粉末冶金压坯残余应力与裂纹损伤研究
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摘要
粉末冶金作为一种近净成形制造技术，具有高效、省材、节能、环保等诸多优点，故备受工业界的重视。对于粉末冶金机械零件行业来说，生产过程中零件压坯中产生裂纹是一个长期没有解决的课题。实际上，粉末压坯的裂纹可能出现在压制成形和运送阶段的各个环节。为了避免和防止裂纹产生，除了传统的经验方法，将计算机仿真技术引入粉末冶金模具和工艺设计，对粉末冶金零件生产过程中的工艺过程与裂纹缺陷进行分析预测，进而制定合理的工艺方案及参数，是目前最为有效的科学手段。
由于粉末成形机理与过程复杂，尚没有一个公认的数学模型，对于粉末压坯裂纹形成的定量分析则更少。为此，本文基于更具应用前景的广义塑性力学模型研究金属粉末压制致密化过程以及压坯脱模后残余应力分布规律，并在此基础之上对不同生产阶段的压坯裂纹损伤进行研究和预测分析，为优化模具和工艺参数，提高粉末冶金产品的质量，提供科学有效的依据。论文主要研究内容和成果如下：
1、建立了适用于本文所用金属材料成形的密度相关的广义塑性力学屈服模型，即修正的Drucker-Prager Cap屈服模型。结合粉末闭模压制成形实验和压坯强度实验推导了模型待定参数的求解公式，以Distaloy AE扩散预合金铁粉为实验材料，确定了模型各参数与相对密度的函数关系。
2、基于所建立的金属粉末广义塑性力学模型，利用Abaqus二次开发技术，实现了金属粉末成形过程的弹塑性有限元模拟；对比了压制力曲线和相对密度分布的有限元分析与实验结果，二者吻合良好，验证了金属粉末广义塑性力学模型的正确性。
3、采用X射线衍射技术，对不同压制压力（450MPa和600MPa）以及润滑条件下，ASC100.29和Distaloy AE两种金属粉末压坯表层的残余应力进行测试，获得了金属粉末压坯残余应力分布规律。
4、采用所建立的金属粉末广义塑性力学模型，对粉末压坯脱模后残余应力分布进行了有限元数值模拟。讨论了粉末压制与脱模过程粉体单元的网格参数和阴模材料类型对压坯残余应力计算结果的影响，并根据实验数据对有限元模型进行了合理的修正，保证了残余应力的分析精度，为粉末压坯裂纹损伤研究奠定了基础。
5、分析了金属粉末压制与脱模过程中的裂纹成形机理，结合该环节的裂纹损伤特点，基于金属粉末广义塑性力学模型导出了粉末压坯韧性损伤模型，并确定了裂纹损伤阈值。
6、基于上述韧性损伤模型，利用Abaqus二次开发技术，实现了粉末压制以及压坯脱模过程裂纹损伤的有限元模拟分析，讨论了压坯几何形状、模腔润滑条件、以及阴模出口脱模角度三种因素对压坯损伤的影响。
7、采用圆弧型加载方式的巴西圆盘实验方法，结合理论分析、有限元数值模拟，获得了ASC100.29和Distaloy AE两种金属粉末压坯的力学性能和损伤断裂参数，包括压坯抗拉强度t、弹性模量E、断裂韧度KI和断裂能量Gf与相对密度的函数关系，为压坯损伤与断裂模拟提供了可靠的数据。
8、建立了适用于夹持损伤分析的基于断裂能量的双线性和指数型两种金属粉末压坯内聚力损伤模型，通过粉末压坯巴西圆盘实验及其有限元数值模拟，对两种内聚力损伤模型的有效性和精确性进行了分析；计及压坯脱模后残余应力，采用精度更高的指数型内聚力模型，对环形零件粉末冶金压坯运送过程中夹持裂纹损伤进行了有限元预测分析，进而结合零件技术要求对夹持工况参数进行了研究，得到了环形零件族粉末冶金压坯的极限夹持工况参数。
Powder metallurgy is an effective process of manufacturing near net shapeproducts. It offers many advantages, including high productivity, low production costs,less energy consumption and environmental friendship, which is widely concern inpowder metallurgy industry. Cracking in green compact has always been theimportant issue for a long time in powder metallurgy part industry. In fact, cracks ingreen compacts may occur in all phases of consolidation and handling process.Besides the traditional experience method, numerical simulation technology whichcombined with die and process design, is today a powerful tool in prediction of crackin powder metallurgy process in order to prevent the defect.
There is not a uniform mathematical model as the complex mechanism ofpowder compaction. So, little has been published about quantitative analysis of thecrack in green compacts. Thus, a generalized plastic mechanics model has beendeveloped to research the metal powder densification process in this work. And cracksand damage in metal powder compacts have been studied in different phases ofprocess. These provide an effective scientific method to improve the quality ofpowder metallurgy products and optimize the tool and process parameters. Specificareas of development described in this dissertation include:
1. A density-dependent generalized plastic mechanics model named modifiedDrucker-Prager Cap model was developed, which parameters were identified throughderivation by powder compaction experiment and strength tests of green compacts.And the model parameters of diffusion prealloyed iron powder Distaloy AE weredetermined as functions of relative density.
2. The constitutive model was implemented in Abaqus by writing a usersubroutine to three dimensional simulate the compaction process of metal powder.The simulation results agree well with the experiment data including the curve ofpressing force and relative density distribution.
3. The residual stresses were investigated by X-ray diffraction measurement.Two kinds of metal powder compacts (ASC100.29and Distaloy AE) have beenmeasured the residual stresses in different directions on surfaces based on differentpressing forces (450MPa and600MPa) and lubrication conditions. The test results were ananlyzed to obtain the residual stress distribution law of green compacts, whichhave been the validation criteria of residual stress finite element simulation.
4. The ejection process of green compact was simulated to predict the residualstress based on the calibrated constitutive model. The influence of model parameterson residual stress of green compact has been discussed. And the suitable parameterswere determined according to the experimental results. The finite element model wasfurther modified on the aspect of the stress calculation, which was the basis ofresearch on the crack and damage of green compact.
5. The ductile damage model was derived based on the modified Drucker-PragerCap model considering the mechanism of cracks on the powder compaction process.Meanwhile, the damage threshold of crack was identified.
6. The ductile damage model was implemented in Abaqus by writing a usersubroutine to predict the crack and damage in green compact during the pressing andejection process. Furthermore, the impact of factors including the geometric shape ofthe compacts, the lubrication of die and the taper of the die wall on the damge ofgreen compact was discussed.
7. The mechanical properties and fracture process of two kinds of greencompacts (ASC100.29and Distaloy AE) were investigated by the Brazilian disc testof circular loading. The paramenters including tensile strengtht, elastic modulus E,fracture toughness KIand fracture energy Gfas functions of relative density weredetermined according to the theoretical and numerical analysis and experimental data,which provided the reliable data for the damage and fracture simulation of greencompact.
8. Two kinds of fracture energy based cohesive zone models for metal powdercompacts were established. These models were analyzed combined with the Braziliandisc experiment results. The cracks and damage of the annular compact in handlingprocess was predict considering the residual stress after ejection by the exponent typecohesive zone model with higer simulation precision.
由于粉末成形机理与过程复杂，尚没有一个公认的数学模型，对于粉末压坯裂纹形成的定量分析则更少。为此，本文基于更具应用前景的广义塑性力学模型研究金属粉末压制致密化过程以及压坯脱模后残余应力分布规律，并在此基础之上对不同生产阶段的压坯裂纹损伤进行研究和预测分析，为优化模具和工艺参数，提高粉末冶金产品的质量，提供科学有效的依据。论文主要研究内容和成果如下：
1、建立了适用于本文所用金属材料成形的密度相关的广义塑性力学屈服模型，即修正的Drucker-Prager Cap屈服模型。结合粉末闭模压制成形实验和压坯强度实验推导了模型待定参数的求解公式，以Distaloy AE扩散预合金铁粉为实验材料，确定了模型各参数与相对密度的函数关系。
2、基于所建立的金属粉末广义塑性力学模型，利用Abaqus二次开发技术，实现了金属粉末成形过程的弹塑性有限元模拟；对比了压制力曲线和相对密度分布的有限元分析与实验结果，二者吻合良好，验证了金属粉末广义塑性力学模型的正确性。
3、采用X射线衍射技术，对不同压制压力（450MPa和600MPa）以及润滑条件下，ASC100.29和Distaloy AE两种金属粉末压坯表层的残余应力进行测试，获得了金属粉末压坯残余应力分布规律。
4、采用所建立的金属粉末广义塑性力学模型，对粉末压坯脱模后残余应力分布进行了有限元数值模拟。讨论了粉末压制与脱模过程粉体单元的网格参数和阴模材料类型对压坯残余应力计算结果的影响，并根据实验数据对有限元模型进行了合理的修正，保证了残余应力的分析精度，为粉末压坯裂纹损伤研究奠定了基础。
5、分析了金属粉末压制与脱模过程中的裂纹成形机理，结合该环节的裂纹损伤特点，基于金属粉末广义塑性力学模型导出了粉末压坯韧性损伤模型，并确定了裂纹损伤阈值。
6、基于上述韧性损伤模型，利用Abaqus二次开发技术，实现了粉末压制以及压坯脱模过程裂纹损伤的有限元模拟分析，讨论了压坯几何形状、模腔润滑条件、以及阴模出口脱模角度三种因素对压坯损伤的影响。
7、采用圆弧型加载方式的巴西圆盘实验方法，结合理论分析、有限元数值模拟，获得了ASC100.29和Distaloy AE两种金属粉末压坯的力学性能和损伤断裂参数，包括压坯抗拉强度t、弹性模量E、断裂韧度KI和断裂能量Gf与相对密度的函数关系，为压坯损伤与断裂模拟提供了可靠的数据。
8、建立了适用于夹持损伤分析的基于断裂能量的双线性和指数型两种金属粉末压坯内聚力损伤模型，通过粉末压坯巴西圆盘实验及其有限元数值模拟，对两种内聚力损伤模型的有效性和精确性进行了分析；计及压坯脱模后残余应力，采用精度更高的指数型内聚力模型，对环形零件粉末冶金压坯运送过程中夹持裂纹损伤进行了有限元预测分析，进而结合零件技术要求对夹持工况参数进行了研究，得到了环形零件族粉末冶金压坯的极限夹持工况参数。
Powder metallurgy is an effective process of manufacturing near net shapeproducts. It offers many advantages, including high productivity, low production costs,less energy consumption and environmental friendship, which is widely concern inpowder metallurgy industry. Cracking in green compact has always been theimportant issue for a long time in powder metallurgy part industry. In fact, cracks ingreen compacts may occur in all phases of consolidation and handling process.Besides the traditional experience method, numerical simulation technology whichcombined with die and process design, is today a powerful tool in prediction of crackin powder metallurgy process in order to prevent the defect.
There is not a uniform mathematical model as the complex mechanism ofpowder compaction. So, little has been published about quantitative analysis of thecrack in green compacts. Thus, a generalized plastic mechanics model has beendeveloped to research the metal powder densification process in this work. And cracksand damage in metal powder compacts have been studied in different phases ofprocess. These provide an effective scientific method to improve the quality ofpowder metallurgy products and optimize the tool and process parameters. Specificareas of development described in this dissertation include:
1. A density-dependent generalized plastic mechanics model named modifiedDrucker-Prager Cap model was developed, which parameters were identified throughderivation by powder compaction experiment and strength tests of green compacts.And the model parameters of diffusion prealloyed iron powder Distaloy AE weredetermined as functions of relative density.
2. The constitutive model was implemented in Abaqus by writing a usersubroutine to three dimensional simulate the compaction process of metal powder.The simulation results agree well with the experiment data including the curve ofpressing force and relative density distribution.
3. The residual stresses were investigated by X-ray diffraction measurement.Two kinds of metal powder compacts (ASC100.29and Distaloy AE) have beenmeasured the residual stresses in different directions on surfaces based on differentpressing forces (450MPa and600MPa) and lubrication conditions. The test results were ananlyzed to obtain the residual stress distribution law of green compacts, whichhave been the validation criteria of residual stress finite element simulation.
4. The ejection process of green compact was simulated to predict the residualstress based on the calibrated constitutive model. The influence of model parameterson residual stress of green compact has been discussed. And the suitable parameterswere determined according to the experimental results. The finite element model wasfurther modified on the aspect of the stress calculation, which was the basis ofresearch on the crack and damage of green compact.
5. The ductile damage model was derived based on the modified Drucker-PragerCap model considering the mechanism of cracks on the powder compaction process.Meanwhile, the damage threshold of crack was identified.
6. The ductile damage model was implemented in Abaqus by writing a usersubroutine to predict the crack and damage in green compact during the pressing andejection process. Furthermore, the impact of factors including the geometric shape ofthe compacts, the lubrication of die and the taper of the die wall on the damge ofgreen compact was discussed.
7. The mechanical properties and fracture process of two kinds of greencompacts (ASC100.29and Distaloy AE) were investigated by the Brazilian disc testof circular loading. The paramenters including tensile strengtht, elastic modulus E,fracture toughness KIand fracture energy Gfas functions of relative density weredetermined according to the theoretical and numerical analysis and experimental data,which provided the reliable data for the damage and fracture simulation of greencompact.
8. Two kinds of fracture energy based cohesive zone models for metal powdercompacts were established. These models were analyzed combined with the Braziliandisc experiment results. The cracks and damage of the annular compact in handlingprocess was predict considering the residual stress after ejection by the exponent typecohesive zone model with higer simulation precision.
引文
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