聚合物注射成型流动残余应力的数值分析

建立了可压缩黏弹性聚合物熔体在薄壁型腔中充模/保压过程中非等温、非稳态流动 的数学模型,用数值方法实现了注射成型过程中流动应力和取向建立及松弛过程的模拟,研 究了熔体温度、模具温度和注射速率等工艺条件对分子冻结取向的影响,取得了与实验相符 的结果.     

Prediction of residual flow and thermoviscoelastic stresses in injection molding

A general model for predicting the total residual stresses generated during filling and cooling stages of injection-molded parts has been developed. The model takes into account the phenomena associated with non-isothermal stress relaxation. The main hypothesis in our approach is to use the kinematics of a generalized Newtonian fluid at the end of the filling stage as the initial state for the calculation of residual flow stresses. These stresses are calculated using a single integral rheological model (Wagner model). The calculation of stresses developed during the cooling stage is based on a thermoviscoelastic model with structural relaxation. Illustrative results emphasizing the effect of both the melt temperature and the flow rate during the filling stage are presented.     

NUMERICAL PREDICTION OF PROCESS-INDUCED RESIDUAL STRESSES IN GLASS BULB PANEL

A numerical simulation model for predicting residual stresses which arise during the solidification process of pressed glass bulb panel was developed. The solidification of a molten layer of glass between cooled parallel plates was used to model the mechanics of the buildup of residual stresses in the forming process. A thermorheologically simple thermoviscoelastic model was assumed for the material. The finite element method employed was based on the theory of shells as an assembly of flat elements. This approach calculates residual stresses layer by layer like a truly three-dimensional calculation, which is well suited for thin pressed products of complex shape. An experimental comparison was employed to verify the proposed models and methods.     

Calculation of flow-induced residual stresses in injection moulded products

Flow-induced residual stresses that arise during the injection moulding of amorphous thermoplastic polymers are calculated in both the filling and post-filling stage. To achieve this a compressible version of the Leonov model is employed. Two techniques are investigated. First a direct approach is used where the pressure problem is formulated using the viscoelastic material model. Secondly, generalized Newtonian material behaviour is assumed, and the resulting flow kinematics is used to calculate normal stresses employing the compressible Leonov model. The latter technique gives comparable results, while reducing the computational cost significantly.     

注塑成型充填／后充填过程统一的可压缩流动分析

注塑成型是重要的塑料成型工艺,成型过程中熔体在模腔中的流动和传热对最终制品的性能和质量有重要的影响,因此,精确预测注塑过程的流动及传热历史,并进一步预测注塑制品的收缩、翘曲和机械性能等性能和质量指标具有重要意义。为了精确地描述成型过程中材料的流动及传热行为,本文针对注塑成型过程的工艺特点,将充填后充填过程作为一个统一的过程,考虑材料可压缩性及相变对充填和后充填过程的影响,建立了充填后充填过程的统一数学模型。采用有限元/有限差分/控制体积混合数值方法,实现了注塑成型充填后充填一体化模拟。数值模拟结果与实验结果的对比,验证了本文模型和算法。     

Calculation of Reynolds stresses in turbulent supersonic flows

The baseline numerical procedure of interest in this study combines flux vector splitting, flux difference splitting and an explicit treatment of the diffusion terms of the flow equations. The viscous terms are treated explicitly to preserve the wave propagation properties of the Euler fluxes and permit splitting. The experience with this scheme has been limited to laminar or, at best, ‘eddy viscosity’ flows. In this paper the applicability of the scheme is extended to include the calculation of turbulent Reynolds stresses in supersonic flows. The schemes and our implementation are discussed. Both laminar and turbulence subsets of the Reynolds/Favre-averaged equations are tested, with a discussion of relative performance. The test problem for turbulence consists of a zero-pressure-gradient supersonic boundary layer as well as a supersonic boundary layer experiencing the combined effects of adverse pressure gradient, bulk compression and a concave streamline curvature. Excellent agreement with experimental measurements is observed for most of the quantities compared, which suggests that the numerical procedures presented in this paper are potentially very useful.     

复合材料层合板粘弹性固化残余应力分析

基于Ｓｃｈａｐｅｒｙ积分型粘弹性本构关系，推导了考虑横向剪切效应的复合材料层合板线性热粘弹性有限元分析列式，对层合板的粘弹性响应和加工成型过程中的残余应力进行了分析，给出一些有意义的结果     

Investigation of stresses in he orthogonal cutting of fiber-reinforced plastics

A photoelastic study was conducted to examine the stress fields in the cutting process of fiber-reinforced plastics (FRPs). Force measurements were made and used in the analysis of the stress fields. Machined surfaces of workpieces with fibers oriented away from the cutting direction showed that the fibers were machined by shearing and tensile fracture; and when fibers were inclined towards the cutting tool, the fibers failed by shearing and bending. In addition, fiber-matrix debonding was observed to be maximum for fibers oriented at 45 deg towards the tool's path. Fiber orientation was shown to have an influence on the machining forces and stresses.Paper was presented at the 1994 SEM Spring Conference held in Baltimore, MD on June 6–9.     

塑料注射成型保压过程的数值模拟

保压过程是塑料注射成开型一个重要阶段，它直接关系到最终制件的内部结构、尺寸稳定性和变形等，本文在对塑料注射成型保压过程进行深入分析的基础上，基于合理的假设和选用恰当的材料模型，导出了保压过程可压缩、非牛顿粘性流体在模具型腔中非等温流动的控制方程，采用有限元/有限差分混合法实现了对保压过程的模拟，并通过算例讨论了保压压力、浇口凝固时间、锁模力等工程关心的实际问题。     

Use of the hole-drilling method for measuring residual stresses in highly stressed shot-peened surfaces

The same shot-peening treatment was applied to five steels with different mechanical properties. The induced residual stress profiles were analyzed using X-ray diffraction and incremental hole drilling (IHD). The results of both techniques showed that IHD can still be successfully used for measuring shot-peening residual stresses, even if these exceed the yield strength of the bulk material. Expected errors due to the plasticity effect are reduced by the strain hardening of the surface. For an assessment of the reliability of IHD data, strain-hardening variation was quantified by microhardness measurements to estimate the yield strength of the plastified layer. All the main calculation methods for IHD were applied. The results were compared and discussed with respect to the characteristics of each method.     

注塑成型充模过程的温度场计算

对注塑成型过程中充填阶段的非等温效应的数值模拟进行了研究 ,模拟了非牛顿流体在任意形状型腔内的流动。这里 ,数学模型是基于非牛顿流体在非等温状态下的广义 Hele-Shaw流动 ,利用有限元 /有限差分混合数值方法求解流场中的压力和温度分布     

Hybrid experimental-numerical concept of residual stress analysis in laser weldments

The concept, methodology and instrumentation for hybrid experimental-numerical residual stress analysis in a laser weldment are presented. Grating interferometry and digital speckle photography are applied as complementary experimental methods for the determination of the initial model of residual strains and of the material properties at the various zones of a laser weldment. These data inserted into a finite element model enable one to analyze the formation of the residual stress state of the object, which is compared and modified by means of experimental data in a closed iterative loop. This full hybrid approach is tested successfully on a laser-welded steel specimen in uniaxial tensile tests.     

微沟槽结构注塑成形的充型过程计算方法

微注塑成形制造方法适合于热塑性材料微小型器件大批量加工,对微注塑关键步骤——充型进行分析计算,有助于微注塑工艺参数和模具结构优化。目前研究表明,微尺度聚合物熔体流动与常规流动存在显著差异,采用常规尺度流动计算分析工具会带来较大偏差。本文以开源计算代码OpenFOAM为基础,综合由实验获得的熔体表面特性规律和粘度变化规律等,采用面向对象编程方法构建了熔体填充微结构型腔流动过程的计算模块,以微流体器件中的典型微结构——微沟槽注塑充型过程为例进行数值模拟,分析了表面力和粘度作用对其注塑充型填充率的影响。     

Application of X-ray diffraction, micromagnetic and hole drilling methods for residual stress determination in a ball bearing steel ring

A basic understanding of distortion problems requires the analysis of a complete manufacturing process including an almost complete overview of residual stress states in the component during each production step. To reduce the measurement time in the future, three measurements methods (X-ray diffraction, micromagnetic and blind hole drilling methods) have been used to analyze residual stress states in machined AISI 52100 ball bearing rings. X-ray diffraction was used as a state-of-the-art method for machining induced residual stresses with pronounced gradients. The ring exhibited a complex residual stress state with high tensile residual stresses at the surface, a strong gradient in depth, and also showed some variation along the outer circumference due to a superimposition of machining induced residual stresses and effects from the clamping device process. Due to this surface state, micromagnetic signals depend on the analyzing frequency. A calibration of the signals was only possible with the X-ray diffraction data. The results of the three different measurement methods correlate reasonably well.     

An assessment of residual-stress measurements around cold-worked holes

An X-ray diffraction technique was employed to determine the residual stresses introduced by cold working a fastener hole in a 6-mm thick 2024-T351 aluminum plate. The radial and tangenital residual stresses were measured at both faces of the plate and the measurements compared with the results from a two-dimensional axisymmetric finite-element model. The comparisons were favorable, although modifying the finite-element model to simulate the X-ray process provided better agreement. Experimental determinations of residual stresses showed differences between the two faces of the plate. This feature was attributed to the directional nature of the cold-working process. Paper was presented at the 1994 SEM Spring Conference on Experimental Mechanics held in Baltimore, MD on June 8–10.     

结构随机分析的Monte Carlo加权残值法

本文提出一种结构随机分析的Monte Carlo加权残值法。文中建立了这种方法的基本列式,并通过静力挠度、固有频率和屈曲荷载等算例,表明本文方法理论简捷,计算工程量少,精度较高,是随机结构数值分析的有效方法。     

Effect of residual oil saturation on the flow through a porous medium in the neighborhood of an injection well

Models of the residual oil saturation and models of its effect on the flow in injection wells are proposed. The threshold nature of the dependence of the residual oil saturation on the capillary number determines a change in the flow regimes in the neighborhood of the injection well. The cases of pure, contaminated, and compressible reservoirs are considered. The dependences of the basic problem parameters on the displacement conditions and the state of the reservoir are obtained, together with formulas for the pressure distribution and well injectivity. The topicality of such a simulation for field calculations is demonstrated.     

一种改进的残余力向量法在结构损伤识别中的应用

残余力向量法是结构损伤识别中常用的方法,复杂结构中单元数量较多而损伤位置较少,容易造成无关变量增多,进而导致计算量过大的问题。鉴于此,本文提出一种改进的残余力向量法用于结构的损伤识别。该方法利用刚度联系向量与残余力向量之间线性相关的特性,以向量投影值作为损伤定位的影响系数,初步筛选出结构可能出现损伤的单元范围。在此基础上,构建出残余力向量对应的线性方程组,根据顺序主子式不为零的条件,对线性方程组进行行初等变换,再根据单元的数量保留前n维线性方程,通过求解该方程组的代数解可得到该结构单元的刚度损伤参数。以简支梁为例的数值模拟表明,本文方法可减少无关单元变量的计算,降低残余力向量的维度并且具有较好的抗噪能力。     

复合材料层合板在加工固化后期降温速率对残余热应力的影响

本文采用非线性有限元方法，对材料性质与温度有关的复合材料层合板在加工固化后期降温过程中的温度速场和热应力场进行了分析，对降温度速率对板中固化残余热应力的影响进行了研究，获得一些对层合板固化成型工艺和固化残余热应力分析模型的选取均有意义的结果。     

圆管流动水击压力波测量及水力计算

为探索水击现象的物理过程和机理,研制了自循环定常流动管路瞬态特性计算机控制试验装置,并利用该装置进行圆管流动水击压力波实验测量。用12只扩散硅压力传感器测定圆管流动水击压力波瞬态分布及最大、最小压力值,由试验数据拟合出水击波波形,揭示了水击压力波传播方式、特性及衰减规律。通过分析随机捕捉测量技术方法,理论上推断出测量数据达到可信精度。在归纳分析试验数据基础上,得出最大压力随关阀时间的关系曲线,对圆管流动直接水击等概念进行了探讨,用数值分析方法拟合出水击最大压力水力计算修正方程式。