构成了加工表面组织;储存在变形晶格中的变形能超过一定值时,晶格被打破,形成非晶态结构是切屑形成的最终阶段.     

难加工材料切削机理研究的新进展

航空发动机重要零件如机匣、压气机风扇叶片等广泛采用钛、镍基合金等先进结构材料.钛、镍基合金材料切削加工性较差,主要表现在材料热硬度和热强度很高,所需切削力很大,工件、刀具容易产生较大变形;材料热扩散率低;刀具切削深度线位置缺口现象严重,以及形成锯齿状切屑等几个方面.深入研究此类难加工材料的切削机理,对于实现薄壁件高效精密数控加工技术至关重要.本文重点介绍了关于高硬度金属材料锯齿状切屑的形成机制;非连续切屑形成过程的有限元数值模拟关键技术,包括自适应网格细化、切屑与工件之间的分离准则,以及用以描述单元网格中裂纹形核与扩展的断裂准则和算法;切削区域高温、高应变率条件下材料屈服流动行为的准确描述,系统考虑应变、应变率和温度三者之间的相互影响作用;切削温度场、工件表层残余应力场的分布规律,以期消除残余扭曲变形对航空工业中普遍使用的薄壁结构件加工精度的显著影响.      

正交切削过程的刚塑性有限元算法及其实现

对刚塑性有限元用于正交切削分析中的切屑与基体材料分离准则、切屑与前刀面脱离判据等关键技术问题进行了系统的研究;建立了求解该问题的刚塑性有限元基本方程,给出了单元刚度矩阵和节点载荷列阵的详细算法以及金属大变形过程中网格畸变问题的处理技术。利用自行开发的正交切削模拟计算程序,对铝合金ZL-301创削过程进行了全程模拟,计算结果与试验结果吻合。     

影响金属玻璃中剪切带行为的微观机制

论文对金属玻璃发生剪切失稳形成剪切带的行为进行了分析,得到了其发生剪切失稳时的临界自由体积浓度,预测结果与实验观察和模拟结果吻合;利用两种方法对其剪切带厚度进行了预测,结果表明基于剪切失稳临界波长预测金属玻璃剪切带厚度的方法只在发生剪切失稳后极短的时间内有效,对成熟剪切带厚度的预测必须考虑自由体积的扩散效应;考察了金属玻璃的宏微观材料参数对其剪切带厚度的影响及其微观机制,发现金属玻璃剪切带厚度对其宏观材料参数(泊松比)不敏感,对与剪切相变区相关的微结构参数敏感.     

高速切削过程中诱发绝热剪切带形成的热塑性剪切波

提出了高速切削过程中诱发绝热剪切带形成的热塑性剪切波的传播机理,针对锯齿形切屑中热望性区域内的塑性梯度变形特征、动量和能量耗散情况,建立了与切削条件相关的热塑性剪切波的传播模型及剪切带宽度模型.在此基础上,通过淬硬45钢的切削实验并结合改进的Johnson-Cook本构模型分析了热塑性剪切波的传播规律,并将剪切带宽度模型与已提出的DB模型、WR模型和DM模型做了对比,结果表明,由热塑性剪切波传播理论推导的剪切带宽度模型与实验结果较其他模型吻合较好.     

泡沫金属压痕试验的数值模拟及其反演

在理论研究的基础上，将泡 沫金属压痕试验的有限元数值模拟结果与用无量纲分析法构造出的一系列无量纲函数相结 合，建立了泡沫金属压痕试验中载荷-压痕深度关系曲线与泡沫金属的弹塑性材料参数之 间的联系. 利用这种联系，就可以实现用压痕试验通过反演分析来确定泡沫金属的材料参数. 研究结果表明，泡沫金属材料的杨氏模量，屈服强度及塑性可压缩因子等参数均可由其压痕 试验唯一的确定，但其塑性平台区终点应变的确定还需进一步的研究.     

类固体非晶态材料的变形与失效

自20世纪70年代以来, 类固体非晶态材料变形与失效的理论模型相继出现, 这些模型基于应力驱动分子重排从而在局部流动缺陷处发生剪切转变这一物理图像. 该图像是现代剪切转变区理论的基础, 也是本综述的焦点. 我们将首先概述该理论框架并给出一些应用案例, 特别是块体金属玻璃应力?应变测量结果的阐释, 剪切带数值模拟分析和剪切转变区运动方程在自由边界计算中的应用. 在本综述的第二部分, 为简单起见, 将关注非晶塑性的非热模型, 并基于该模型说明剪切转变区理论是如何从非平衡热力学的系统描述中发展起来的.      

基于无量纲分析的法向恢复系数模型研究

作为描述接触碰撞过程能量损失的重要参量,恢复系数的深入研究对于提升现有接触碰撞力模型预测性能、准确描述接触碰撞现象,并进一步探明其对机械系统整体动态特性影响规律方面具有重要作用.鉴于现有恢复系数模型计算精度的局限性,本文基于无量纲分析方法,提出了一种考虑材料特性与初始碰撞速度的新型恢复系数模型.具体实施过程如下:首先,利用有限元软件ABAQUS建立弹性球-理想弹塑性基底法向接触碰撞数值仿真模型,分别从最小网格尺寸设置与接触碰撞能量转换角度验证了所建模型的有效性;基于此模型开展多工况下的数值模拟研究,分析不同材料弹塑性参数与初始碰撞速度对接触碰撞响应的影响;在此基础上,引入无量纲化参数E*/(ρv_nc²)与σ_y/E*,寻找恢复系数与弹塑性参数及初始碰撞速度间的函数关系;进一步结合Johnson塑性碰撞理论,反向推算获取屈服速度与材料属性的映射关系,最终建立无量纲化恢复系数新模型;通过与低速试验数据、高速有限元模拟结果的对比,验证了新模型的预测精度和泛化性能.     

具确定弱区域正交各向异性薄板的弹塑性屈曲分析

基于弹塑性力学和损伤理论,建立了一个与应力球张量有关的具损伤正交各向异性材料的混合硬化屈服准则,该准则无量纲化后与各向同性材料的Mises准则同构,在此基础上,建立了正交各向异性材料的增量型和全量型弹塑性损伤本构方程,并以具确定弱区域正交各向异性矩形薄板为例,根据屈曲时的能量准则和全量理论,以等效塑性应变为内变量,对其弹塑性屈曲问题进行了分析,讨论了几何参数和弱区域对正交各向异性薄板弹塑性屈曲临界应力的影响.     

Adiabatic shear banding and scaling laws in chip formation with application to cutting of Ti–6Al–4V

The phenomenon of adiabatic shear banding is analyzed theoretically in the context of metal cutting. The mechanisms of material weakening that are accounted for are (i) thermal softening and (ii) material failure related to a critical value of the accumulated plastic strain. Orthogonal cutting is viewed as a unique configuration where adiabatic shear bands can be experimentally produced under well controlled loading conditions by individually tuning the cutting speed, the feed (uncut chip thickness) and the tool geometry. The role of cutting conditions on adiabatic shear banding and chip serration is investigated by combining finite element calculations and analytical modeling. This leads to the characterization and classification of different regimes of shear banding and the determination of scaling laws which involve dimensionless parameters representative of thermal and inertia effects. The analysis gives new insights into the physical aspects of plastic flow instability in chip formation. The originality with respect to classical works on adiabatic shear banding stems from the various facets of cutting conditions that influence shear banding and from the specific role exercised by convective flow on the evolution of shear bands. Shear bands are generated at the tool tip and propagate towards the chip free surface. They grow within the chip formation region while being convected away by chip flow. It is shown that important changes in the mechanism of shear banding take place when the characteristic time of shear band propagation becomes equal to a characteristic convection time. Application to Ti–6Al–4V titanium are considered and theoretical predictions are compared to available experimental data in a wide range of cutting speeds and feeds. The fundamental knowledge developed in this work is thought to be useful not only for the understanding of metal cutting processes but also, by analogy, to similar problems where convective flow is also interfering with adiabatic shear banding as in impact mechanics and perforation processes. In that perspective, cutting speeds higher than those usually encountered in machining operations have been also explored.     

QUASI－FLOW CORNER THEORY ON LARGE PLASTIC DEFORMATION OF DUCTILE METALS AND ITS APPLICATIONS

ＱＵＡＳＩ－ＦＬＯＷＣＯＲＮＥＲＴＨＥＯＲＹＯＮＬＡＲＧＥＰＬＡＳＴＩＣＤＥＦＯＲＭＡＴＩＯＮＯＦＤＵＣＴＩＬＥＭＥＴＡＬＳＡＮＤＩＴＳＡＰＰＬＩＣＡＴＩＯＮＳＨｕＰｉｎｇ（胡平）ＬｉｕＹｕｑｉ（柳玉启）ＧｕｏＷｅｉ（郭威）ＴａｉＦｅｎｇ（台风）（Ｒ...     

Numerical predictions of oblique detonation stability boundaries

Oblique detonation stability was studied by numerically integrating the two-dimensional, one-step reactive Euler equations in a generalized, curvilinear coordinate system. The integration was accomplished using the Roe scheme combined with fractional stepping; nonlinear flux limiting was used to prevent unphysical solution oscillations near discontinuities. The method was verified on one- and two-dimensional flows with exact solutions, and its ability to correctly predict one-dimensional detonation stability boundaries was demonstrated. The behavior of straight oblique detonations attached to curved walls was then considered. Using the exact, steady oblique detonation solution as an initial condition, the numerical simulation predicted both steady and unsteady oblique detonation solutions when a detonation parameter known as the normal overdrive, , was varied. For a standard test case with a specific heat ratio of , a dimensionless activation energy of , and dimensionless heat release of , an oblique detonation with a constant dimensionless component of velocity tangent to the lead shock, , underwent transition to unstable behavior at . This is slightly higher than the threshold of predicted by one-dimensional theory; thus, the two-dimensionality renders the flow slightly more susceptible to instability. Received 4 August 1996 / Accepted 5 March 1996     

基于非关联流动规律的Gotoh屈服准则的参数确定方法

屈服准则对板料成形过程的理论解析、工艺优化和有限元模拟有着重要的影响. 通过提高屈服准则的各向异性表征能力, 可以确保成形过程的可靠性及实际预测的准确性. 本文基于非关联流动法则, 给出了Gotoh屈服准则一套全新的参数求解方法. 在结合常用屈服准则并考虑流动规律的基础上, 分别以5754O铝合金、DP980先进高强钢和SAPH440结构钢作为研究对象, 进行了不同加载路径下各向异性变形行为的预测. 根据Gotoh屈服准则推导的屈服函数、塑性势函数以及基于关联流动的理论函数计算出屈服应力和各向异性指数$r$值随加载角度的分布趋势, 进而针对平面应力状态的屈服轨迹展开分析, 验证了不同屈服准则和流动规律对各向异性屈服行为的预测精度. 理论与实验数据对比结果表明: 不同屈服准则针对同种板料在流动规律一致的情形下其表征各向异性的能力有显著差异; 相同屈服准则基于不同流动规律其表征能力也具有明显差别. 基于非关联流动的屈服准则能极大地提高精度, 各向异性表征能力显著加强. 相关结果能够为各向异性屈服准则在塑性成形领域的实际应用方案提供重要参考.      

预估在非比例加载下薄金属板成型极限的损伤基力学模型

探讨了用损伤基力学模型研究应变路径对薄金属板塑性失稳的影响,这种力学模型考虑了材料损伤作用．基于这种模型,在等效应变空问建立了考虑损伤的塑性失稳判据,并用以预估在比例或非比例加载下薄金属板成型极限曲线(FLC)．借助这种理论模型和方法,预估薄金属板的理论成型极限曲线与Graf和Hosford的实验结果一致。     

Mechanism of flow instability and transition to turbulence

In this paper, a new mechanism of flow instability and turbulence transition is proposed for wall bounded shear flows. It is stated that the total energy gradient in the transverse direction and that in the streamwise direction of the main flow dominate the disturbance amplification or decay. Thus, they determine the critical condition of instability initiation and flow transition under given initial disturbance. A new dimensionless parameter K for characterizing flow instability is proposed which is expressed as the ratio of the energy gradients in the two directions for the flow without energy input or output. It is suggested that flow instability should first occur at the position of K_max which may be the most dangerous position. This speculation is confirmed by Nishioka et al.'s experimental data. Comparison with experimental data for plane Poiseuille flow and pipe Poiseuille flow indicates that the proposed idea is really valid. It is found that the turbulence transition takes place at a critical value of K_max of about 385 for both plane Poiseuille flow and pipe Poiseuille flow, below which no turbulence will occur regardless the disturbance. More studies show that the theory is also valid for plane Couette flows which holds a critical value of K_max of about 370.     

Plastic strip model of circular crack under cyclic loading with damage accumulation

A cylindrical solid containing a penny-shaped crack in its mid plane is subjected to a remote tensile stress field. In the plastic region near the crack border, damage due to continuous deterioration of the material accumulates, and may lead to crack instability and crack growth. A damage model relating the crack opening displacement in the plastic zone to the fraction of the cross-sectional area occupied by voids is used to describe the conditions necessary for the onset of crack instability, fatigue crack propagation by cyclic loading, and rates of crack growth for time-dependent environmental effects.     

位移加载条件下微小尺寸单晶金属的应变突变模型及其间歇性塑性变形行为研究

微压缩实验发现,微小尺度单晶金属柱体在塑性变形过程中会发生显著的应变突变,呈现出特殊的间歇性塑性流动特征。本文以数百纳米直径的单晶Au柱体为研究对象,探讨其在位移加载条件下的间歇性流动行为。首先根据位移加载条件下的塑性变形特征,提出了分析其应变突变的三阶段模型。进一步结合经典晶体塑性理论框架的有限元方法,建立了以二阶功参量为基础的连续塑性力学模型。通过与实验结果相对比发现,新模型能够较好地描述位移加载条件下微小尺度面心立方单晶金属材料的应变突变现象,能够合理预测单晶柱体的特殊变形行为。此外,二阶功准则作为位移加载条件下应变突变现象的判据是有效的。进而使用该理论模型,探讨了微小金属柱体应变突变随机性、尺寸相关性以及率敏感性等问题。     

Three-dimensional elastic–plastic finite element analysis for orthogonal cutting with discontinuous chip of 6-4 brass

An elastic–plastic finite element model is developed for 3D orthogonal cutting of discontinuous chips. The tool is P20 while the workpiece is made of 6-4 brass. Examined under the condition of low cutting speed are the initial crack location, the direction of crack growth and variations of discrete chips. These predictions are made possible by application of the strain energy density (SED) theory. The initial crack was formed above the tool tip and grew progressively along the stationary values of the SED function until the trajectory intersects with the free surface. The plastic deformation and friction result in a high equivalent stress in the secondary deformation zone of the first longitudinal chip. Stresses are also high at the location of crack initiation. The chip node near the tool face is sensitive to the contact of the tool face. As more residual stress prevails after the first longitudinal cut, degradation of the workpiece surface prevails and should be accounted for.