A progressive approach to predict shot peening process parameters for forming integral panel of Al7050-T7451

In this paper, a progressive approach to predict the multiple shot peening process parameters for complex integral panel is proposed. Firstly, the invariable parameters in the forming process including shot size, mass flow, peening distance and peening angle are determined according to the empirical and machine type. Then, the optimal value of air pressure for the whole shot peening is selected by the experimental data. Finally, the feeding speed for every shot peening path is predicted by regression equation. The integral panel part with thickness from 2 mm to 5 mm and curvature radius from 3200 mm to 16000 mm is taken as a research object, and four experiments are conducted. In order to design specimens for acquiring the forming data, one experiment is conducted to compare the curvature radius of the plate and stringer-structural specimens, which were peened along the middle of the two stringers. The most striking finding of this experiment is that the outer shape error range is below 3.9%, so the plate specimens can be used in predicting feeding speed of the integral panel. The second experiment is performed and results show that when the coverage reaches the limit of 80%, the minimum feeding speed is 50 mm/s. By this feeding speed, the forming curvature radius of the specimens with different thickness from the third experiment is measured and compared with the research object, and the optimal air pressure is 0.15 MPa. Then, the plate specimens with thickness from 2 mm to 5 mm are peened in the fourth experiment, and the measured curvature radius data are used to calculate the feeding speed of different shot peening path by regressive analysis method. The algorithm is validated by forming a test part and the average deviation is 0.496 mm. It is shown that the approach can realize the forming of the integral panel precisely.     

A progressive approach to predict shot peening process parameters for forming integral panel of AI7050-T7451

In this paper,a progressive approach to predict the multiple shot peening process parameters for complex integral panel is proposed.Firstly,the invariable param...     

铝锂合金喷丸强化数值模拟及试验

根据喷丸强化工艺过程的特点,利用ABAQUS有限元计算软件建立了模拟喷丸残余应力场的三维有限元模型.在此模型基础上研究了喷丸速度、弹丸直径及弹丸数量等因素对铝锂合金喷丸残余应力场的影响规律,进而对比了单弹丸模型、均布式阵列弹丸模型和随机弹丸模型下残余应力场的分布规律.采用X射线残余应力仪和电解抛光法得到喷丸强化后沿铝锂合金试件厚度方向的残余应力分布规律.残余应力层深度约为0.24mm,最大残余应力出现在距表面深度为0.08mm处,验证了有限元模型的有效性.      

基于DEM-FEM耦合的超声喷丸强化数值分析

为了研究超声喷丸处理过程弹丸与构件之间弹塑性接触状态、应力场及表面状态分布规律,基于显式微粒离散函数的多弹丸撞击模型和Hertz-Mindlin(No Slip)碰撞接触力学定律,建立了弹丸冲击速度与恢复系数之间的模型。针对超声喷丸过程,建立DEM-FEM(离散元-有限元)耦合数值模型,建立ALE自适应网格模型,通过数值模拟研究恒定恢复系数与动态恢复系数对构件表面残余应力、残余应力层深度、表面宏观形貌的影响,恒定恢复系数增加的过程中,表面残余压应力、残余压应力层深度、表面粗糙度均增加,相比残余应力层深度与表面粗糙度,表面残余应力分布极值差低约12%,相比残余应力层深度内外端均值差值,表面残余应力与表面粗糙度差值低约9%～15%。结果表明,在恒定与动态恢复系数下,与残余压应力层深度相比,表面残余应力与表面宏观形貌更容易实现均匀性;与恒定恢复系数相比,动态恢复系数对构件表面引入的残余应力与试验结果误差均低于5%,预测更接近真实值。     

喷丸强化Ti6Al4V钛合金的数值模拟

为了更加真实地模拟Ti6Al4V钛合金的喷丸强化过程,建立了一个基于概率控制多弹丸冲击靶面位置的三维喷丸有限元模型,以考虑喷丸强化过程中弹丸之间的相互作用。模拟了喷丸角度为60°和90°的两种工况,结果表明:对于相同的弹丸尺寸和初始速度,达到完全喷丸覆盖率和饱和喷丸强度,60°喷丸角度工况在单位受喷面积上需要的弹丸个数为15/D2(D是弹丸直径),90°喷丸角度工况需要的弹丸个数为35/D2;在达到完全喷丸覆盖率的过程中,随着弹丸个数的增加,喷丸强化的残余压应力逐渐增大并趋于稳定,而受喷表面粗糙度基本呈线性增大;在完全喷丸覆盖率下,相对于60°喷丸角度工况,90°喷丸角度工况的表面残余压应力较小,但最大残余压应力较大,表面粗糙度也较大。      

A unifying approach in simulating the shot peening process using a 3D random representative volume finite element model

Using a modified 3D random representative volume (RV) finite element model,the effects of model dimensions (impact region and interval between impact and representative regions),model shapes (rectangular,square,and circular),and peening-induced thermal softening on resultant critical quantities (residual stress,Almen intensity,coverage,and arc height) after shot peening are systematically examined.A new quantity,i.e.,the interval between impact and representative regions,is introduced and its optimal value is first determined to eliminate any boundary effect on shot peening results.Then,model dimensions are respectively assessed for all model shapes to reflect the actual shot peening process,based on which shape-independent critical shot peening quantities are obtained.Further,it is found that thermal softening of the target material due to shot peening leads to variances of the surface residual stress and arc height,demonstrating the necessity of considering the thermal effect in a constitutive material model of shot peeing.Our study clarifies some of the finite element modeling aspects and lays the ground for accurate modeling of the SP process.     

不同喷丸强度对TC17钛合金抗疲劳性能影响

为提升TC17钛合金抗疲劳性能,对其表面进行喷丸处理。通过旋转弯曲疲劳试验、断口分析、残余应力场分析、表层组织分析及喷丸前、后钛合金表面完整性分析等手段,开展不同喷丸强度对TC17钛合金抗疲劳性能影响研究。结果表明：喷丸强化后钛合金表面粗糙度增大,由0.315μm变为0.5～1.0μm;表层发生塑性变形,晶粒发生细化;表面引入残余压应力,残余压应力层深约为125～151μm,最大残余压应力位于层深30μm附近处。0.3 mm·N喷丸状态旋转弯曲试样疲劳寿命优于其他状态试样,在740 MPa和840 MPa应力水平下,分别比未喷丸状态试样疲劳寿命提升4.5倍与7.5倍。疲劳寿命提升归因于试样表层晶粒细化、高密度位错组织及残余压应力对疲劳裂纹萌生与扩展的抑制作用。0.35 mm·N与0.4 mm·N喷丸状态试样疲劳寿命下降与喷丸强度过大时试样表面粗糙度高,并有脱层及微裂纹生成有关。     

喷丸残余应力及夹杂影响小裂纹仿真概率模型

提出考虑喷丸残余应力及内部夹杂影响的随机内部小裂纹形核扩展概率模型,实现构件内部疲劳裂纹萌生过程的仿真。针对高温合金X,在开展试验的数据基础上,识别模型所需的残余应力分布参数、“形核相关”夹杂尺寸分布参数、微观结构相关塑性本构参数及小裂纹形核扩展参数。模型成功预测喷丸等直棒两种主要的形核方式：残余拉应力平衡层夹杂形核及无残余应力区夹杂形核。与试验对比,模型预测内部裂纹萌生寿命及其分散精度高,残余拉应力平衡层预测萌生寿命中值误差为2%,-3σ寿命误差为37%,无残余应力区预测萌生寿命中值误差为3%,-3σ寿命误差为3%;此外,模型仿真的内部裂纹形貌为“鱼眼形”,贴合试验件断口形貌。     

喷丸强化对TC11合金模拟叶片高周疲劳寿命影响的试验

针对三种叶片:钢丸强化、二次强化和未强化的钛合金叶片进行了振动特性测量和高周疲劳对比试验.通过试验结果,结合断口分析,对三种叶片的固有频率、振型阻尼比、高周疲劳极限及裂纹起源等方面进行了对比研究.研究表明:喷丸后叶片1阶振型阻尼比增大40%～50%,高周疲劳极限提高40%以上,叶片的高周疲劳寿命也相应地提高.从强化机理方面分析了高周疲劳极限得到提高的原因.该积累的试验数据及研究成果可为TC11喷丸叶片的高周疲劳工程设计提供参考.      

7050凹槽铝板激光冲击强化残余应力分布与疲劳寿命

激光冲击强化（LSP）是改善结构疲劳性能的重要手段,传统数值模拟方法很难模拟复杂结构的多点冲击强化过程。本文利用一种连续动态冲击方法对7050凹槽铝板进行激光冲击强化数值模拟,得到了冲击后稳定的残余应力场,并与试验测量的残余应力相对比,验证了该方法的精度与较高效率。运用4种基于临界平面法的应变模型,最大正应变模型、最大剪应变模型、BM模型和SWT模型分别对未强化件和强化件进行疲劳寿命预测。完成了激光冲击强化件和未强化件的疲劳试验,得到其疲劳寿命。结果表明：寿命预测值与试验结果吻合较好;对未强化件进行平均应力修正后,前3种模型误差分别为31.2%、22.6%和40.7%,而SWT模型的计算结果过于保守;对强化件进行最大正应力修正后,前3种模型误差分别为1.84%、24.0%和46.4%,而SWT模型的计算结果过于危险。     

304奥氏体不锈钢喷丸引起的组织转变和两相残余应力测定

采用X射线衍射技术研究了304奥氏体不锈钢喷丸过程所引起的组织结构变化以及两相组织中每相的残余应力。试验结果表明,喷丸强化可使亚稳态304奥氏体材料表面发生γ→α转变,在相同的喷丸强度下转变量与喷丸弹丸种类规格关系很大,而且与喷丸时间有关;表面两相组织γ和α相各自的残余应力可采用X射线衍射应力仪进行测定,两相的残余应力数值相差很大。     

40CrNi2Si2MoVA钢机械加工与喷丸试样旋转弯曲疲劳寿命的预测方法

为了预测机械加工及喷丸强化后40CrNi2Si2MoVA钢试样在室温下的旋转弯曲疲劳寿命,结合商用有限元软件ABAQUS和疲劳寿命分析软件FE-SAFE对不同数值计算方法的适用性及准确性进行比较,提出了喷丸强化40CrNi2Si2MoVA钢的寿命预测经验公式。结果表明:对于机械加工试样,选择Brown-Miller算法和表面残余应力用于计算可获得比较准确的预测结果;对于喷丸强化试样,高应力水平下也可选用Brown-Miller算法及表面残余应力,而低应力水平下则应改用Stress-based Brown Miller算法及最大残余应力。基于上述两种方法提出的经验公式:σmax=–64.378·lgN+1449.268,可改善40CrNi2Si2MoVA钢喷丸强化试样疲劳寿命预测的准确性。     

Improvement of titanium alloy TA19 fatigue life by submerged abrasive waterjet peening: Correlation of its process parameters with surface integrity and fatigue performance

Submerged abrasive waterjet peening(SAWJP) is an effective anti-fatigue manufacturing technology that is widely used to strengthen aeroengine components. This study investigated the correlation of SAWJP process parameters on surface integrity and fatigue life of titanium alloy TA19. SAWJP with different water pressures and standoff distances(SoDs) was conducted on the TA19 specimens. The surface integrity of the specimens before and after SAWJP with different process parameters was experimentall...     

跨介质冲压发动机理论性能与工作参数分析

针对空水一体跨介质导弹应用需求,提出了一种采用同一金属基固体推进剂,能够实现在空中和水中工作的跨介质冲压发动机方案。分析了空中和水中典型工况下,金属基固体推进剂配方、空/水燃比、金属种类等对跨介质冲压发动机理论性能的影响。针对给定的跨介质导弹飞行弹道和金属基固体推进剂配方,对发动机设计参数进行了选取,并完成了空中和水中工作条件下发动机工作参数计算,从理论上验证了该跨介质冲压发动机方案的可行性。     

Calculation of pipe expansion and sizing process parameters

The calculation of the die diameter in the course of sizing taking into account reverse elastic strain of pipes is presented. Also determined are the necessary pressure value and the stress strain state in the process of tips deformation.     

确定总应变寿命方程参数的一种方法

为了使总应变寿命方程能够在较大寿命范围内具有理想的预测精度且其参数物理意义明确,基于总应变寿命方程中疲劳强度系数与疲劳延性系数的物理意义,建立了总应变寿命方程参数与单调拉伸强度极限和断面收缩率之间的关系,并结合TC4,GH4169及GH901合金的单调拉伸及疲劳试验数据,对其各自的总应变寿命方程参数进行了拟合,进而开展了疲劳寿命预测.结果表明:采用该方法确定的总应变寿命方程参数具有明确的物理意义,且对TC4,GH4169及GH901合金的疲劳寿命预测结果较为理想,其分散带基本在2倍以内.      

Effects of process parameters on mechanical properties of abrasive-assisted electroformed nickel

A cathode mandrel with translational and rotational motion, which was supposed to obtain uniform friction effect on surface, was employed in abrasive-assisted electroforming for revolving parts with complex profile. The effects of current density, translational speed and rotational speed on the deposit properties were studied by orthogonal test. The tensile strength, elongation and micro hardness value were measured to find out how the factors affected the properties. The optimized results show that changes of current density affect the tensile strength of nickel layer most, while translational speed has the most remarkable influences on both elonga-tion and micro hardness. The low rotational speed affects the properties least. In this experiment, a smooth nickel layer with tensile strength 581 MPa, elongation 17%and micro hardness 248HV is obtained by the orthogonal test.     

Influences of characteristic parameters on starting-up process of an arcjet thruster

Arcjet thruster has been a widely used electrical propulsion technology on GEO satellites since 1993. In its long history of technical development and commercial application, lifetime verification of an arcjet thruster is always one of the most important and expensive tasks.Considering that the main life limitation of an arcjet thruster is electrode ablation and a significant share of the total ablation happens in its starting-up process, the starting-up process is studied with arc voltage signa...     

激光冲击强化提高压气机叶片疲劳性能研究

根据1Cr11Ni2W2MoV不锈钢材料性能,确定了激光冲击强化参数;并通过标准试片疲劳试验,验证了该参数条件下激光冲击强化提高不锈钢材料振动疲劳寿命的有效性.设计了不锈钢叶片振动疲劳试验,确定了叶片冲击强化部位和方式,对强化叶片进行了型面检查、一阶弯曲振动疲劳试验和强化机理研究.结果表明:激光冲击强化后的叶片各个截面尺寸在设计范围之内,强化后叶片的应力-循环次数(S-N)曲线往上移动,提高了叶片的疲劳强度,在660MPa应力水平下,叶片的振动中值疲劳寿命提高70%;激光冲击强化引起的残余应力和表层微观组织变化是疲劳强度提高的主要原因.      

TC4钛合金激光冲击强化数值模拟

采用连续显式动态冲击策略对航空用TC4钛合金进行激光冲击强化数值模拟研究.根据冲击波能量变化曲线确定单次冲击求解时间为3000ns,并分析了应力波传播过程.在此基础上开展多点冲击模拟,分析了功率密度、冲击次数和光斑搭接率对残余应力、应变场的影响.得出增加功率密度对增大表面残余压应力的效果更好;增加冲击次数对增大残余压应...