一种改进的Lemaitre韧性断裂准则及其在旋压成形中的应用

采用Lemaitre韧性断裂准则与有限元模拟相结合来预测材料在塑性成形过程中的开裂是广泛应用的一种方法,其中的Lemaitre准则是以损伤值与塑性应变呈线性关系为基础的,而实际一些材料的损伤值与塑性应变间却是非线性的.为此,本文将原Lemaitre准则中反映损伤值与塑性应变间的线性关系修正为非线性关系,得到了改进的Le...     

非耦合韧性断裂准则及其在航空金属材料中的应用

结构轻量化是航空航天和汽车领域的重要发展趋势,对以铝合金、镁合金和钛合金为代表的轻质高强金属材料的需求与日俱增。预测材料的损伤断裂行为是高性能航空构件成形工艺设计和服役性能评估的关键,而发展先进的韧性断裂准则是其主要途径。本文首先介绍了金属材料损伤断裂的微观机制,包括剪切和压缩应力主导的剪切型断裂、拉应力主导的拉伸型断裂及复合型断裂。回顾了韧性断裂准则的研究现状,传统非耦合韧性断裂准则的发展历程、特点和适用场合,重点论述了近年来几种典型的非耦合韧性断裂准则的特点和优势。传统的非耦合韧性断裂准则通常只考虑最大主应力或平均应力对损伤断裂的影响,忽略了偏应力的作用,不适合于低应力三轴度或复杂应力状态下的断裂行为预测;而新的韧性断裂准则综合考虑应力三轴度和罗德角参数对损伤演化的共同影响,适用于复杂的应变路径和应力状态。最后,评述了非耦合韧性断裂准则在铝合金、镁合金和钛合金等航空金属材料中的发展现状和典型应用,展望了韧性断裂准则的发展趋势和研究方向。非耦合韧性断裂准则需针对先进结构金属材料的变形特点,综合考虑应力状态、应变速率、温度及各向异性等对损伤断裂的作用,使其具有更好的普适性和预测精度。     

Constitutive behavior and microstructural evolution in hot deformed 2297 Al-Li alloy

The microstructural evolution mechanism and constitutive behavior of 2297 Al-Li alloy were studied via thermal compression test with the constant strain rates of 0.001–1 s⁻¹ and the deformation temperatures ranging from 623 to 773 K. To verify the predictable ability of diverse constitutive models under different stress states, the hot compression experiments with stress triaxiality varying from −0.33 to 0.46 were conducted. The microstructures of the deformed specimens under diverse deformation conditions are probed to reveal the mechanism of hot deformation behavior. The experimental results indicate that the work-hardening and dynamic softening are competitive during the hot compression process, and the dynamic softening is more obvious under low deformation temperature and high strain rate. The microstructural analysis manifests that the dynamic recovery gets predominant at high deformation temperature to produce fine grains. Meanwhile, the dynamic recrystallization becomes more dominant as the strain rate decreases, which is sensitive to the stress triaxiality. In addition, both the modified Johnson-Cook model and strain-compensated Arrhenius-type function are suitable for describing the flow behavior of 2297 alloy, while the latter reveals a more accurate prediction. However, the predictability of the two kinds of models is worsened with the transformation of stress triaxiality, and the validity of the Arrhenius-type model is restricted by high stress triaxiality.     

AZ31镁合金板热成形中的屈服和损伤:本构实现与数值分析

为了准确预测各向异性镁合金板的成形质量,将改进的GTN损伤模型与各向异性拉压不对称的CPB06屈服本构耦合,并考虑了屈服面形状随塑性应变累积的变化,得到了考虑本构参数随塑性应变演化的各向异性屈服CPB06-GTN损伤模型。基于该模型,在ABAQUS/Explict中编译得到了相应的VUMAT子程序,采用单个单元进行了单轴拉伸和压缩模拟,并通过与实验一致性对比验证了子程序的正确性。使用子程序不仅能够模拟镁合金的各向异性屈服及其不规则的硬化,同时也能够模拟镁合金的损伤破坏。此外,采用编写的子程序进行了热拉深成形的数值模拟,模拟预测与实验结果对比表明,采用各向异性损伤模型的计算结果能够准确预测镁合金的变形及其损伤破坏,模拟结果与实验数据吻合;采用合适的压边力和成形的温度条件及非等温成形方法能够提高镁合金的成形性。     

Formability enhancement in hot spinning of titanium alloy thin-walled tube via prediction and control of ductile fracture

The damage and fracture in hot spinning of titanium alloy is a very complex process under the combined effects of microstructure evolution and stress state. In this study, their dependences on processing parameters were investigated by an integrated FE model considering microstructure and damage evolution, and revealing the effects of microstructure and stress states on damage evolution. The results show that the inner surface of workpiece with the largest voids volume fraction is the place with...     

一种镍基单晶合金多轴低周疲劳损伤参量

用损伤应变能释放率作为热力学广义力描述正交各向异性材料的疲劳损伤过程,定义了含有3个弹性常数的镍基单晶应力三轴性因子,它不仅反映多轴载荷下的复杂应力状态,还显示正交各向异性材料偏轴受载时存在的正应力与剪应力的耦合效应,是对各向同性材料应力三轴性因子的拓展。用镍基单晶应力三轴性因子修正Mises应变范围作为疲劳损伤参量,引入损伤驱动力循环特征参数反映循环载荷的交变特性,提出了单晶合金低周疲劳损伤模型。利用DD3和CMSX-2单晶合金低周疲劳试验数据,采用多元线性回归分析方法拟合疲劳损伤模型参数,试验所得数据都落在2倍和2.5倍偏差分布带内。      

延性材料断裂准则与平面应变断裂韧度

延性材料的临界断裂规律对结构完整性评价和金属塑性成形分析具有重要意义,但相关的弹塑性断裂强度研究长期存在瓶颈。本文针对30Cr2Ni4MoV低压转子钢和3Cr13不锈钢,完成了不同应力三轴度的4类试样拉伸破坏试验,基于FAT （Finite-element-analysis Aided Testing）方法,通过有限元迭代分析实现试样的载荷-位移关系逼近,进而获得材料直至断裂的全程等效应力-应变关系,并以此通过有限元正向分析获取4种试样的临界断裂阈值和临界应力三轴度,提出了基于临界断裂单元的应力三轴度与第一主应力阈值之间的对数型断裂强度准则。结果表明,2种材料、4类试样的FAT阈值分析结果与断裂强度准则符合良好。最后,基于断裂强度准则提出了依据I型裂纹尖端的应力分布预测材料平面应变启裂断裂韧度的新方法,并获得了30Cr2Ni4MoV低压转子钢和3Cr13不锈钢的平面应变启裂断裂韧度,结合临界断裂准则和裂纹静态扩展机理,提出了I型裂纹的材料J阻力曲线的理论预测方法,并给出了30Cr材料的预测结果。     

GH4169合金蠕变疲劳行为的有限元模拟及寿命预测

考虑蠕变-疲劳损伤,对部件材料进行合理的循环变形描述和准确的寿命预测,是保证航空发动机等高温设备长周期安全运行需要解决的关键问题之一。基于大型有限元软件ABAQUS,采用组合Chaboche随动强化准则和Voce各向同性硬化准则的循环弹塑性本构模型,叠加应变强化的蠕变本构模型,对GH4169合金在蠕变-疲劳载荷下伴有应力松弛的循环变形行为进行了准确的有限元模拟。同时,将Wang等最新修正的基于逐周次概念的蠕变-疲劳损伤模型进行了有限元移植,结合有限元模拟所得的循环应力、应变状态,实现了对GH4169合金蠕变-疲劳寿命的准确预测。研究结果将为进一步实现对航空发动机关键部件精确的寿命预测提供理论基础和技术手段。     

基于改进SWT模型的FGH96合金低周疲劳寿命预测

针对SWT（Smith-Watson-Topper）模型未考虑材料对平均应力影响的灵敏度以及忽略平均应力对材料塑性变形影响的问题,利用材料的屈服强度和抗拉强度,对Walker指数γ的计算公式进行了改进,并将其引入到SWT模型中对损伤控制参数进行了修正。同时结合M-H（Manson-Halford）模型塑性部分平均应力修正方法对SWT模型中的塑性变形参数进行了修正,从而提出了一种基于改进SWT模型的FGH96粉末高温合金低周疲劳寿命预测方法。利用不同材料的γ试验计算值对改进的Walker指数计算方法进行了验证,计算平均相对误差为10.25%。并利用FGH96合金和其他航空发动机材料的低周疲劳试验数据,对改进SWT模型的寿命预测精度及适用范围进行了评估,并与M-H、SWT和Lv模型进行了对比。结果表明,改进SWT模型对不同材料的预测结果基本位于±2倍分散带之内,其寿命预测能力要高于其他3种模型。     

不同应力三维度下空穴缩胀的模拟计算与分析

 用弹塑性大变形有限元方法对含微空洞的40 Cr材料制轴对称拉伸试件进行了模拟计算与分析,表明空穴沿轴向和径向长大规律的不同,主要表现在对应力三维度水平的依赖程度不一样;在所考察的范围内,空穴横纵扩张比与应力三维度成线性关系。该计算模型在一定程度上反映了真实试件中的空穴变形情况,简单推算表明它在一定程度上也能反映裂纹体裂端空穴长大规律,并有可能用于估计材料的韧脆转变的研究。     

TMF本构和寿命模型:从光棒到涡轮叶片

针对空心涡轮叶片，发展了考虑瞬态变温效应的热机械疲劳（TMF）本构模型和寿命预测方法。第一，以某涡轮叶片用定向凝固合金DZ125为对象，开展了光棒、缺口TMF试验，结合已有的高温疲劳试验数据，获得了相位、温度范围、应力集中等因素对TMF寿命影响规律；第二，利用材料微观组织分析手段，揭示了导致光棒和缺口TMF失效的疲劳裂纹萌生机理；第三，借助于Chaboche本构模型，进行了各向异性、变温、蠕变损伤修正，建立了考虑变温效应的循环-蠕变本构模型，实现了DZ125合金拉伸、等温循环、蠕变、疲劳-蠕变以及TMF应力应变响应的统一建模和预测；第四，发展了疲劳-蠕变-氧化损伤累积的TMF寿命模型，利用简单纯疲劳和蠕变基础数据获得了寿命模型参数，并进一步发展了名义应力法预测了缺口模拟件的TMF寿命；最后，以某涡轮叶片为对象，进行了模拟飞行载荷谱条件下的瞬态变形响应计算和叶片TMF寿命预测。     

发生风雨激振拉索表面水膜形态数值分析和实测初探

结合Lemaitre斜拉索表面水膜风致形变解析算法,对数学模型中拉索运动方程进行修正,使其能计入拉索风致运动对表面附着水膜形态的影响,通过差分方法对方程进行数值求解,并进行参数分析:研究拉索表面水膜在重力、表面风压、表面摩擦力、表面张力作用下的形态变化,得到拉索发生风雨激振时表面水线的运动规律及形态变化.采用超声波探测仪对拉索表面水膜进行动态测量,实时获得拉索风雨激振形态下表面水膜动态响应数据,通过与水膜运动数值算法结果进行对比一定程度上探讨了圆截面斜拉索风雨振发生机理.     

Prediction of combined cycle fatigue life of TC11 alloy based on modified nonlinear cumulative damage model

The nonlinear cumulative damage model is modified to have high prediction accuracy when the high-low cycle stress frequency ratio m is large (m ≥ 500). The low cycle fatigue (LCF) tests, high cycle fatigue (HCF) tests and combined high and low cycle fatigue (CCF) tests of TC11 titanium alloy were carried out, and the influencing factors of CCF life were analysed. The CCF life declines with the decrease of the ratio of high-low cycle stress frequency m. Both linear and nonlinear cumulative damage models are used to predict the CCF life. The CCF life prediction error of the linear cumulative damage model is great and the predictions tend to be overestimated, which is dangerous for engineering application. The accuracy is relatively high when the high-low cycle stress frequency ratio m ≤ 500. The accuracy of nonlinear cumulative damage model is higher than that of linear model when the high-low cycle stress frequency ratio m ≥ 500. Based on the relationship between high cycle average stress σ_major and material yield limit σ_p,0.2, a correction term is added to the nonlinear cumulative damage model and verified, which made the modified model more accurate when m ≥ 500.     

高应变率条件下38CrMoAl钢的动态力学行为及失效模型

38CrMoAl钢是飞机某频繁经受冲击载荷结构的主要材料，为了获得该钢在冲击载荷下的力学行为和失效参数，本文对38CrMoAl钢开展了准静态试验、应变率从650 s^-1至5 500 s^-1的动态力学试验以及应力三轴度试验，对材料的金相组织和断口形貌进行了微观观察分析，最后基于试验结果确定了材料的修正强度模型和失效模型参数。试验结果表明，38CrMoAl钢具有较强的应变率敏感性，材料屈服强度随着应变率的增加具有正应变率强化效应，应变率在10^-3~5 500 s^-1的范围变化时，屈服应力从450 MPa上升到了1 085 MPa，应变率为5 500 s^-1时材料的屈服应力达到了准静态条件下的2.41倍。对材料组织的微观观察分析发现材料主要由呈现颗粒状的回火索氏体组成，材料在高应变速率加载下其塑性发生了下降，断口由韧窝型塑性断口向局部解理断面发生转变，韧窝尺寸也随着应变率的升高而变小。对Johnson-Cook（J-C）强度模型中的应变率强化项进行了修正，使修正后的本构模型可以更有效地描述38CrMoAl钢的动态力学行为，最后结合数值模拟方法确定了材料的J-C失效准则参数。     

高温低周疲劳-蠕变的改进型广义应变能损伤函数方法

通过对广义应变能损伤函数(GSEDF)法进行分析,用非弹性应变能表征低周疲劳(LCF)损伤,提出了一种高温低周疲劳-蠕变(LCF-C)寿命预测的改进型GSEDF模型,修正了GSEDF法中的能量参数,使其与工程实际更吻合.所提出的模型具有模型参数少、适用性广和试验数据利用率高等优点,且能综合反映加载方式、保载时间和平均应...     

正交各向异性韧性材料的损伤力学

 以含内变量的不可逆热力学基本原理,最小强度原理、正交性流动法则,以及Hill所定义的有效应力等为基础,引入含内损伤变量的比自由能和塑性势,建立了正交各向异性韧性材料的损伤模型和损伤演化方程。并用正交各向异性板材破坏成形的实验数据对本文所建立的损伤演化方程作了验证,结果表明,该模型和损伤演化方程是合理的。     

单晶高温合金接近使用条件下的寿命估算与损伤分析

针对发动机热端部件承受的典型载荷谱，发展了一种通用的寿命预测方程和损伤分析方法。这个方法是在疲劳蠕变交互作用断裂特征图及其最大应力修正的寿命方程基础上建立的。根据ＤＤ３单晶合金的疲劳蠕变交互作用断裂特征图及其最大应力修正的寿命方程，验证了本方法是切实可行的。预测精度是符合要求的。     

Reliability analysis of aero-engine blades considering nonlinear strength degeneration

To comprehensively consider the effects of strength degeneration and failure correlation, an improved stress-strength interference (SSI) model is proposed to analyze the reliability of aeroengine blades with the fatigue failure mode. Two types of TC4 alloy experiments are conducted for the study on the damage accumulation law. All the parameters in the nonlinear damage model are obtained by the tension-compression fatigue tests, and the accuracy of the nonlinear damage model is verified by the damage tests. The strength degeneration model is put forward on the basis of the Chaboche nonlinear damage theory and the Griffith fracture criterion, and determined by measuring the fatigue toughness during the tests. From the comparison of two kinds of degeneration models based on the Miner’s linear law and the nonlinear damage model respectively, the nonlinear model has a significant advantage on prediction accuracy especially in the later period of life. A time-dependent SSI reliability model is established. By computing the stress distribution using the finite element (FE) technique, the reliability of a single blade during the whole service life is obtained. Considering the failure correlation of components, a modified reliability model of aero-engine blades with common cause failure (CCF) is presented. It shows a closer and more reasonable process with the actual working condition. The improved reliability model is illustrated to be applied to aero-engine blades well, and the approach purposed in this paper is suitable for any actual machinery component of aero-engine rotor systems.     

Stress-controlled LCF experiments and ratcheting behaviour simulation of a nickel-based single crystal superalloy with [001] orientation

Uniaxial ratcheting behaviour and low cycle fatigue (LCF) failure mechanism of nickel-based single crystal superalloy DD6 with [001] orientation are investigated through the stress-controlled LCF tests with stress ratio of −1. Then the deformation behaviour during the whole-lifetime from the beginning of the experiment to the fracture of the specimen, as well as the fractographic/metallographic morphology, are compared with the strain-controlled LCF experimental results. Through the scanning electron microscope (SEM) observations, it is shown that the failure characteristics under stress-controlled LCF loading are similar with those under strain-controlled loading. Nevertheless, unlike strain-controlled LCF loading, even under fully reversed cycle loading for stress-controlled LCF, DD6 shows significant ratcheting behaviour due to the tension-compression asymmetry. In addition, the LCF lifetimes under stress control are significantly shorter than the LCF lifetimes under strain control, and the culprit might be the detrimental effect of ratcheting strain on LCF lifetime. Based on these phenomena, an improved crystal plasticity constitutive model on the basis of slip-based Walker constitutive model is developed through modifying the kinematic hardening rule in order to overcome the inaccurate prediction of decelerating stage and stable stage of ratcheting behaviour. Furthermore, combining the continuum damage mechanics, a damage-coupled crystal plasticity constitutive model is proposed to reflect the damage behaviour of DD6 and the accelerating stage of ratcheting behaviour. The simulation results for the stress-controlled LCF deformation behaviour including the whole-lifetime ratcheting behaviour show good agreement with the experimental data.     

Modeling on mechanical behavior and damage evolution of single-lap bolted composite interference-fit joints under thermal effects

This paper reports the modeling method and outcomes of mechanical performance and damage evolution of single-lap bolted composite interference-fit joints under extreme temperatures. The anisotropic continuum damage model involving thermal effects is established on continuum damage mechanics which integrates the shear nonlinearity constitutive relations characterized by Romberg-Osgood equation. The temperature-induced modification of thermal strains and material properties is incorporated in stress-strain analysis, extended 3D failure criteria and exponential damage evolution rules. The proposed model is calibrated and employed to simulate behavior of composite joints in interference fitting, bolt preloading, thermal and bearing loading processes, during which the influence of interference-fit sizes, preload levels, laminate layups and service temperatures is thoroughly investigated. The predicated interfacial behavior, bearing response and failure modes are in good agreement with experimental tests. The numerical model is even capable of reflecting some non-intuitive experimental findings such as residual stress relaxation and matrix softening at elevated temperatures.