铝合金喷丸应力-变形的仿真分析与实验
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摘要
目的揭示喷丸处理对7075-T651铝合金材料表面应力场和形貌改变的作用机制。方法首先利用ANSYS/LS-DYNA有限元软件分别建立单颗弹丸和多颗弹丸撞击铝合金靶材的有限元模型,并在符合实验外场边界条件的前提下,获得材料表面200μm深度的内应力分布和不同撞击次数后的表面变形情况。然后通过实验所测结果修正模型丸粒撞击参数,包括网格划分密度、丸粒撞击次数、接触速度等,并结合仿真计算结果阐述喷丸表面应力分布和变形强化层的形成机理。结果计算与实验结果对比表明,喷丸仿真模型的计算结果与实验吻合较好。一方面,表面逐层应力分布规律与喷丸实际接近,表面应力最大偏差小于25 MPa,这说明模型中设置的喷丸强度正确。另一方面,6次弹丸撞击造成的强化层变形率小于6%,并逐步趋于稳定,这与实验中采用多次喷丸表面覆盖导致的材料硬化现象一致,从而间接说明靶材模型单元与参数设置的准确性。结论分析认为,喷丸建模方法能够快速准确地计算出材料表面应力-变形状况,为揭示喷丸工艺对材料表面的强化规律发挥积极作用。
The work aims to discover the mechanism of shot peening(SP) to change the surface field and surface morphology of 7075-T651 Al-based alloy. Firstly, the finite element models(FEM) of SP involving single projectile and projectiles were set by ANSYS/LS-DYNA respectively to calculate the 200 μm deep stress distribution on materials surface and the surface deformation via different peening times based on the boundary condition of experiment. Then the collision parameters in the model were corrected by experimental results, including meshing density, number of peening times by shot and contact speed, etc. Finally, the calculation of FEM dedicated the surface stress distribution and mechanism of strengthened layer on surface by SP treatment. Through the contrast, the calculation and experimental results of SP simulation model matched with each other. The stress profile from surface to subsurface via FEM agreed with experimented data. The maximum deviation of surface stress was less than 25 MPa, which indicated that the shot peening strength in the model was correct. Furthermore, the deformation ratio of strengthened layer by 6 times of projectile impacts was less than 6% and gradually tended to be stable. This phenomenon was consistent with the hardening situation of the material via the multiple surface coverage in the SP experiment, which indicated the accuracy of the target model and parameters in FEM indirectly. Through the analysis, the FEM of SP can calculate the stress-deformation on materials surface quickly and correctly and play a positive role in exploring the influence rules of SP technology on the characteristics of materials surface.
The work aims to discover the mechanism of shot peening(SP) to change the surface field and surface morphology of 7075-T651 Al-based alloy. Firstly, the finite element models(FEM) of SP involving single projectile and projectiles were set by ANSYS/LS-DYNA respectively to calculate the 200 μm deep stress distribution on materials surface and the surface deformation via different peening times based on the boundary condition of experiment. Then the collision parameters in the model were corrected by experimental results, including meshing density, number of peening times by shot and contact speed, etc. Finally, the calculation of FEM dedicated the surface stress distribution and mechanism of strengthened layer on surface by SP treatment. Through the contrast, the calculation and experimental results of SP simulation model matched with each other. The stress profile from surface to subsurface via FEM agreed with experimented data. The maximum deviation of surface stress was less than 25 MPa, which indicated that the shot peening strength in the model was correct. Furthermore, the deformation ratio of strengthened layer by 6 times of projectile impacts was less than 6% and gradually tended to be stable. This phenomenon was consistent with the hardening situation of the material via the multiple surface coverage in the SP experiment, which indicated the accuracy of the target model and parameters in FEM indirectly. Through the analysis, the FEM of SP can calculate the stress-deformation on materials surface quickly and correctly and play a positive role in exploring the influence rules of SP technology on the characteristics of materials surface.
引文
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[12]陈国清,田唐永,张新华,等.Ti-6Al-4V钛合金陶瓷湿喷丸表面强化微观组织与疲劳性能[J].中国有色金属学报,2013,23(1):122-127.CHEN Guo-qing,TIAN Tang-yong,ZHANG Xin-hua,et al.Microstructure and fatigue properties of Ti-6Al-4Vtitanium alloy treated by wet shot peening of ceramic beads[J].The Chinese journal of nonferrous metals,2013,23(1):122-127.
[13]MOLINARI A,SANTULIANA E,CRISTOFOLINI I,et al.Surface modifications induced by shot peening and their effect on the plane bending fatigue strength of a Cr-Mo steel produced by powder metallurgy[J].Materials science&engineering A,2011,528(6):2904-2911.
[14]PUROHIT R,VERMA C S,RANA R S,et al.Optimization of process parameters of shot peening using ABQUS[J].Materials today proceedings,2017,4(2):2119-2128.
[15]SEDDIK R,BAHLOUL A,ATIG A,et al.A simple methodology to optimize shot-peening process parameters using finite element simulations[J].International journal of advanced manufacturing technology,2016,90(5-8):1-17.
[16]BADREDDINE J,ROUHAUD E,MICOULAUT M,et al.Simulation of shot dynamics for ultrasonic shot peening:effects of process parameters[J].International Journal of mechanical sciences,2014,82(5):179-190.
[17]王利平,王建明,裴信超,等.喷丸残余应力场SPH/FEM耦合建模与仿真[J].郑州大学学报(工学版),2014,35(6):108-112.WANG Li-ping,WANG Jian-ming,PEI Xin-chao,et al.Numerical simulating for residual compressive stress of shot-peening based on SPH coupled FEM[J].Journal of Zhengzhou University(engineering science),2014,35(6):108-112.
[18]刘飞宏,王建明,余丰,等.基于SPH耦合有限元法的喷丸残余应力场数值模拟[J].山东大学学报(工学版),2010,40(6):67-71LIU Fei-hong,WANG Jian-ming,YU Feng,et al.Numerical simulation for compressive residual stress of shot peening based on SPH coupled FEM[J].Journal of Shandong University(engineering science),2010,40(6):67-71.
[19]张洪伟,陈家庆,张以都.基于多丸粒模型的喷丸表面强化过程数值模拟[J].塑性工程学报,2012,19(6):118-125.ZHANG Hong-wei,CHEN Jia-qing,ZHANG Yi-du.Numerical simulation of shot-peening process based on multiple shot model[J].Journal of plasticity engineering,2012,19(6):118-125.
[20]卢国鑫,宋颖刚,王仁智,等.300M钢喷丸强化残余应力场的数值模拟[J].中国表面工程,2013,26(4):72-76.LU Guo-xin,SONG Ying-gang,WANG Ren-zhi,et al.Numerical simulation of 300M steel residual stress field caused by shot peening[J].China surface engineering,2013,26(4):72-76.
[21]路会龙,姚平喜,刘海英.基于ANSYS/LS-DYNA的受控喷丸工艺过程仿真[J].机械设计与制造,2009(2):214-216.LU Hui-long,YAO Ping-xi,LIU Hai-ying.Simulation of controlled shot peening process based on ANSYS/LS-DYNA[J].Mechanical design and manufacturing,2009(2):214-216.
[22]XIE Le-chun,WANG Cheng-xi,WANG Li-qiang,et al.Numerical analysis and experimental validation on residual stress distribution of titanium matrix composite after shot peening treatment[J].Mechanics of materials,2016,99:2-8.
[23]HASSANI-GANGARAJ S M,CHO K S,VOIGT H J L,et al.Experimental assessment and simulation of surface nanocrystallization by severe shot peening[J].Acta materialia,2015,97:105-115.
[24]POURALI S,KIANIRASHID A R,BABAKHANI A.Surface nanocrystallization and gradient microstructural evolutions in the surface layers of 321 stainless steel alloy treated via severe shot peening[J].Vacuum,2017,144:152-159.
[25]QANDIL A,ZAID A I O.Effect of shot peening and grain refinement on the fatigue life and strength of commercially pure Al and two of its alloys:Al-2024-T3 and Al-7075-T6[J].2016,146(1):012-028.
[26]MAHMOUDI A H,GHASEMI A,FARRAHI G H,et al.A comprehensive experimental and numerical study on redistribution of residual stresses by shot peening[J].Materials&design,2016,90:478-487.
[27]张洪伟,张以都,吴琼.喷丸强化残余应力场三维数值分析[J].航空动力学报,2010,25(3):603-609.ZHANG Hong-wei,ZHANG Yi-du,WU Qiong.Threedimensional numerical analysis of residual stress field for shot peening[J].Journal of aerospace power,2010,25(3):603-609.
[2]常艳艳,孙涛,李增强.硬铝合金超精密车削残余应力的仿真及试验[J].哈尔滨工业大学学报,2015,47(7):41-46.CHANG Yan-yan,SUN Tao,LI Zeng-qiang.Simulation and experiments of residual stress on ultra-precision turning of hard aluminum alloy[J].Journal of Harbin Institute of Technology,2015,47(7):41-46.
[3]HUANG Xiao-ming,SUN Jie,LI Jian-feng.Effect of initial residual stress and machining-induced residual stress on the deformation of aluminium alloy plate[J].Journal of mechanical engineering,2015,61(2):131-137.
[4]YANG Y,LI M,LI K R.Comparison and analysis of main effect elements of machining distortion for aluminum alloy and titanium alloy aircraft monolithic component[J].International journal of advanced manufacturing technology,2014,70(9-12):1803-1811.
[5]CHEN J.Study on machining distortion of residual stress release[J].Advanced materials research,2012,426:143-146.
[6]廖凯,张萧笛,车兴飞,等.铝合金薄壁件加工变形的力学模型构建与分析[J].哈尔滨工业大学学报,2018,50(5):166-172.LIAO Kai,ZHANG Xiao-di,CHE Xing-fei,et al.Construction and analysis of mechanic model of deformation for Al alloy thin-walled component[J].Journal of Harbin Institute of Technology,2018,50(5):166-172.
[7]唐志涛.航空铝合金残余应力及切削加工变形研究[D].济南:山东大学,2008.TANG Zhi-tao.Residual stress and deformation of aerospace aluminum alloy in machining[D].Jinan:Shandong University,2008.
[8]谭靓,姚倡锋,张定华.7055铝合金高速加工表面完整性对疲劳寿命的影响[J].机械科学与技术,2015,34(6):872-876.TAN Liang,YAO Chang-feng,ZHANG Ding-hua.Influence of surface integrity on the fatigue life for high-speed milling of 7055 aluminum alloy[J].Mechanical science and technology,2015,34(6):872-876.
[9]李占明,王红美,孙晓峰,等.高速微粒轰击对微弧氧化铝合金疲劳性能的影响[J].稀有金属材料与工程,2018,47(7):2179-2184.LI Zhan-ming,WANG Hong-mei,SUN Xiao-feng,et al.Effect of high-speed particles bombarding pre-treatment on the fatigue properties of micro-arc oxidation aluminum alloy[J].Rare metal materials and engineering,2018,47(7):2179-2184.
[10]臧志刚,王建明,郑林彬.2024铝合金喷丸试件疲劳寿命试验及仿真研究[J].材料保护,2018,51(5):69-73.ZANG Zhi-gang,WANG Jian-ming,ZHENG Lin-bin.Fatigue life experiment and simulation study on 2024aluminum alloy specimen with shot peening[J].Material protection,2018,51(5):69-73.
[11]邓红华,夏琴香,程秀全,等.喷丸对预腐蚀后铝合金疲劳性能的影响[J].表面技术,2016,45(1):118-123.DENG Hong-hua,XIA Qin-xiang,CHENG Xiu-quan,et al.Effect on anti-corrosion fatigue property of aluminum alloy after shot peening[J].Surface technology,2016,45(1):118-123.
[12]陈国清,田唐永,张新华,等.Ti-6Al-4V钛合金陶瓷湿喷丸表面强化微观组织与疲劳性能[J].中国有色金属学报,2013,23(1):122-127.CHEN Guo-qing,TIAN Tang-yong,ZHANG Xin-hua,et al.Microstructure and fatigue properties of Ti-6Al-4Vtitanium alloy treated by wet shot peening of ceramic beads[J].The Chinese journal of nonferrous metals,2013,23(1):122-127.
[13]MOLINARI A,SANTULIANA E,CRISTOFOLINI I,et al.Surface modifications induced by shot peening and their effect on the plane bending fatigue strength of a Cr-Mo steel produced by powder metallurgy[J].Materials science&engineering A,2011,528(6):2904-2911.
[14]PUROHIT R,VERMA C S,RANA R S,et al.Optimization of process parameters of shot peening using ABQUS[J].Materials today proceedings,2017,4(2):2119-2128.
[15]SEDDIK R,BAHLOUL A,ATIG A,et al.A simple methodology to optimize shot-peening process parameters using finite element simulations[J].International journal of advanced manufacturing technology,2016,90(5-8):1-17.
[16]BADREDDINE J,ROUHAUD E,MICOULAUT M,et al.Simulation of shot dynamics for ultrasonic shot peening:effects of process parameters[J].International Journal of mechanical sciences,2014,82(5):179-190.
[17]王利平,王建明,裴信超,等.喷丸残余应力场SPH/FEM耦合建模与仿真[J].郑州大学学报(工学版),2014,35(6):108-112.WANG Li-ping,WANG Jian-ming,PEI Xin-chao,et al.Numerical simulating for residual compressive stress of shot-peening based on SPH coupled FEM[J].Journal of Zhengzhou University(engineering science),2014,35(6):108-112.
[18]刘飞宏,王建明,余丰,等.基于SPH耦合有限元法的喷丸残余应力场数值模拟[J].山东大学学报(工学版),2010,40(6):67-71LIU Fei-hong,WANG Jian-ming,YU Feng,et al.Numerical simulation for compressive residual stress of shot peening based on SPH coupled FEM[J].Journal of Shandong University(engineering science),2010,40(6):67-71.
[19]张洪伟,陈家庆,张以都.基于多丸粒模型的喷丸表面强化过程数值模拟[J].塑性工程学报,2012,19(6):118-125.ZHANG Hong-wei,CHEN Jia-qing,ZHANG Yi-du.Numerical simulation of shot-peening process based on multiple shot model[J].Journal of plasticity engineering,2012,19(6):118-125.
[20]卢国鑫,宋颖刚,王仁智,等.300M钢喷丸强化残余应力场的数值模拟[J].中国表面工程,2013,26(4):72-76.LU Guo-xin,SONG Ying-gang,WANG Ren-zhi,et al.Numerical simulation of 300M steel residual stress field caused by shot peening[J].China surface engineering,2013,26(4):72-76.
[21]路会龙,姚平喜,刘海英.基于ANSYS/LS-DYNA的受控喷丸工艺过程仿真[J].机械设计与制造,2009(2):214-216.LU Hui-long,YAO Ping-xi,LIU Hai-ying.Simulation of controlled shot peening process based on ANSYS/LS-DYNA[J].Mechanical design and manufacturing,2009(2):214-216.
[22]XIE Le-chun,WANG Cheng-xi,WANG Li-qiang,et al.Numerical analysis and experimental validation on residual stress distribution of titanium matrix composite after shot peening treatment[J].Mechanics of materials,2016,99:2-8.
[23]HASSANI-GANGARAJ S M,CHO K S,VOIGT H J L,et al.Experimental assessment and simulation of surface nanocrystallization by severe shot peening[J].Acta materialia,2015,97:105-115.
[24]POURALI S,KIANIRASHID A R,BABAKHANI A.Surface nanocrystallization and gradient microstructural evolutions in the surface layers of 321 stainless steel alloy treated via severe shot peening[J].Vacuum,2017,144:152-159.
[25]QANDIL A,ZAID A I O.Effect of shot peening and grain refinement on the fatigue life and strength of commercially pure Al and two of its alloys:Al-2024-T3 and Al-7075-T6[J].2016,146(1):012-028.
[26]MAHMOUDI A H,GHASEMI A,FARRAHI G H,et al.A comprehensive experimental and numerical study on redistribution of residual stresses by shot peening[J].Materials&design,2016,90:478-487.
[27]张洪伟,张以都,吴琼.喷丸强化残余应力场三维数值分析[J].航空动力学报,2010,25(3):603-609.ZHANG Hong-wei,ZHANG Yi-du,WU Qiong.Threedimensional numerical analysis of residual stress field for shot peening[J].Journal of aerospace power,2010,25(3):603-609.