滚压加工形成螺旋形变对扭力轴疲劳寿命的影响
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摘要
针对滚压加工中参数会影响扭力轴疲劳寿命的问题,建立扭力轴滚压加工仿真模型,研究滚轮进给速度、滚压次数以及滚轮数对扭力轴表面残余应力、塑性应变及疲劳寿命的影响。研究表明,随着滚轮进给速度的增加,滚压后,扭力轴表面的残余压应力、等效塑性应变逐渐减小,轴的疲劳寿命有减小趋势;较低的进给速度有利于轴表面残余压应力的分布。滚压次数增加,扭力轴表面残余压应力、塑性应变随之增大,在合适的进给速度下,一次滚压即可满足加工要求。滚轮数增加,扭力轴残余应力、塑性应变有增大趋势,从工程力学的角度考虑采用3个滚轮较为合理。
Aiming at the problem that the rolling parameters could affect the fatigue life of the torsion axis in rolling process,the rolling machining simulation model was established,and the effects of roller feed speed,rolling times and different number of rollers on the residual stress,plastic strain and fatigue life of the torsion shaft were studied. The study shows that with the increase of roller feed rate,the residual stress and equivalent plastic strain of the torsion axis after rolling gradually decrease,and the fatigue life exhibits decreasing trend.The lower feed rate is favorable to the distribution of residual stress. When increasing the number of times of rolling,the residual compressive stress and the plastic strain on the surface of the torsion shaft increase. With the appropriate feed rate,processing requirement can be met with only one roll. With the number of rollers increasing,the residual stress and the plastic strain of the torsion shaft has increasing trend. Using three rollers is more reasonable from the perspective of force.
Aiming at the problem that the rolling parameters could affect the fatigue life of the torsion axis in rolling process,the rolling machining simulation model was established,and the effects of roller feed speed,rolling times and different number of rollers on the residual stress,plastic strain and fatigue life of the torsion shaft were studied. The study shows that with the increase of roller feed rate,the residual stress and equivalent plastic strain of the torsion axis after rolling gradually decrease,and the fatigue life exhibits decreasing trend.The lower feed rate is favorable to the distribution of residual stress. When increasing the number of times of rolling,the residual compressive stress and the plastic strain on the surface of the torsion shaft increase. With the appropriate feed rate,processing requirement can be met with only one roll. With the number of rollers increasing,the residual stress and the plastic strain of the torsion shaft has increasing trend. Using three rollers is more reasonable from the perspective of force.
引文
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[2]卢杰.抗侧滚扭杆参数化设计与疲劳寿命研究[D].成都:西南交通大学,2014.LU Jie.Simulation research on dynamics performance of air spring in railway vehicles[D].Chengdu:Southwest Jiaotong University,2014.
[3]钱晓明,姜银方,管海兵,等.飞机结构件紧固孔强化技术综述[J].机械强度,2011,33(5):749-753.QIAN Xiaoming,JIANG Yinfang,GUAN Haibing,et al.Research and application of strengthening technologyfor fastening holes of aircraft structures[J].Journal of Mechanical Strength,2011,33(5):749-753.
[4]刘福超,雷丽萍,曾攀.滚压有限元模型数值模拟[J].塑性工程学报,2012,19(2):17-21.LIU Fuchao,LEI Liping,ZENG Pan.Surface rolling FE model for numerical simulation[J].Journal of Plasticity Engineering,2012,19(2):17-21.
[5]许正功,陈宗帖,黄龙发.表面形变强化技术的研究现状[J].装备制造技术,2007,148:75-77,81.XU Zhenggong,CHEN Zongtie,HUANG Longfa.Research status of surface plastic deformation strengthening technology[J].E-quipment Manufacturing Technology,2007,148:75-77,81.
[6]何嘉武,马世宁,巴德玛.表面滚压强化技术研究与应用进展[J].装甲兵工程学院学报,2013,27(3):75-81.HE Jiawu,MA Shining,BA Dema.Research and application progress of surface rolling strengthening technology[J].Journal of Academy of Armored Force Engineering,2013,27(3):75-81.
[7]MAJZOOBI G H,AZADIKHAH K,NEMATI J.The effects of deep rolling and shot peening on fretting fatigue resistance of Aluminum-7075-T6[J].Materials Science and Engineering,2009,16:235-247.
[8]NALLA R K,ALTENBERGER I,NOSTER U,et al.On the influence of mechanical surface treatments-deep rolling and laser shock peening-on the fatigue behavior of Ti-6Al-4V at ambient and elevated temperatures[J].Materials Science&Engineering A,2003,355(1):216-230.
[9]李风雷,夏伟,周照耀,等.滚轮滚挤压过程的有限元建模与分析[J].机床与液压,2007,231:60-62,122.LI Fenglei,XIA Wei,ZHOU Zhaoyao,et al.Finite element modeling and analysis of roller burnishing process[J].Machine Tool&Hydraulics,2007,231:60-62,122.
[10]王立东,阮雪榆,陈楚杰,等.缺口滚压强化后残余应力应变分布的数值模拟[J].兵器材料科学与工程,1996,(1):15-19,48.WANG Lidong,RUAN Xueyu,CHEN Chujie,et al.Numerical simulation of distribution of residual stress and strain after rolling beneath a notch[J].Ordnance Material Science and Engineering,1996,(1):15-19,48.
[11]徐聪聪,苏铁熊,王军,等.基于ANSYS Workbench的曲轴圆角形状及其下沉量的研究[J].煤矿机械,2010,31(11):79-81.XU Congcong,SU Tiexiong,WANG Jun,et al.Study on fillet radius and subsidence of crankshaft based on ANSYS Workbench[J].Coal Mine Machinery,2010,31(11):79-81.
[12]姜伟,于恩林.螺旋槽管材滚压成形过程的数值模拟及试验研究[J].钢铁,2005,40(9):57-59.JIANG Wei,YU Enlin.Numerical simulation and experimental researchon roll-pressing process of spiral grooved tube[J].Iron and Steel,2005,40(9):57-59.
[13]薛隆泉,王玉秋,刘荣昌,等.曲轴滚压加工残余变形的有限元分析[J].机床与液压,2005,(10):45-46,84.XUE Longquan,WANG Yuqiu,LIU Rongchang,et al.Finite element analysis of residual deforming of crankshaft rolling process[J].Machine Tool&Hydraulics,2005,(10):45-46,84.
[14]宋玉泉,徐振国,赵泼,等.金属平面滚压塑性精加工的实验分析[J].吉林大学学报(工学版),2006,36(2):50-56.SONG Yuquan,XU Zhenguo,ZHAO Po,et al.Experimental analysis of roller burnishing process for metal plane[J].Journal of Jilin University(Engineering and Technology Edition),2006,36(2):50-56.