高强铝合金板淬火及残余应力研究
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摘要
高强铝合金厚板具有比重小、比强度比刚度大等一系列优点，近年来广泛应用于航空航天、武器装备、汽车等行业中。铝合金厚板经固溶、淬火时效后有大量弥散强化相析出，可使其强度显著提高。但剧烈冷却的过程极容易在厚板中产生严重的淬火残余应力，使厚板在后续机械加工时出现弯曲和翘曲变形，还会影响材料的动态使用性能如断裂韧度，抗应力腐蚀性能等。因此，为了满足工业的需要，控制淬火残余应力的大小具有非常大的实际意义。
本文采用有限元分析方法，利用Deform软件模拟铝合金厚板的淬火冷却过程，同时利用点跟踪技术得到了淬火温度场分布、淬火冷却曲线、淬火残余应力分布场；系统研究了淬火后该合金板件的残余应力消除工艺，具体研究内容及结果有：
采用X射线衍射法测量了经残余应力校正工艺后沿厚度方向板件表层的残余应力分布情况。结果表明，沿厚度方向板件侧表面的中心部分应力为拉应力，其最大拉应力位于离上表面130mm处为76MPa；板件上下表面附近处的应力基本上都是压应力，最大压应力位于板件的下表面处，为-113MPa。
1．利用有限元软件deform-3D模拟了铝合金板件的淬火冷却过程，同时利用点跟踪技术得到了淬火温度场分布、淬火冷却曲线、淬火残余应力分布场。在淬火过程中板件内外存在着很大的温度梯度，当淬火到500s时，最大温度梯度可达370℃。这种冷热不均的温度将使板件在淬火后产生很大的残余应力。淬火结束后，板件上残余应力表现为内拉外压。最大压应力位于板件表面上，为-150MPa；而最大拉应力则位于板件心部附近，为153MPa。板件在淬火后，其三向残余应力都为内拉外压。在长宽厚方向上，主要受X向残余应力作用，Y、Z向残余应力作用很小。
3．采用Deform-3D模拟了垫块压缩法消除淬火后板件残余应力的工序，优化了垫块宽度及压下量等控制参数。制定了正反两方向垫块压缩板件消除残余应力的工艺方案，并对压缩过程进行了数值模拟。通过点跟踪技术分析得到了正反两方向垫块压缩后板件的残余应力分布情况。结果表明，第一次下压3.6mm后再反向下压2.4mm,可使板件的残余应力得到较好的控制。当第一次采用3.6mm的压缩量时，可得到板件较小的残余应力值，增大或较小这个临界压缩量都不利于有效控制残余应力。在经过第二次反向下压2.4mm后，板件的X方向应力分量值整体上变得更为均匀；侧面上的压应力由-135MPa减为零-57MPa，中部到下表面的拉应力也减小到了45MPa以内。
The high strength aluminum alloy thick plate with a small proportion, theintensity ratio of specific strength and specific stiffness of a series of advantages,is widely used in aerospace, weapons, equipment, and automobile industries inrecent years. Thick aluminum alloy plate after solid solution quenching afteraging a large number of dispersion strengthening precipitates may be its strengthsignificantly improved. Intense cooling process is very easy in the slab togenerate serious residual stress of quenched, so that the thick plate bending andwarpage in the subsequent machining, will also affect the dynamic use of thematerial properties such as fracture toughness, stress corrosion resistance and soon. Therefore, in order to meet the needs of industry, control the size of theresidual stress of quenched very great practical significance. Using the finiteelement analysis methods, the use of the quenching process of deform softwaresimulation of thick aluminum alloy plate, quenching temperature distribution atthe same time point tracking technology to quench curve, quenching residualstress distribution field; System to study the residual stress after quenching thealloy plate to eliminate the process, specific research contents and results:
1. X-ray diffraction method measured by the residual stress correctionprocess, the residual stress distribution plate surface along the thicknessdirection. The results showed that the plate along the thickness direction sidesurface of the central part of the stress is tensile stress, its maximum tensilestress is located from the upper surface of130mm at76MPa;Plates near thesurface at the upper and lower stress are basically compressive stress, themaximum compressive stress is located in the lower surface of the platesat-113MPa.
2. Using finite element software deform-3D simulation of the aluminumalloy plate quench process, the quenching temperature distribution while takingadvantage of tracking technology to quench curve, quenching residual stressdistribution field. Plates inside and outside in the quenching process there is alarge temperature gradient, the maximum temperature gradient of up to370°C. When quenched to500s.The Enthusiasm of temperature would make the board alot of residual stress after quenching. After quenching, the residual stress in theplate on the performance of the outside pressure is within the pull. Themaximum compressive stress at the surface of the plates is-150MPa; themaximum tensile stress in the plates near the core part, as153MPa.Plates afterquenching, the residual stress of the three-way is within the pull externalpressure. In the long generous direction, mainly due to the role of the X to theresidual stress, Y, and Z to the residual stress is very small.
3. Using the Deform-3D simulation of the plates of pad compressionmethod to eliminate the quenching residual stress of the process, optimizing thecontrol parameters of the pad width and reduction. To develop the pros and consof the direction pad compression plates to eliminate the residual stress of theprocess program, and the compression process was simulated. The analysis hasbeen both positive and negative direction pad compression plates residual stressdistribution through a point of tracking technology. The results showed that forthe first time under the pressure of the pressure2.4mm3.6mm and then reversethe residual stress of the enable the board to get better control. When first using3.6mm compression, available to board a smaller residual stress values largeror smaller this critical amount of compression is not conducive to effectivecontrol of residual stress.2.4mm after the pressure of the second reverse, theboard of the X direction stress component value as a whole has become moreuniform; compressive stress on the side reduced to zero-57MPa-135MPa, centralto the under surface of the tensile stress reduced to less than45MPa.
本文采用有限元分析方法，利用Deform软件模拟铝合金厚板的淬火冷却过程，同时利用点跟踪技术得到了淬火温度场分布、淬火冷却曲线、淬火残余应力分布场；系统研究了淬火后该合金板件的残余应力消除工艺，具体研究内容及结果有：
采用X射线衍射法测量了经残余应力校正工艺后沿厚度方向板件表层的残余应力分布情况。结果表明，沿厚度方向板件侧表面的中心部分应力为拉应力，其最大拉应力位于离上表面130mm处为76MPa；板件上下表面附近处的应力基本上都是压应力，最大压应力位于板件的下表面处，为-113MPa。
1．利用有限元软件deform-3D模拟了铝合金板件的淬火冷却过程，同时利用点跟踪技术得到了淬火温度场分布、淬火冷却曲线、淬火残余应力分布场。在淬火过程中板件内外存在着很大的温度梯度，当淬火到500s时，最大温度梯度可达370℃。这种冷热不均的温度将使板件在淬火后产生很大的残余应力。淬火结束后，板件上残余应力表现为内拉外压。最大压应力位于板件表面上，为-150MPa；而最大拉应力则位于板件心部附近，为153MPa。板件在淬火后，其三向残余应力都为内拉外压。在长宽厚方向上，主要受X向残余应力作用，Y、Z向残余应力作用很小。
3．采用Deform-3D模拟了垫块压缩法消除淬火后板件残余应力的工序，优化了垫块宽度及压下量等控制参数。制定了正反两方向垫块压缩板件消除残余应力的工艺方案，并对压缩过程进行了数值模拟。通过点跟踪技术分析得到了正反两方向垫块压缩后板件的残余应力分布情况。结果表明，第一次下压3.6mm后再反向下压2.4mm,可使板件的残余应力得到较好的控制。当第一次采用3.6mm的压缩量时，可得到板件较小的残余应力值，增大或较小这个临界压缩量都不利于有效控制残余应力。在经过第二次反向下压2.4mm后，板件的X方向应力分量值整体上变得更为均匀；侧面上的压应力由-135MPa减为零-57MPa，中部到下表面的拉应力也减小到了45MPa以内。
The high strength aluminum alloy thick plate with a small proportion, theintensity ratio of specific strength and specific stiffness of a series of advantages,is widely used in aerospace, weapons, equipment, and automobile industries inrecent years. Thick aluminum alloy plate after solid solution quenching afteraging a large number of dispersion strengthening precipitates may be its strengthsignificantly improved. Intense cooling process is very easy in the slab togenerate serious residual stress of quenched, so that the thick plate bending andwarpage in the subsequent machining, will also affect the dynamic use of thematerial properties such as fracture toughness, stress corrosion resistance and soon. Therefore, in order to meet the needs of industry, control the size of theresidual stress of quenched very great practical significance. Using the finiteelement analysis methods, the use of the quenching process of deform softwaresimulation of thick aluminum alloy plate, quenching temperature distribution atthe same time point tracking technology to quench curve, quenching residualstress distribution field; System to study the residual stress after quenching thealloy plate to eliminate the process, specific research contents and results:
1. X-ray diffraction method measured by the residual stress correctionprocess, the residual stress distribution plate surface along the thicknessdirection. The results showed that the plate along the thickness direction sidesurface of the central part of the stress is tensile stress, its maximum tensilestress is located from the upper surface of130mm at76MPa;Plates near thesurface at the upper and lower stress are basically compressive stress, themaximum compressive stress is located in the lower surface of the platesat-113MPa.
2. Using finite element software deform-3D simulation of the aluminumalloy plate quench process, the quenching temperature distribution while takingadvantage of tracking technology to quench curve, quenching residual stressdistribution field. Plates inside and outside in the quenching process there is alarge temperature gradient, the maximum temperature gradient of up to370°C. When quenched to500s.The Enthusiasm of temperature would make the board alot of residual stress after quenching. After quenching, the residual stress in theplate on the performance of the outside pressure is within the pull. Themaximum compressive stress at the surface of the plates is-150MPa; themaximum tensile stress in the plates near the core part, as153MPa.Plates afterquenching, the residual stress of the three-way is within the pull externalpressure. In the long generous direction, mainly due to the role of the X to theresidual stress, Y, and Z to the residual stress is very small.
3. Using the Deform-3D simulation of the plates of pad compressionmethod to eliminate the quenching residual stress of the process, optimizing thecontrol parameters of the pad width and reduction. To develop the pros and consof the direction pad compression plates to eliminate the residual stress of theprocess program, and the compression process was simulated. The analysis hasbeen both positive and negative direction pad compression plates residual stressdistribution through a point of tracking technology. The results showed that forthe first time under the pressure of the pressure2.4mm3.6mm and then reversethe residual stress of the enable the board to get better control. When first using3.6mm compression, available to board a smaller residual stress values largeror smaller this critical amount of compression is not conducive to effectivecontrol of residual stress.2.4mm after the pressure of the second reverse, theboard of the X direction stress component value as a whole has become moreuniform; compressive stress on the side reduced to zero-57MPa-135MPa, centralto the under surface of the tensile stress reduced to less than45MPa.
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