基于BBD实验方法的铝合金喷丸工艺预测模型及应用
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摘要
研究了喷丸强化工艺对7075铝合金工件表面性能的影响,获得了材料表面应力、硬度特征和喷丸工艺参数之间的对应关系。通过Box-Behnken design(BBD)方法设计喷丸实验,研究了颗粒尺寸、空气压力、喷丸时间和距离等4个喷丸工艺参数对试样表面性能的影响,采用X射线衍射分析仪与表面显微硬度仪分析了试样表面硬度与应力的分布规律。在对喷丸处理数据进行归纳分析后,构建了喷丸工艺下表面应力与硬度的预测函数,该函数在给定的预期应力与硬度值前提下,可获得喷丸工艺参数组,以此进行实验和计算结果对比,并最后验证预测函数的可靠性。预测函数与实验结果对比表明:在给定一个预期-304 MPa表面应力时,函数给出了10组工艺参数,挑选出硬度期望值为211 HV0.5的那组工艺确定为目标工艺参数组,照此喷丸实验后,对3组试样的应力和硬度进行测量显示,实验与期望值偏差小于6%,说明函数预测与实验结果一致性较好。
The effect of shot peening on surface properties of 7075 aluminum alloy workpiece was studied. The relationship between the surface stress and hardness of the alloy and the shot peening parameters was obtained. The effects of four shot peening parameters, such as particle size, air pressure, shot peening time and distance, on the surface properties of the 7075 aluminum alloy samples were studied by means of the Box-Behnken design(BBD) method. The distribution of surface hardness and stress of the samples was analyzed by means of X-ray diffraction analyzer and surface microhardness analyzer. After regression analysis of the data of shot peening, a prediction function of surface stress and hardness under shot peening process was constructed. Under the premise of given expected stress and hardness value, the parameters group of shot peening process could be obtained. Finally, the reliability of the prediction function was verified. The comparison between the prediction function and the experimental results shows that, given a predicted surface stress of-304 MPa, the prediction function gives 10 groups of process parameters, and selects the group with expected hardness of 211 HV0.5 as the target process parameter group. After the shot peening experiment with the target process parameter group, the measurement of stress and hardness of the specimens shows that the deviation between experiment and expected value is less than 6%, which shows that the function prediction is in good agreement with the experimental results.
The effect of shot peening on surface properties of 7075 aluminum alloy workpiece was studied. The relationship between the surface stress and hardness of the alloy and the shot peening parameters was obtained. The effects of four shot peening parameters, such as particle size, air pressure, shot peening time and distance, on the surface properties of the 7075 aluminum alloy samples were studied by means of the Box-Behnken design(BBD) method. The distribution of surface hardness and stress of the samples was analyzed by means of X-ray diffraction analyzer and surface microhardness analyzer. After regression analysis of the data of shot peening, a prediction function of surface stress and hardness under shot peening process was constructed. Under the premise of given expected stress and hardness value, the parameters group of shot peening process could be obtained. Finally, the reliability of the prediction function was verified. The comparison between the prediction function and the experimental results shows that, given a predicted surface stress of-304 MPa, the prediction function gives 10 groups of process parameters, and selects the group with expected hardness of 211 HV0.5 as the target process parameter group. After the shot peening experiment with the target process parameter group, the measurement of stress and hardness of the specimens shows that the deviation between experiment and expected value is less than 6%, which shows that the function prediction is in good agreement with the experimental results.
引文
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[21] 关艳英,王治业,鲁世红,等.基于正交试验的超声波喷丸成形工艺参数分析及弧高值预测[J].宇航材料工艺,2018,2:7-12.GUAN Yan-ying,WANG Zhi-ye,LU Shi-hong,et al.Analysis of ultrasonic peen forming (UPF) parameters and prediction of formed arc height based on orthogonal test[J].Aerospace Materials and Technology,2018,2:7-12.
[22] 刘维伟,朱昆,单晨伟,等.基于Box-Behnken方法的GH4169铣削力试验研究[J].机械制造,2011,49(564):88-92.LIU Wei-wei,ZHU Kun,SHAN Chen-wei,et al.Experimental study on milling force of GH4169 based on Box-Behnken method[J].Machinery,2011,49(564):88-92.
[23] Hakkak F,Rafizadeh M,Sarabi A A,et al.Optimization of ionic conductivity of electrospun polyacrylonitrile/poly (vinylidene fluoride) (PAN/PVdF) electrolyte using the response surface method (RSM)[J].Ionics,2015,21 (7):1945-1957.
[24] 杨振朝,林允博,刘三娃.基于Box-Behnken设计的高速铣削TC11钛合金切削力预测模型研究[J].航空精密制造技术,2018,54(4):14-18.YANG Zhen-chao,LIN Yun-bo,LIU San-wa.Cutting force prediction models based on Box-Behnken Design in high-speed milling of titanium alloy TC11[J].Aviation Precision Manufacturing Technology,2018,54(4):14-18.
[2] Ozer G,Karaaslan A.Properties of AA7075 aluminum alloy in aging and retrogression and reaging process[J].Transactions of Nonferrous Metals Society of China,2017,27 (11):2357-2362.
[3] 于鑫,孙杰,熊青春,等.7050-T7451铝合金铣削加工表面材料特性与本构关系模型的建立[J].中国有色金属学报,2015,25(11):2982-2989.YU Xin,SUN Jie,XIONG Qing-chun,et al.Milling surface properties of 7050-T7451 aluminum alloy and establishment of constitutive model[J].The Chinese Journal of Nonferrous Metals,2015,25(11):2982-2989.
[4] 廖凯,黄鑫,龚海,等.喷砂表面覆盖率对7075铝合金表面完整性的影响[J].材料热处理学报,2018,39(8):122-128.LIAO Kai,HUANG Xin,GONG Hai,et al.Effect of shot-peening on surface integrity of 7075 Al alloy[J].Transactions of Materials and Heat Treatment,2018,39(8):122-128.
[5] 曾元松,黄遐.铝合金7075T651高压水喷丸强化工艺试验研究[J].塑性工程学报,2017,24(5):219-225.ZENG Yuan-song,HUANG Xia.Experimental research on the high pressure water jet peening process for aluminum alloy 7075T651[J].Journal of Plasticity Engineering,2017,24(5):219-225.
[6] 门向南,陈雪梅.微小弧度壁板零件喷丸工艺研究[J].塑性工程学报,2016,23(3):88-91.MEN Xiang-nan,CHEN Xue-mei.Shot peening for the panel with small curvature[J].Journal of Plasticity Engineering,2016,23(3):88-91.
[7] Liu Y G,Li H M,Li M Q.Characterization of surface layer in TC17 alloy treated by air blast shot peening[J].Materials and Design,2015,65(65):120-126.
[8] Terres M A,Laalai N,Sidhom H.Effect of nitriding and shot-peening on the fatigue behavior of 42CrMo4 steel:experimental analysis and predictive approach[J].Materials and Design,2012,35:741-748.
[9] 王帅.喷丸残余应力和表面粗糙度对疲劳寿命的综合影响研究[D].济南:山东大学,2018.WANG Shuai.Research on the comprehensive effect of shot-peening residual stress and surface roughness on fatigue life[D].Jinan:Shandong University,2018.
[10] 盖鹏涛,陈福龙,尚建勤,等.喷丸强化对表面完整性影响的研究现状与发展[J].航空制造技术,2016,515(20):16-21.GAI Peng-tao,CHEN Fu-long,SHANG Jian-qin,et al.Recent situation and development trend of shot peening on surface integrity[J].Aeronautical Manufacturing Technology,2016,515(20):16-21.
[11] Luong H,Hillill M R.The effects of laser peening and shot peening on high cycle fatigue in 7050-T7451 aluminum alloy[J].Materials Science and Engineering A,2010,527(3):699-707.
[12] Gao Y K.Improvement of fatigue property in 7050-T7451 aluminum alloy by laser peening and shot peening[J].Materials Science and Engineering A,2011,528(10):3823-3828.
[13] Zhan K,Jiang C H,Ji V.Effect of prestress state on surface layer characteristic of S30432 austenitic stainless steel in shot peening process[J].Materials and Design,2012,42:89-93.
[14] Ali A,An X,Rodopoulos C A,et al.The effect of controlled shot peening on the fatigue behaviour of 2024-T3 aluminium friction stir welds[J].International Journal of Fatigue,2007,29(8):1531-1545.
[15] Cho K T,Song K,Sang H O,et al.Surface hardening of aluminum alloy by shot peening treatment with Zn based ball[J].Materials Science and Engineering A,2012,543(5):44-49.
[16] Prakash S,Lillymercy J,Nithiyalakshmi S,et al.Prediction of surface roughness parameters in drilling of MDF composite panel using Box-Behnken experimental design (BBD)[J].Frontiers in Automobile and Mechanical Engineering,2011,5(1):68-74.
[17] Nam Y S,Jeong Y I,et al.Enhancing surface layer properties of an aircraft aluminum alloy by shot peening using response surface methodology[J].Materials and Design,2015,83:566-576.
[18] 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.
[19] 王锐坤,郑志军,高岩.表面喷丸工艺对Super304H奥氏体耐热钢组织与性能的影响[J].中南大学学报,2017,48(4):903-909.WANG Rui-kun,ZHENG Zhi-jun,GAO Yan,et al.Effect of surface shot peening on microstructure and properties of Super304H austenitic heat-resistant steels[J].Journal of Central South University,2017,48(4):903-909.
[20] 刘雪梅,顾佳巍,祁国栋,等.基于CFD-DEM仿真的喷丸工艺参数优选[J].表面技术,2018,47(1):8-15.LIU Xue-mei,GU Jia-wei,QI Guo-dong,et al.Optimization of shot peening process parameters based on CFD-DEM simulation[J].Surface Technology,2018,47(1):8-15.
[21] 关艳英,王治业,鲁世红,等.基于正交试验的超声波喷丸成形工艺参数分析及弧高值预测[J].宇航材料工艺,2018,2:7-12.GUAN Yan-ying,WANG Zhi-ye,LU Shi-hong,et al.Analysis of ultrasonic peen forming (UPF) parameters and prediction of formed arc height based on orthogonal test[J].Aerospace Materials and Technology,2018,2:7-12.
[22] 刘维伟,朱昆,单晨伟,等.基于Box-Behnken方法的GH4169铣削力试验研究[J].机械制造,2011,49(564):88-92.LIU Wei-wei,ZHU Kun,SHAN Chen-wei,et al.Experimental study on milling force of GH4169 based on Box-Behnken method[J].Machinery,2011,49(564):88-92.
[23] Hakkak F,Rafizadeh M,Sarabi A A,et al.Optimization of ionic conductivity of electrospun polyacrylonitrile/poly (vinylidene fluoride) (PAN/PVdF) electrolyte using the response surface method (RSM)[J].Ionics,2015,21 (7):1945-1957.
[24] 杨振朝,林允博,刘三娃.基于Box-Behnken设计的高速铣削TC11钛合金切削力预测模型研究[J].航空精密制造技术,2018,54(4):14-18.YANG Zhen-chao,LIN Yun-bo,LIU San-wa.Cutting force prediction models based on Box-Behnken Design in high-speed milling of titanium alloy TC11[J].Aviation Precision Manufacturing Technology,2018,54(4):14-18.