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.     

金属材料在复杂应力状态下的塑性流动特性及本构模型

工程应用中,金属材料和结构往往处于复杂应力状态。材料的塑性行为会受到应力状态的影响,要精确描述材料在复杂应力状态下的塑性流动行为,必须在本构模型中考虑应力状态效应的影响。然而,由于在动态加载下材料的应变率效应和应力状态效应相互耦合、难以分离,给应力状态效应的研究和模型的建立造成很大困难。通过对Ti-6Al-4V钛合金材料开展不同加载条件下的力学性能测试,提出了一个包含应力三轴度和罗德角参数影响的新型本构模型,并通过VUMAT用户子程序嵌入ABAQUS/Explicit软件。分别采用新提出的塑性模型和Johnson-Cook模型对压剪复合试样的动态实验进行了数值模拟。结果表明,新模型不仅在对材料本构曲线的拟合方面具有较强的优势,而且由该模型所得到的透射脉冲和载荷-位移曲线均更加准确。因此,该模型能够更精确地描述和预测金属材料在复杂应力状态下的塑性流变行为。

     

热障涂层弹性模量和残余应力测试研究

采用数字图像相关法实验研究了热喷涂制作的热障涂层的弹性模量和残余应力。首先,采用三点弯测试方法对热障涂层试件进行加载,并利用二维数字图像相关方法对热障涂层试件加装过程中的弯曲变形进行了精确的测量,进而获得了热障涂层在受拉和受压两种状态下的弹性模量,结果表明,受拉时热障涂层试件陶瓷层的弹性模量为31GPa,而受压时其弹性模量为34GPa。其次,基于内力平衡,推导了考虑曲率变化的涂层残余应力计算公式;利用三维数字图像相关法测量了喷涂前后基体曲率的变化,进而获得了涂层残余应力的大小,结果表明,热喷涂后的热障涂层残余应力为压应力,大小为-86^-70MPa。     

考虑焊接残余应力的波形钢腹板PC梁关键细节疲劳可靠度研究

焊接残余应力对波形钢腹板细节疲劳寿命的影响不可忽略,本文以头道河大桥为工程背景,基于ABAQUS有限元软件,建立波形钢腹板焊接构件数值模型,提出不同波折角度的波形钢腹板残余应力模型。采用瞬态分析方法,分析6种典型车辆作用下波折角区域焊缝细节的应力时程。在此基础上,构建考虑焊接残余应力和车辆荷载共同作用下的波形钢腹板细节疲劳极限状态方程,讨论不同波折角度和交通增长率对疲劳可靠度指标的影响规律。研究表明,翼缘板-波形钢腹板焊接构件斜边两侧的纵向残余应力呈对称分布,焊接细节转角区域圆弧外侧的纵向残余应力整体高于圆弧内侧,随着波折角度的增加,两侧焊缝附近的纵向残余应力变大;在桥梁设计基准期取100年时,30°波折角度焊缝细节疲劳可靠度是60°波折角度的1.05倍;交通量的线性增长对头道河大桥焊缝细节的疲劳可靠度影响较大,不考虑交通增长率的焊缝细节疲劳可靠度是α=5%的1.84倍。     

Transient temperature fields in functionally graded materials with different shapes under convective boundary conditions

This paper presents analyses of the transient temperature fields in an infinite plate, an infinite solid cylinder and a solid sphere made of functionally graded materials (FGMs) under convective boundary conditions. The composition and the thermo-physical properties of the infinite FGM plate, the infinite FGM solid cylinder and the FGM solid sphere are of planar symmetric, axially symmetric and spherically symmetric distributions, respectively. The analytical formulae of the one-dimensional transient temperature fields for the three FGM solids are obtained respectively by using the separation-of-variables method and the variable substitution method. Numerical results reveal that the transient temperature fields of the FGM components exhibit similar shape effect to that of homogeneous components. The present work provides valuable basis for the investigation of the thermal shock resistance of FGMs with various shapes.     

An acoustoelastic method for measuring residual stresses in slightly orthotropic materials

An acoustoelastic method for residual stress measurement in slightly orthotropic materials by using ultrasonic longitudinal and shear waves is presented. A shear transducer with small vibrator 2 × 2mm² is developed and described, and the measurement of 2-D residual stresses in a seam welded plate was carried out by this method with the shear transducer developed.This project was supported by National Natural Science Fundation of China     

Plane-stress crack-tip stress fields for orthotropic perfectly-plastic materials

Under the hypothesis that the stress components of crack-tip fields are only thefunctions ofθ,the differential equations of plane-stress crack-tip stress fields fororthotropic perfectly-plastic materials are obtained by using Hill’s yield condition andequilibrium equations.By combining the general analytical expression with the numericalmethod the crack-tip stress fields for orthotropic perfectly-plastic materials for plane stressare presented.     

Residual stress evolution regularity in thermal barrier coatings under thermal shock loading

Residual stress evolution regularity in thermal barrier ceramic coatings (TBCs) under different cycles of thermal shock loading of 1100°C was investigated by the microscopic digital image correlation (DIC) and micro-Raman spectroscopy, respectively. The obtained results showed that, as the cycle number of the thermal shock loading increases, the evolution of the residual stress undergoes three distinct stages: a sharp increase, a gradual change, and a reduction. The extension stress near the TBC surface is fast transformed to compressive one through just one thermal cycle. After different thermal shock cycles with peak temperature of 1100°C, phase transformation in TBC does not happen, whereas the generation, development, evolution of the thermally grown oxide (TGO) layer and micro-cracks are the main reasons causing the evolution regularity of the residual stress.     

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。     

The analytic theory of the temperature fields of bituminous pavement over semi-rigid roadbase

Projectofthe'Eight-Fi\e-NationalMajorScienceal1dTechnoIog}'.85-403-02-02I.IntroductionPavementstructureisexposedtonaturalenvironment,andisweatheredbycontinuousatmosphereinfluencesuchasthesolarradiation,theskyradiationandtheexternalairtemperature.Apartofth…     

Finite element analysis of temperature field with phase transformation and non-linear surface heat-transfer coefficient during quenching

I.IntroductionItiswell-knownthatthemechanicalpropertiescanbeimprovedbyquenchingtechnique.Thetemperaturefieldofworkpiecehasagreatinfluenceupontheresiduals'ressesandmicrostructureafterquenching.Thus,thecalculationoftemperaturefieldduringquenchinghasbeenthesubjectofmanyinvestigations.Inthepastresearches,thesurfaceheat-transfercoefficientshavebeenusuallytreatedasconstantitmayleadtotheerrorofcalculationintheanalysisoftemperature.Infact,thesurfaceheat-transfercoefficientsarethenonlinearfunctionofte…     

Using laser ultrasonics for nondestructive residual stress evaluation

A non-contact measuring technique of ultrasonic waves velocity is proposed, in which Rayleigh waves are detected by a laser Doppler velocimeter and the velocity is measured precisely by means of a sing-around unit and a digital oscilloscope. With the proposed technique, the acoustoelastic coefficient of Rayleigh waves in mild steel SS41 is obtained, which is in good agreement with that obtained by the contact method. Furthermore the non-contact technique is applied to evaluate the residual stress in a butt-welded steel plate, the result is reasonable.     

Numerical simulation of welding induced damage and residual stress of martensitic steel 15-5PH

This paper is about the modeling of damage and residual stresses induced by a complex history of thermo-elasto-plastic multiphase in welding heat affected zone (HAZ). A two-scale model for elasto-plastic damaged multiphase is developed. The constitutive equations of the model are coupling ductile damage, elasto-plastic strains, phase transformation and transformation plasticity. In this study, an equation of damage evolution is proposed based on the continuum damage mechanics. In order to validate the proposed damage evolution, a set of flat notched bars with various notches are to simulated and then compared to experimental results. An example of laser heated disk is simulated to elaborate the two-scale model and the simulated results of the two-scale model in CAST3M^® is compared the results calculated by a homogenized macroscopic model in SYSWELD^®. The study shows the two-scale model provides valuable freedom to choose the material or mechanical law for each phase. The proposed damage equation extends the application of existing ductile damage models. In the calculation of residual stresses, damage decreases the residual stresses in HAZ by a small amount.     

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.     

RUDIMENTAL EQUATIONS FOR THERMO－ELASTO－PLASTIC STRESS ANALYSIS DURING CONTINUOUS CASTING WITH PHASE CHANGE

ＲＵＤＩＭＥＮＴＡＬＥＱＵＡＴＩＯＮＳＦＯＲＴＨＥＲＭＯ－ＥＬＡＳＴＯ－ＰＬＡＳＴＩＣＳＴＲＥＳＳＡＮＡＬＹＳＩＳＤＵＲＩＮＧＣＯＮＴＩＮＵＯＵＳＣＡＳＴＩＮＧＷＩＴＨＰＨＡＳＥＣＨＡＮＧＥＺｈａｏＸｉｎｇ－ｈｕａ（赵兴华）;ＣｈｅｎｇＸｉａｏ－ｄｉ...     

Transient stress of steel phase transformation and transformation-induced fatigue

Expansion changes the size of any machine element and can thus generate severe stress or distortion failures during its operation if this phenomenon is not taken into account during the design process. On the other hand, most steels contract during heating within a short temperature range as a result of microstructural phase transformations. This transient contraction may generate further short- and long-term dysfunction of a metallic structure. The current paper focuses on this issue; investigating the effects of the microstructural transformation on the transient stress response of a metallic structure. Analysis is carried out by means of finite element simulation employing material data from typical constructional steel. The paper emphasizes the necessity of considering material phase changes when dealing with the transient stress or displacement response of a metallic structure and demonstrates the differences obtained when the transformation effects are ignored or accounted for in the design process. The mechanism of transformation-induced fatigue is thus discussed and proposed to the engineering community for establishment.     

An experimental/computational approach to identify moduli and residual stress in MEMS radio-frequency switches

In this paper, we identify the Young's modulus and residual stress state of a free-standing thin aluminum membrane, used in MEMS radio-frequency (rf) switches. We have developed a new methodology that combines a membrane deflection experiment (MDE) and three-dimensional numerical simulations. Wafer-level MDE tests were conducted with a commercially available nanoindenter. The accuracy and usefulness of the MDE is confirmed by the repeatability and uniformity of measured load-deflection curves on a number of switches with both wedge and Berkovich tips. It was found that the load-deflection behavior is a function of membrane elastic properties, initial residual stress state and corresponding membrane shape. Furthermore, it was assessed that initial membrane shape has a strong effect on load-deflection curves; hence, its accurate characterization is critical. Through an iterative process and comparison between MDE data and numerical simulations, the Young's modulus and residual stress state, consistent with measured membrane shape, were identified. One important finding from this investigation is that variations in membrane elastic properties and residual stress state affect the load-deflection curve in different regimes. Changes in residual stress state significantly affect the load-deflection slope at small values of deflection. By contrast, variations in Young's modulus result in changes in load-deflection slope at large deflections. These features are helpful to decouple both effects in the identification process.     

Effects of residual stress and viscous and hysteretic dampings on the stability of a spinning micro-shaft

This study examines the effects of the residual stress and viscous and hysteretic dampings on the vibrational behavior and stability of a spinning Timoshenko micro-shaft.A modified couple stress theory(MCST) is used to elucidate the sizedependency of the micro-shaft spinning stability,and the equations of motion are derived by employing Hamilton’s principle and a spatial beam for spinning micro-shafts.Moreover,a differential quadrature method(DQM) is presented,along with the exact solution for t...     

Fatigue strength of metallic and composite materials under repeated tension-compression

The fatigue strength of metallic and composite materials under combined static and cyclic loading is analyzed. The analysis is based on limit-state models, which allow us to describe limiting-stress diagrams of all known shapes, including convex, rectilinear, S-shaped, and concave. The fatigue strength of the following materials is evaluated: carbon and alloy steels, aluminum alloys, creep-resistant nickel alloys, unidirectional composites, plastic laminates, glassfiber-reinforced plastics, and polymers. The calculated results and experimental data are in satisfactory agreement __________ Translated from Prikladnaya Mekhanika, Vol. 42, No. 1, pp. 48–58, January 2006.