爆炸法消除焊接接头残余应力的数值模拟

利用非线性动力有限元法对爆炸处理消除焊接接头残余应力的全过程进行了数值模拟。首先，采用温度场与位移场的间接耦合方法计算了钢板对接焊的焊后冷却及残余应力的生成过程，求得焊接接头处由高温冷却到室温由于变形受到阻碍而产生的不均匀的残余塑性变形和应力。然后，在焊缝区引入移动的爆炸载荷，计算了爆炸波作用下该钢板焊接接头附近应力的变化。计算结果表明，爆炸处理可引起板内应力的重新分布，从而有效地释放超过塑性极限的残余应力。利用炸药爆炸消除大型焊接结构残余应力是一种经济有效的方法，本文的数值模拟为研究炸药爆炸消除焊接结构残余应力的机理提供了有力的工具。     

A633D斗杆的疲劳裂纹形成寿命

分析了A633D钢焊接接头在循环哉荷下的疲劳特性,进行了疲劳特性和静态拉伸实验,得到了该材料的静力参数,常规机械性能,焊接接头的循环σ-ε曲线以及焊接接头的应变寿命曲线,将局部应力－应变法用于该材料的10m3斗杆的裂纹形成寿命的估算,采用Miner法则结合概率的方法计算了不同可靠度下的疲劳寿命,其间考虑了焊接残余应力的影响,得出了焊接残余应力的存在使斗杆的裂纹形成寿命降低约10％。     

基于大型炉体焊接残余应力测试的盲孔法研究

为提高炉体焊接残余应力测试精度,对传统的盲孔法进行改进,即在测点打孔后多次扩孔并增加孔深;通过对SM400ZL钢焊接残余应力测试时的应变释放系数A,B进行实验标定,得出多组应变释放系数值,计算可得残余应力的估算值,并对不同状况下的残余应力值进行比较.通过大拉力标定试验得出SM400ZL钢盲孔的孔边塑性变形对测量精度的影响和塑性修正公式.结果表明,改进的盲孔法能够更准确地测得焊接残余应力值,测量结果经塑性修正,最大误差减小到2%以下.测试方法和结果可直接在相关的工程实际中应用.     

钻孔法测定焊接残余应力时的εp

用钻孔法测定焊接残余应力，孔边塑性变形对测量精度有很大影响。本文对孔边屈服过程进行了研究。克服了以往在误差修正方法中的不足，确定了塑性释放应变εｐ与主应力δ１、δ２和主方向角β的函数关系：εｐ＝ｆ（δ１、δ２、β），用以修正这塑变引起的测量误差，使得在二维应力状态下最大值近２０％的测量误差降至２％以下。     

自紧球形容器内残余应力的弹塑性研究

根据材料的不可压缩性假设,研究了线性强化材料球形容器的弹塑性加卸载过程.通过把材料的包辛格系数考虑为等效塑性应变的函数,建立起了等向硬化、随动硬化和混合硬化模型下的自紧厚壁球壳的残余应力公式.算例分析表明包辛格效应对自紧残余应力有较大的影响,最后还通过计算研究了球形容器内残余应力在不同自紧度下的分布情况.     

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。     

考虑夹杂相互作用的复合陶瓷夹杂界面的断裂分析

复合材料中夹杂含量较高时,夹杂间的相互作用能显著改变材料细观应力应变场分布,基体和夹杂中的平均应力应变水平也会发生较大变化,导致复合材料强度等力学性能发生显著变化. 为修正单一夹杂模型运用在实际材料中的误差,基于相互作用直推估计法,建立一种考虑含夹杂相互作用的夹杂界面裂纹开裂模型. 首先根据相互作用直推估计法,得到残余应力和外载应力共同作用下夹杂中的平均应力,再计算无限大基体中相同的夹杂达到相同应力场时的等效加载应力,将此加载应力作为含界面裂纹夹杂的等效应力边界条件,在此边界条件下求得界面裂纹尖端的应力强度因子,进而得到界面裂纹开裂的极限加载条件,并分析了夹杂弹性性能、含量、热残余应力、夹杂尺寸等因素对界面裂纹开裂条件的影响. 结果表明,方法能够有效修正单夹杂模型运用在实际材料中的误差,较大的残余应力对界面裂纹开裂有重要的影响,夹杂刚度的影响并非单调且比较复杂;在残余应力较小时,降低柔性夹杂刚度或者增大刚性夹杂刚度都有利于提高材料强度;扩大夹杂尺寸将导致裂纹开裂极限应力显著降低,从而降低材料强度.      

爆炸处理消除16MnJ超厚钢板焊接残余应力

研究了炸药性能、药条尺寸、布药方式以及引爆方式等对消除７０ｍｍ厚１６ＭｎＪ对接接头焊接残余应力效果的影响。在此基础上提出优化的工艺方案，为将爆炸消除焊接残余应力技术应用到大型或特大型焊接结构上提供工艺参考。     

基于多因素的焊接结构疲劳裂纹扩展速率分析

以Donahue等提出的疲劳裂纹扩展速率计算模型为基础,通过引入形状系数、张开比和残余应力等参数,建立了适用于焊接结构的疲劳裂纹扩展速率计算模型,分析了多种因素对焊接结构疲劳裂纹扩展速率的影响规律。结果表明,焊板厚度和焊缝余高的变化均会对焊接结构疲劳裂纹的扩展速率产生影响,在对焊接结构表面形状进行设计时应保有一定的焊缝余高;有效应力比的增大会降低焊接结构疲劳裂纹的扩展速率,且裂纹深度的变化不会改变有效应力比对焊接结构疲劳裂纹扩展速率的影响;残余应力的增大会提高焊接结构疲劳裂纹的扩展速率,且残余应力对疲劳裂纹扩展速率的促进作用随着裂纹深度的增加而增大,在对焊接结构的疲劳性能进行设计时须考虑残余应力对结构性能的影响。     

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.     

Numerical study of the plastic behaviour in tension of welds in high strength steels

The influence of the mismatch between material properties and constraint on the plastic deformation behaviour of the heat affected zone of welds in high strength steels is investigated in this study, using finite element simulations. An elastoplastic implicit three-dimensional finite element code (EPIM3D) was used in the analysis. The paper presents the mechanical model of the code and the methodology used for the numerical simulation of the tensile test of welded joints. Numerical results of the tensile test of welded samples with different hypothetical widths for the Heat Affected Zone and various material mismatch levels are shown. The analysis concerns the overall strength and ductility of the joint and in relation to the plastic behaviour of the heat affected zone. The influence of the yield stress, tensile strength and constraint on the stress and plastic strain distribution in the soft heat affected zone is also discussed.     

Upper bound of the limit load for a tensile cylinder with a soft welded (soldered) joint containing a crack

The limit load is one of the main characteristics in estimating the performance of different structures, in particular, structures with soft welded (soldered) joints. In some cases, the difference between the yield strengths of the main material and the joint material is so great that plastic strain is localized in a thin joint. With some features of such strain distribution taken into account, an upper bound of the limit load of a tensile axisymmetric sample with a crack in a welded (soldered) joint is obtained.     

Incremental Hole Drilling for Residual Stress Analysis of Thin Walled Components with Regard to Plasticity Effects

The incremental hole-drilling method is widely used in residual stress depth distribution analysis. However, two specific difficulties with the generalization of the incremental method exist, including the consideration of the sample thickness and residual stress states close to the local material’s yield strength. The stress concentration effect of the hole can lead to plastic deformation in the vicinity of the hole, which results in an overestimation of residual stresses. Typically, the effect of the component’s thickness and the plasticity effects are analyzed separately and correction approaches are proposed. In the current paper, we analyze the combined effects of plasticity and thickness on residual stress analysis using the incremental hole-drilling method. A systematic study was performed on steel samples with (i) isotropic and (ii) anisotropic elastic and elasto-plastic material behavior with varying thicknesses ranging between 1 mm and 4 mm. Electronic speckle pattern interferometry (ESPI) hole-drilling experiments were conducted on beam samples loaded using a 4-point bending fixture. Finite element simulations were conducted to gain insight into the effects of incremental hole-drilling. The results indicate that reducing the component’s thickness increases the plastic deformation in the vicinity of the hole and results in significant stress deviations. Thin components bend during hole-drilling as a result of the loss of stiffness, which amplifies the plasticity effect.     

Stress–strain curve and stored energy during uniaxial deformation of polycrystals

The subject of this paper is an attempt to obtain information about the energy stored during plastic deformation from experimentally measured stress–strain curve.Theoretical analysis of the stress–strain curve for elastic-perfectly plastic polycrystalline material has shown that only the part of stored energy can be calculated from the stress–strain curve. This part is the energy stored during non-homogeneous plastic deformation.The results of such calculation have been compared with the total stored energy determined experimentally. It has been shown that part of total stored energy related to non-homogeneous plastic deformation of investigated materials is much lower than that corresponding to homogeneous one.     

Ultrasonic Measurements of Residual Stresses Caused by Severe Thermomechanical Deformation during FSW

In engineering processes, residual stresses can be intense once high plastic deformation and temperature gradient are involved. This is exactly the case for friction stir welding (FSW) in which both rotational and translational movements of the tool induce extreme temperature gradient and plastic deformation. In this research, the extents of longitudinal and transverse residual stresses are measured within the AA7075-T6 plates welded through FSW process using ultrasonic method. According to the obtained results, it can be found that the residual stress is of the tensile type adjacent to the welding line whereas it is of the compressive type far from the welding line. Another observation is that the longitudinal residual stresses are considerably greater than the transverse residual stresses. Furthermore, with the aim of investigating the effects of rotation and traverse velocities of the tool on residual stress, experiments are carried out at three different rotation and traverse velocities. Based on the acquired results, it is observed that upon increasing the rotation and traverse velocities, the longitudinal and transverse residual stresses decrease and increase, respectively.     

焊趾表面裂纹的形态发展曲线与疲劳寿命预测

以作者建立的焊地椭圆表面裂纹应力强度因子数据库以及复杂应力场中焊践半随圆表面裂纹前缘应力强度因子分布计算的基本模式法为基础上,给出了复杂应力场中焊践表面表纹在疲劳扩展过程中形态变化规律及寿命的工程分析方法。     

Development of a technology for laser welding of the 1424 aluminum alloy with a high strength of the welded joint

Results of an experimental study of properties of joints obtained by using different regimes of laser welding of the 1424 alloy (Al–Mg–Li) are reported. The strength and structure of the welded joints are determined. The influence of various types of welded joint straining on its strength is studied. It is demonstrated that the joint strength increases in the case of plastic straining.     

Mechanics of formation and rupture of human aneurysm

The mechanical response of the human arterial wall under the combined loading of inflation, axial extension, and torsion is examined within the framework of the large deformation hyper-elastic theory. The probability of the aneurysm formation is explained with the instability theory of structure, and the probability of its rupture is explained with the strength theory of material. Taking account of the residual stress and the smooth muscle activities, a two layer thick-walled circular cylindrical tube model with fiber-reinforced composite-based incompressible anisotropic hyper-elastic materials is employed to model the mechanical behavior of the arterial wall. The deformation curves and the stress distributions of the arterial wall are given under normal and abnormal conditions. The results of the deformation and the structure instability analysis show that the model can describe the uniform inflation deformation of the arterial wall under normal conditions, as well as formation and growth of an aneurysm under abnormal conditions such as the decreased stiffness of the elastic and collagen fibers. From the analysis of the stresses and the material strength, the rupture of an aneurysm may also be described by this model if the wall stress is larger than its strength.     

爆炸处理消除大型柱壳结构环焊缝残余应力实验研究

为探讨大型耐压柱壳结构对接环焊缝焊接残余应力消除方法,根据耐压柱壳结构环焊缝焊接工艺,设计并制作了大型耐压柱壳结构对接环焊缝模拟焊接模型,并采用沿焊缝条状布药,分别进行了单、双面布药爆炸处理消除大型耐压柱壳结构对接环焊缝焊接残余应力模型实验。结果表明:大型耐压柱壳结构对接环焊缝存在较大的焊接残余应力;单、双面爆炸处理均能有效调整、消除焊接残余应力,残余应力分布明显均匀化;焊后残余应力越大,爆炸处理效果越明显,当焊接残余应力大于0.5s时,单面爆炸处理后残余应力m下降幅度在40%以上,双面爆炸处理后残余应力m下降幅度在60%以上;采用沿焊缝条状布药,爆炸处理能有效消除沿焊缝的纵向残余应力;双面爆炸处理效果优于单面爆炸处理效果。