Viscoelastic analysis of residual stress in quenched thermosetting resin beams

The residual stress generated by the molding process of thermosetting resins exerts serious influences upon their mechanical properties. This residual stress is generally classified by two groups: one produced by shrinkage in the curing reaction of monomers, the other produced by the nonuniformity of the temperature distribution in the cooling process. This paper is concerned with the theoretical and experimental analysis of the generation of residual stress of the latter type, using examples of rectangular beams of thermosetting resins quenched on both the upper and lower surfaces. First, a viscoelastic model is applied to make a qualitative prediction of the residual stress in quenched beams. Second, using linear-viscoelastic theory, fundamental equations are derived for the residual stress in a viscoelastic rectangular beam, where an unsteady and nonuniform temperature distribution is assumed in the direction of depth. The theoretical values of the residual stress in rectangular beams are calculated under various quenching conditions for two resins having different viscoelastic characteristics, i.e., epoxy and unsaturated polyester. The theoretical residual-stress distributions agree fairly well with the residual stress measured experimentally at every quenching condition for both resins. The qualitative prediction that the residual stress in quenched beams is compressive in the vicinity of the upper and lower surfaces and is tensile in the inner parts is confirmed. The relaxation modulus of epoxy resin changes more greatly with time and temperature than that of unsaturated polyester resin. The theoretical and experimental analysis shows that the residual stress for the former resin is larger than that for the latter. Therefore, it is concluded that the generation of residual stress is more significant where the relaxation modulus of resin changes greatly with time and temperature.     

硅基底多层薄膜结构材料残余应力的微拉曼测试与分析

针对MEMS器件制备中两种典型的硅基底多层薄膜结构的残余应力问题,本文提出了利用微拉曼光谱技术测量其残余应力的方法,分析并给出了硅基底多层薄膜结构中的残余应力分布规律。实验结果表明,在硅基底和薄膜内存在较大的工艺残余应力,残余应力在基底内靠近薄膜两侧部分呈非线性变化,在基底内主要呈线性变化,并引起基底整体翘曲。基于实验结果分析,提出了硅基底多层薄膜结构的分层结构模型。本文工作表明微拉曼光谱技术是测量与研究硅基底多层薄膜结构残余应力的一种有力手段。     

Residual stress prediction and determination in 7010 aluminum alloy forgings

Precipitation-hardened aluminum alloys gain their high strength through heat treatment involving a severe quenching operation, which can have the adverse effect of introducing residual stresses. The finite element code ABAQUS is used to simulate the quenching of aluminum alloy 7010 in an attempt to predict the residual stress distribution that develops in simple shapes. The rate of heat transfer from the material is determined using the finite element method to predict the heat transfer coefficient from surface cooling curves achieved experimentally. The flow stress of the material is assumed to be strain rate dependent and to behave in a perfectly plastic manner. The predicted residual stress magnitudes and directions are compared to values determined using the holedrilling strain gage method and the X-ray diffraction technique.     

A Novel Cutting Strategy for Measuring Two Components of Residual Stresses Using Slitting Method

An exact knowledge of residual stresses that exist within the engineering components is essential to maintain the structural integrity. All mechanical strain relief (MSR) techniques to measure residual stresses rely on removing a section of material that contains residual stresses. Therefore, these techniques are destructive as the integrity of the components is compromised. In slitting method, as a MSR technique, a slot with an increasing depth is introduced to the part incrementally that results in deformations. By measuring these deformations the residual stress component normal to the cut can be determined. Two orthogonal components of residual stresses were measured using the slitting method both experimentally and numerically. Different levels of residual stresses were induced into beam shaped specimens using quenching process at different temperatures. The experimental results were then compared with those numerically predicted. It was shown that while the first component of residual stress was being measured, its effect on the second direction that was normal to the first cut was inevitable. Finally, a new cutting configuration was proposed in which two components of residual stresses were measured simultaneously. The results of the proposed method indicated a good agreement with the conventional slitting.     

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.      

2.5维自愈合C/SiC复合材料的压缩力学行为

试验研究了2.5维自愈合C/SiC复合材料的压缩力学行为,根据材料的细观结构特点,建立了压缩载荷下的损伤力学模型,得到了经纬向压缩的非线性应力应变关系,预测结果与试验值吻合较好。结果表明,经向和纬向的力学行为不同,纬向的压应力逐渐增大时,切线模量逐渐增大,压缩强度为270.05MPa,而经向压应力逐渐增大时,层间损伤逐渐发生,经纱承受的弯矩越来越大,切线模量逐渐降低,破坏强度为128.66MPa。     

Determination of residual stresses by an optical correlative hole-drilling method

In conjunction with the incremental hole-drilling method, a new evaluation procedure is presented for determining the residual stress state in components. In contrast to the classical method, the whole displacement field around the drilled hole is measured using the electronic speckle pattern interferometry technique. The displacement patterns, measured without contact to the surface, are then correlated with those obtained by finite-element simulations using statistical methods. The simulated displacement patterns, used for calibration purposes, result from the application of properly defined basic loads. In this way, the values and the orientation of the residual stresses can be determined by superposition of these properly scaled and shifted basic loads. Even complex states of stress can be evaluated. The theoretical background and experimental results are presented.     

Two-Dimensional Mapping of In-plane Residual Stress with Slitting

This paper describes the use of slitting to form a two-dimensional spatial map of one component of residual stress in the plane of a two-dimensional body. Slitting is a residual stress measurement technique that incrementally cuts a thin slit along a plane across a body, while measuring strain at a remote location as a function of slit depth. Data reduction, based on elastic deformation, provides the residual stress component normal to the plane as a function of position along the slit depth. While a single slitting measurement provides residual stress along a single plane, the new work postulates that multiple measurements on adjacent planes can form a two-dimensional spatial map of residual stress. The paper uses numerical simulations to develop knowledge of two fundamental problems regarding two-dimensional mapping with slitting. The first fundamental problem is to estimate the quality of a slitting measurement, relative to the proximity of a given measurement plane to a free surface, whether that surface is the edge of the original part or a free surface created by a prior measurement. The second fundamental problem is to quantify the effects of a prior slitting measurement on a subsequent measurement, which is affected by the physical separation of the measurement planes. The results of the numerical simulations lead to a recommended measurement design for mapping residual stress. Finally, the numerical work and recommended measurement strategy are validated with physical experiments using thin aluminum slices containing residual stress induced by quenching. The physical experiments show that two-dimensional residual stress mapping with slitting, under good experimental conditions (simple sample geometry and low modulus material), has precision on the order of 10 MPa. Additional validation measurements, performed with x-ray diffraction and ESPI hole drilling, are within 10 to 20 MPa of the results from slitting.     

复合材料层合板的低速冲击损伤及其剩余压缩强度研究

本文采用理论和实验方法研究了复合材料层合板的低速冲地及其剩余压缩强度。文中利用有限元方法和能量转换原理计算了层合板受到低速冲击的受载最危险状态，以及此时的应力分布；并用Ｔｓａｉ－Ｗｕ张量准则判断损伤情况，对产生损伤的单元进行相应的刚度折减，且作重复计算直至不产生新的损伤为止；最后，对受冲击的层合板还进行剩余压缩强度计算。在实验中，采用激光全息无损检测法测量了层合板的冲击损伤，并对受冲击的层合板进行     

Photoviscoelastic analysis of thermal stress in a quenched epoxy beam

This paper reports on a procedure for photoviscoelastic analysis where the axes of principal stress, principal strain and polarization of light coincide in the presence of a large temperature change. More specially, the transient-thermal stress and strain due to stress in an epoxy beam subjected to quenching from both the upper and lower surfaces, are determined using the time-temperature-equivalent law for stress, strain and birefringence. The transient-thermal stress and strain in the beam were determined experimentally using hereditary integrations from the measurement of the transient temperature and birefringence due to the quenching of the beam. The transient thermal stress and strain were also calculated theoretically using the linear-viscoelastic theory. The experimentally determined thermal stress agrees closely with the theoretical results. The experimentally determined strain agrees qualitatively with the theoretical values. Thus, it is concluded that the photoviscoelastic technique is useful in analyzing the proposed problem.Paper was presented at 1982 SESA/JSME Spring Meeting held in Maui and Oahu, HI on May 23–28, 1982.     

Whole-field residual stress measurement in rail using moiré interferometry and twyman/green interferometry via thermal annealing

A novel whole-field residual stress measurement technique is developed using moiré interferometry and Twyman/Green interferometry coupled with thermal annealing. The technique is successfully applied to residual stress measurement in rail. In the measurement, a high temperature resistant 1200-lines/mm cross grating is made on a rail transverse slice surface. The whole-field residual stress relief is achieved by thermal annealing. Moiré interferometry and Twyman/Green interferometry are employed to obtain the in-plane and out-of-plane deformations generated by the residual stress relaxation. The whole-field strain redistribution due to the residual stress relief is calculated, and the whole-field residual stress distribution, including the possible stress concentration, is then obtained. Because of the three-dimensional nature of the residual stress relaxation and the measurement, the three-dimensional residual stress reconstruction sometimes becomes possible based on some plausible assumptions. In this paper, the principle of the experimental theory, technique and procedures are described. Three-dimensional residual stress reconstruction in a rail using a transverse slice is shown. Its comparison to the hole-drilling method with moiré interferometry is also presented.     

Residual-stress analysis of an epoxy plate subjected to rapid cooling on both surfaces

This paper presents theoretical and experimental methods of finding the residual stress in an epoxy plate subjected to rapid cooling on both surfaces. The theoretical residual-stress distributions in a plate are calculated by using the fundamental equations based on the linear viscoelastic theory. The specimens in the experiment are subjected to rapid cooling. The residual stresses are measured by the layer-removal method. The theoretical and experimental results are compared and discussed.     

桩网二元组合在加固软基中的应用研究

工程实践表明对软土地基工后沉降和不均匀沉降有特殊要求的构筑物,采用桩网加固地基是一种经济有效的处理方法。由于其作用机理、荷载传递方式是一个复杂的相互作用问题,本文运用应力扩散原理估算筋材承受的荷载,并由此计算筋材的拉力和割线模量,为桩网法设计提供理论依据。     

钨合金弹体对混凝土靶的超高速侵彻机理

为研究钨合金弹体超高速侵彻混凝土靶的相关机理,构建了适用于超高速撞击的金属强度模型、失效模型和混凝土的本构模型,对93钨合金弹体超高速撞击混凝土靶问题进行了数值模拟。开展了钨合金弹体超高速撞击混凝土靶实验,分析了靶板成坑特性,研究了侵彻总深度和残余弹体长度随撞击速度的变化规律,理论分析了长杆钨弹超高速撞击混凝土的侵彻模型和混凝土靶内的应力波传播。得到以下主要结论:（1）利用金属及混凝土的新本构模型获得的超高速撞击混凝土靶的破坏形貌数值模拟结果与实验结果一致;（2）超高速撞击条件下混凝土靶成坑为“弹坑＋弹洞”形,成坑体积与弹体动能近似成正比;（3）超高速撞击条件下,侵彻深度随弹速提高呈现先增大后减小的现象,高速段侵深降低是弹体经历销蚀侵彻后“刚体侵彻阶段”减少造成的;（4）建立的钨合金超高速撞击混凝土侵彻分析模型,可用来预估侵彻深度、残余弹长、蘑菇头直径等参数;（5）采用建立的超高速撞击混凝土靶内应力波传播理论模型得到的计算结果与实验结果吻合较好。     

ABS注塑制品的模内蠕变试验研究

不同于传统的热残余应力分析,本文着眼于注塑制品的模内蠕变研究。通过测试ABS注塑薄板在不同工艺条件下的收缩变形,比较基于弹性理论的热收缩,进而得到了模内蠕变量。分析结果表明,模内蠕变对于降低制品最终的收缩变形起着重要的作用。在研究了各种工艺条件对制件模内蠕变的影响后,发现较低的模腔表面温度或较长的成型周期会导致蠕变增大,而制件在模内的蠕变(或应力松弛)主要发生在固化后的高温区。本文同时探讨了保压压力对蠕变的影响。高注塑保压压力通常会减小注塑件的收缩,但同时会减小制件模内蠕变。     

夹层全息干涉法的残余应力测试

本文用夹层全息干涉法做了模拟残余应力的标定实验,测试了焊缝、铸件的残余应力,并且利用数值方法进行了定量分析,实验结果与理论值比较吻合。     

A Study on Hydraulic Autofrettage of Thick-Walled Cylinders Incorporating Bauschinger Effect

Pressure vessels which are subjected to cyclic external or internal high pressure are used in many fields of industry and need to be sure of reliability and safety. To ensure of reliability and safety, thick-walled cylinder, such as a cannon or nuclear reactor, is autofrettaged to induce advantageous residual stresses. The compressive residual stress which was introduced by autofrettage process acts to offset the tensile residual stress induced by internal pressure. It increases operating pressure and restrains crack initiation and crack propagation. As the autofrettage level increases, the magnitude of compressive residual stress at the bore also increases. However, the Bauschinger effect reduces the compressive residual stresses with prior tensile plastic strain, and decreases the beneficial autofrettage effect. There are some differences between theoretical solution considering elastic-perfectly material behavior and real autofrettage process results. The purpose of the present paper is to predict the accurate residual stress of SNCM 8 high strength steel using the Kendall model which was adopted by ASME Code. The tensile and uniaxial Bauschinger effect tests of SNCM 8 were performed to evaluate Bauschinger effect factor(BEF), thereafter this constant was used in calculating the residual stress. The residual stress distribution which is considering the Bauschinger effect was profiled using Kendall model, and the results were compared with the analytical and Finite Element analysis. The results were found that residual stress incorporating the Bauschinger effect at bore was smaller than ideal calculation. These results should be considered in designing pressure vessels.     

Measurement and Prediction of Machining Induced Redistribution of Residual Stress in the Aluminium Alloy 7449

The residual stress distributions in two 7449 aluminium alloy rectilinear blocks have been determined using neutron diffraction. Heat treatment included cold water immersion quenching and a period of precipitation hardening. Quenching induced very high magnitude residual stresses into the two blocks. One block was measured in this condition while the other was incrementally machined by milling to half thickness. Neutron diffraction measurements were made on the milled half thickness block at equivalent locations to the unmachined block. This permitted through thickness measurements from both blocks to be compared, revealing the redistribution of residual stresses induced by machining. A square cross section post in the centre of the machined face was left to act as a stress free reference sample. The distortions arising on the face opposite to that being milled were measured using a co-ordinate measuring machine. The residual stresses and distortion arising in the blocks have been compared to finite element analysis prediction and found to generally agree. Material removal only caused distortion and the residual stresses to redistribute; there was no stress relaxation evident.     

表层嵌贴CFRP板条-混凝土界面粘结应力模型的试验与理论研究

为研究寒冷地区饱和砂岩的冻融损伤机理,采用DMA450伺服压机,在静载100N、动载80N、波动频率5～200Hz、温度-40～40℃的条件下,进行了饱和砂岩在不同频率正弦波单轴载荷作用下杨氏模量随温度变化的实验研究,获得滞(粘)弹性的弛豫衰减,以及有衰减引起的砂岩样品微结构变化情况。结果表明：饱和砂岩的杨氏模量和弹性波速度随温度升高而降低,随频率提高而增大; -40～20℃温度范围是冻融损伤最严重的区域。同时,在三种低频条件下(1.6Hz、2.8Hz和5.0Hz)用共振法在0℃获得相变衰减峰,反映了饱和砂岩的冻胀融缩效应,其产生的应力导致了饱和砂岩的损伤。从机理来看,前者是微观缺陷的演变,长期积累会导致破坏;后者是一种物理风化作用造成的宏观损伤。本文结果可为研究寒冷地区饱和岩石冻融损伤的机理及规律提供一定的参考。     

Residual Stress Analysis of Orthotropic Materials by the Through-hole Drilling Method

The present study deals with the development and the application of the through-hole drilling method for the residual stress analysis in orthotropic materials. Through a systematic theoretical study of the stress field present on orthotropic plates with a circular hole, the relationships between the relaxed strains measured by a rectangular strain gauge rosette and the Cartesian components of the unknown residual stresses are obtained. The theoretical formulas of each influence coefficient allow the user an easy application of the method to the analysis of uniform-residual stresses on a generic homogeneous orthotropic material. Furthermore, to extend the method to the analysis of the residual stresses on orthotropic laminates, caused by initial in-plane loadings, an alternative formulation is implemented. The accuracy of the proposed method has been assessed through 3D numerical simulations and experimental tests carried out on unidirectional, cross-ply and angle-ply laminates.