喷丸强化改善点式移动感应淬火42CrMo钢残余应力数值模拟分析
|
摘要
目的建立喷丸强化模型,模拟点式移动感应淬火零件过渡区残余拉应力改善情况。方法采用X射线衍射法,测量感应淬火零件过渡区残余应力分布情况,获得的残余应力作为初始应力条件被赋予到喷丸强化模型中,并通过X射线残余应力测试验证模型预测残余应力的准确性。最终通过被验证的喷丸强化模型,探究喷丸处理对初始残余应力状态的改善情况,以及不同喷丸参数对残余应力分布的影响。结果经喷丸强化处理过的淬火零件过渡区表层区域残余拉应力全部转变为残余压应力,不同残余应力状态模型喷丸后残余应力分布差异极小,说明初始残余应力状态对喷丸后残余应力分布的影响微乎其微。增加喷丸速度、弹丸直径和喷丸覆盖率可使残余压应力值增大,残余压应力层深增加,但是二者的增加存在饱和现象,即达到一定程度后变化非常小。结论喷丸强化前,过渡区残余拉应力最大值为295 MPa,喷丸处理后,过渡区残余压应力最大可达-973 MPa,喷丸强化工艺对点式移动感应淬火零件过渡区残余应力改善效果明显。
The work aims to simulate improvement of residual tensile stresses in transitional area of the spot continual induction hardening(SCIH) components by establishing shot peening(SP) model. Distribution of residual stresses induced by SIH was measured in the method of X-ray diffraction, and resulting residual stresses were assigned to the SP model as initial residual stresses. The X-ray residual stress test was performed to verify accuracy of SP model-based residual stress prediction. Finally, the verified SP model was used to study improvement effect of SP on initial tensile residual stresses in transitional area and influences of SP parameters on the distribution of residual stresses. The tensile residual stresses in transitional area on the surface were transformed into compressive residual stresses after SP treatment. The difference in residual stress distribution of the model was very small after SP treatment in different residual stress states, which indicated that the residual stresses introduced by the previous process had little effect on the distribution of residual stress after SP. Increase in shot velocity, shot diameter and peening coverage could lead to increase in both compressive residual stresses and depth of compressive residual stresses. However, increase of the two was saturated, which meant that the values changed slightly after reaching a certain level. The maximum tensile residual stress in transitional area is 295 MPa before SP and-973 MPa after SP, which indicates that SP can improve distribution of tensile residual stresses in the transitional area of SCIH components efficiently.
The work aims to simulate improvement of residual tensile stresses in transitional area of the spot continual induction hardening(SCIH) components by establishing shot peening(SP) model. Distribution of residual stresses induced by SIH was measured in the method of X-ray diffraction, and resulting residual stresses were assigned to the SP model as initial residual stresses. The X-ray residual stress test was performed to verify accuracy of SP model-based residual stress prediction. Finally, the verified SP model was used to study improvement effect of SP on initial tensile residual stresses in transitional area and influences of SP parameters on the distribution of residual stresses. The tensile residual stresses in transitional area on the surface were transformed into compressive residual stresses after SP treatment. The difference in residual stress distribution of the model was very small after SP treatment in different residual stress states, which indicated that the residual stresses introduced by the previous process had little effect on the distribution of residual stress after SP. Increase in shot velocity, shot diameter and peening coverage could lead to increase in both compressive residual stresses and depth of compressive residual stresses. However, increase of the two was saturated, which meant that the values changed slightly after reaching a certain level. The maximum tensile residual stress in transitional area is 295 MPa before SP and-973 MPa after SP, which indicates that SP can improve distribution of tensile residual stresses in the transitional area of SCIH components efficiently.
引文
[1]陈浩,秦训鹏,汪舟,等.三维点式感应淬火电磁热耦合场数值模拟[J].中国表面工程,2013,26(1):79-85.CHEN Hao,QIN Xun-peng,WANG Zhou,et al.Finite element analysis of coupled electromagnetic thermal field for 3D spot induction hardening[J].China surface engineering,2013,26(1):79-85.
[2]中国机械工程学会热处理学会.热处理手册[M].北京:机械工业出版社,2008.China Society of Mechanical Engineering Heat Treatment Society.Heat treatment manual[M].Beijing:Machinery Industry Press,2008.
[3]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.
[4]倪兆荣,盛继生,吴雄彪,等.喷丸处理对汽车变速箱齿轮疲劳强度影响的研究[J].机械传动,2003,27(1):39-41.NI Zhao-rong,SHENG Ji-sheng,WU Xiong-biao,et al.The effect of shot peening on the strength of gears in automobile transmission[J].Journal of mechanical transmission,2003,27(1):39-41.
[5]王仁智,汝继来.汽车内燃机汽门弹簧表面强化处理中的若干问题[J].中国表面工程,2000,13(2):38-41.WANG Ren-zhi,RU Ji-lai.Several problems on the surface strengthening of valve spring in the automobile internalcombustion engine[J].China surface engineering,2000,13(2):38-41.
[6]陈娜,卢威.叶片类零件表面喷丸强化工艺研究[J].热加工工艺,2014(20):121-122.CHEN Na,LU Wei.Research of strengthening shot peen on parts for blade surface[J].Hot working technology,2014(20):121-122.
[7]石德勇.汽车曲轴模具的喷丸强化工艺与生产验证[J].铸造技术,2016(3):559-561.SHI De-yong.Shot peening strengthening of automobile crankshaft die and its application verification[J].Foundry technology,2016(3):559-561.
[8]戴如勇,于中奇,刘忠伟,等.渗碳淬火18CrNiMo7-6钢的表面喷丸强化及表征[J].机械工程材料,2013,37(5):100-102.DAI Ru-yong,YU Zhong-qi,LIU Zhong-wei,et al.Shot peening treatment and characterization of 18Cr Ni Mo7-6steel after carburizing and quenching[J].Materials for mechanical engineering,2013,37(5):100-102.
[9]刘保,汝学斌.强力喷丸对渗碳淬火零件表面质量的影响[J].热处理,2015(3):16-18.LIU Bao,RU Xue-bin.Effect of strong shot peening on surface quality of carburized and hardened part[J].Heat treatment,2015(3):16-18.
[10]王永芳,刘禹炯,冉广,等.1Cr12Ni3Mo2VN钢高频淬火过渡区的喷丸强化和残余应力[J].金属热处理,2006,31(5):53-56.WANG Yong-fang,LIU Yu-jiong,RAN Guang,et al.Shot peening and residual stress distribution in the induction hardening transition zone of 1Cr12Ni3Mo2VN steel[J].Heat treatment of metals,2006,31(5):53-56.
[11]孙献凯,田保红,周世永.柴油机曲轴中频淬火加喷丸处理残余应力分析[J].热加工工艺,2005(5):60-62.SUN Xian-kai,TIAN Bao-hong,ZHOU Shi-yong.Residual stress analysis of medium-frequency quenching for crankcase[J].Hot working technology,2005(5):60-62.
[12]MIAO H Y,LAROSE S,PERRON C,et al.On the potential applications of a 3D random finite element model for the simulation of shot peening[J].Advances in engineering software,2009,40(10):1023-1038.
[13]DIENG L,AMINE D,FALAISE Y,et al.Parametric study of the finite element modeling of shot peening on welded joints[J].Journal of constructional steel research,2017,130:234-247.
[14]凌祥,彭薇薇,倪红芳.喷丸三维残余应力场的有限元模拟[J].机械工程学报,2006,42(8):182-189.LING Xiang,PENG Wei-wei,NI Hong-fang.The finite element analysis of three-dimensional residual stress field for shot peening[J].Chinese journal of mechanical engineering,2006,42(8):182-189.
[15]张广良.不同强度钢喷丸残余应力的有限元模拟[D].上海:上海交通大学,2012.ZHANG Guang-liang.Study on finite element simulation of shot peening of different yield strength steel and its residual stress[D].Shanghai:Shanghai Jiao Tong University,2012.
[16]汪舟.马氏体不锈钢激光淬硬和喷丸实验研究与数值模拟[D].上海:上海交通大学,2011.WANG Zhou.Computer simulation and experimental investigation of laser hardening and shot peening process of martensitic stainless steel[D].Shanghai:Shanghai Jiao Tong University,2011.
[17]许世文,董满生,胡宗军,等.42CrMo钢疲劳试验研究[J].合肥工业大学学报(自然科学版),2008,31(9):1506-1508.XU Shi-wen,DONG Man-sheng,HU Zong-jun,et al.Fatigue test research on steel 42Cr Mo[J].Journal of Hefei University of Technology(natural science),2008,31(9):1506-1508.
[18]张文勇,张鬲君,陈亚维,等.42CrMo钢量化水淬应用研究[J].金属热处理,2007,32(11):101-103.ZHANG Wen-yong,ZHANG Ge-jun,CHEN Ya-wei,et al.Application of quantified water quenching on 42Cr Mo steel[J].Heat treatment of metals,2007,32(11):101-103.
[19]KLEMENZ M.Anwendung der Simulation der Randschichtausbildung beim Kugelstrahlen auf die Absch?tzung der Schwingfestigkeit gekerbter Bauteile[D].Karlsruhe:Karlsruhe University,2009.
[20]MACHERAUCH E,MüLLER P.Das sin2ψ-Verfahren der r?ntgenographischen Spannungsmes-sung[J].Z Angew Phys,1961,13:340-345.
[21]NOYAN I C,COHEN J B.Residual stress-measurement by diffraction and interpretation[M].New York:Springer Verlg,1987.
[22]MOORE M G,EVANS W P.Mathematical correction for stress in removed layers in X-ray diffraction RS analysis[J].SAE Trans,1958,66:340-345.
[23]GAMBIRASIO L,RIZZI E.On the calibration strategies of the Johnson-Cook strength model:discussion and applications to experimental data[J].Mater scieng A,2014,610:370-413.
[24]HIBBITT H D,KARLSSON B I,SORENSEN P.ABAQUS Analysis user’s manual(2010),version 6.10[EB/OL].[2018-04-03].http://laptop-t1ra1n18:2080/v6.10/books/usb/sb/default.htm.
[25]KLEMENZ M,SCHULZE V,V?HRINGER O,et al.Finite element simulation of the residual stress states after shot peening[J].Materials science forum,2006,2006:349-354.
[26]杨新俊.超声冲击处理改善AISI304不锈钢表面完整性及力学性能研究[D].南京:南京工业大学,2014.YANG Xin-jun.Effects of ultrasonic impact treatment on improvements of mechanical properties and surface integrity of AISI304 stainless steel[D].Nanjing:Nanjing Tech University,2014.
[2]中国机械工程学会热处理学会.热处理手册[M].北京:机械工业出版社,2008.China Society of Mechanical Engineering Heat Treatment Society.Heat treatment manual[M].Beijing:Machinery Industry Press,2008.
[3]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.
[4]倪兆荣,盛继生,吴雄彪,等.喷丸处理对汽车变速箱齿轮疲劳强度影响的研究[J].机械传动,2003,27(1):39-41.NI Zhao-rong,SHENG Ji-sheng,WU Xiong-biao,et al.The effect of shot peening on the strength of gears in automobile transmission[J].Journal of mechanical transmission,2003,27(1):39-41.
[5]王仁智,汝继来.汽车内燃机汽门弹簧表面强化处理中的若干问题[J].中国表面工程,2000,13(2):38-41.WANG Ren-zhi,RU Ji-lai.Several problems on the surface strengthening of valve spring in the automobile internalcombustion engine[J].China surface engineering,2000,13(2):38-41.
[6]陈娜,卢威.叶片类零件表面喷丸强化工艺研究[J].热加工工艺,2014(20):121-122.CHEN Na,LU Wei.Research of strengthening shot peen on parts for blade surface[J].Hot working technology,2014(20):121-122.
[7]石德勇.汽车曲轴模具的喷丸强化工艺与生产验证[J].铸造技术,2016(3):559-561.SHI De-yong.Shot peening strengthening of automobile crankshaft die and its application verification[J].Foundry technology,2016(3):559-561.
[8]戴如勇,于中奇,刘忠伟,等.渗碳淬火18CrNiMo7-6钢的表面喷丸强化及表征[J].机械工程材料,2013,37(5):100-102.DAI Ru-yong,YU Zhong-qi,LIU Zhong-wei,et al.Shot peening treatment and characterization of 18Cr Ni Mo7-6steel after carburizing and quenching[J].Materials for mechanical engineering,2013,37(5):100-102.
[9]刘保,汝学斌.强力喷丸对渗碳淬火零件表面质量的影响[J].热处理,2015(3):16-18.LIU Bao,RU Xue-bin.Effect of strong shot peening on surface quality of carburized and hardened part[J].Heat treatment,2015(3):16-18.
[10]王永芳,刘禹炯,冉广,等.1Cr12Ni3Mo2VN钢高频淬火过渡区的喷丸强化和残余应力[J].金属热处理,2006,31(5):53-56.WANG Yong-fang,LIU Yu-jiong,RAN Guang,et al.Shot peening and residual stress distribution in the induction hardening transition zone of 1Cr12Ni3Mo2VN steel[J].Heat treatment of metals,2006,31(5):53-56.
[11]孙献凯,田保红,周世永.柴油机曲轴中频淬火加喷丸处理残余应力分析[J].热加工工艺,2005(5):60-62.SUN Xian-kai,TIAN Bao-hong,ZHOU Shi-yong.Residual stress analysis of medium-frequency quenching for crankcase[J].Hot working technology,2005(5):60-62.
[12]MIAO H Y,LAROSE S,PERRON C,et al.On the potential applications of a 3D random finite element model for the simulation of shot peening[J].Advances in engineering software,2009,40(10):1023-1038.
[13]DIENG L,AMINE D,FALAISE Y,et al.Parametric study of the finite element modeling of shot peening on welded joints[J].Journal of constructional steel research,2017,130:234-247.
[14]凌祥,彭薇薇,倪红芳.喷丸三维残余应力场的有限元模拟[J].机械工程学报,2006,42(8):182-189.LING Xiang,PENG Wei-wei,NI Hong-fang.The finite element analysis of three-dimensional residual stress field for shot peening[J].Chinese journal of mechanical engineering,2006,42(8):182-189.
[15]张广良.不同强度钢喷丸残余应力的有限元模拟[D].上海:上海交通大学,2012.ZHANG Guang-liang.Study on finite element simulation of shot peening of different yield strength steel and its residual stress[D].Shanghai:Shanghai Jiao Tong University,2012.
[16]汪舟.马氏体不锈钢激光淬硬和喷丸实验研究与数值模拟[D].上海:上海交通大学,2011.WANG Zhou.Computer simulation and experimental investigation of laser hardening and shot peening process of martensitic stainless steel[D].Shanghai:Shanghai Jiao Tong University,2011.
[17]许世文,董满生,胡宗军,等.42CrMo钢疲劳试验研究[J].合肥工业大学学报(自然科学版),2008,31(9):1506-1508.XU Shi-wen,DONG Man-sheng,HU Zong-jun,et al.Fatigue test research on steel 42Cr Mo[J].Journal of Hefei University of Technology(natural science),2008,31(9):1506-1508.
[18]张文勇,张鬲君,陈亚维,等.42CrMo钢量化水淬应用研究[J].金属热处理,2007,32(11):101-103.ZHANG Wen-yong,ZHANG Ge-jun,CHEN Ya-wei,et al.Application of quantified water quenching on 42Cr Mo steel[J].Heat treatment of metals,2007,32(11):101-103.
[19]KLEMENZ M.Anwendung der Simulation der Randschichtausbildung beim Kugelstrahlen auf die Absch?tzung der Schwingfestigkeit gekerbter Bauteile[D].Karlsruhe:Karlsruhe University,2009.
[20]MACHERAUCH E,MüLLER P.Das sin2ψ-Verfahren der r?ntgenographischen Spannungsmes-sung[J].Z Angew Phys,1961,13:340-345.
[21]NOYAN I C,COHEN J B.Residual stress-measurement by diffraction and interpretation[M].New York:Springer Verlg,1987.
[22]MOORE M G,EVANS W P.Mathematical correction for stress in removed layers in X-ray diffraction RS analysis[J].SAE Trans,1958,66:340-345.
[23]GAMBIRASIO L,RIZZI E.On the calibration strategies of the Johnson-Cook strength model:discussion and applications to experimental data[J].Mater scieng A,2014,610:370-413.
[24]HIBBITT H D,KARLSSON B I,SORENSEN P.ABAQUS Analysis user’s manual(2010),version 6.10[EB/OL].[2018-04-03].http://laptop-t1ra1n18:2080/v6.10/books/usb/sb/default.htm.
[25]KLEMENZ M,SCHULZE V,V?HRINGER O,et al.Finite element simulation of the residual stress states after shot peening[J].Materials science forum,2006,2006:349-354.
[26]杨新俊.超声冲击处理改善AISI304不锈钢表面完整性及力学性能研究[D].南京:南京工业大学,2014.YANG Xin-jun.Effects of ultrasonic impact treatment on improvements of mechanical properties and surface integrity of AISI304 stainless steel[D].Nanjing:Nanjing Tech University,2014.