车体钢结构表面喷丸强化有限元分析
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摘要
本课题从车体钢结构亟需提高其使用寿命的实际需求出发,运用计算机仿真技术对车体钢结构进行喷丸强化过程的运动仿真,通过喷丸工艺引起的应力、应变场进行数值模拟,运用有限单元法对弹丸撞击后钢板材料表面应力、应变的分布进行了数值计算和统计分析。研究了喷射速度、喷射角度和弹丸直径与残余应力、应变的关系,选择几组典型参数比较,分析不同情况下喷丸对局部变形的影响,进而对车体钢结构喷丸强化工艺参数进行了优化选择。对得到的优化参数进行试验研究,主要研究喷射速度和角度对钢结构表面强化效果的影响规律。
首先建立了有限元模型,设定喷射速度分别为40m/s、60m/s、80m/s、100m/s,喷射角度分别为45°、60°、75°、90°,弹丸直径分别为φ0.8mm、φ1.0mm、φ1.2mm、φ1.6mm、φ2.0mm的情况下,进行单粒弹丸冲击同一目标钢板的喷丸强化过程仿真分析。分析结果表明目标钢板受到弹丸反复冲击时应力和应变的变化规律是:喷射速度和弹丸直径对应力、应变影响很大,而喷射角度主要影响应变。
通过对弹丸直径、喷射速度、喷射角度工艺参数优化,得出:对于弹丸直径为φ1.0mm,喷射角度为90°,选60～80m/s的速度可以获得较好的综合效果;对于喷射速度为80m/s,弹丸直径为1.0mm,喷射角度为60°较合适;喷射速度为80m/s,喷射角度为90°,弹丸直径应取φ1.0～φ1.2mm。
对所确定的优化工艺参数进行了试验研究,主要分析了强化钢板表面宏观粗糙度和硬度的变化规律,从中得出:在其它工艺参数相同时,弹丸速度越大,表面粗糙度Ra升高越大;喷射角度越大,表面粗糙度越大。速度为60m/s时表面硬度提高24.1%;速度为80m/s时,表面硬度提高38.6%;而在其它工艺参数相同时,喷射角度对硬度的影响基本一致,角度为60°时表面硬度提高24.1%;角度为90°时表面硬度提高27.6%。速度一定时,喷射角度为60°比90°。能更好地改善钢板表面质量。角度一定时,仅仅考虑速度对钢板表面粗糙度的影响,60m/s的速度更合适。这一结论与模拟计算得出的优化参数是一致的。
本课题的结果和研究方法应用于铁道车辆的生产与制造,将有助于材料表面处理时选择恰当的工艺参数,对提高车体钢结构表面质量,延长车辆使用寿命有重要的现实意义。
This topic researched on how to enhance its service life of the chassis steel structure urgently according to our actual demand. It carries on using the computer simulation technology to the chassis steel structure shot peening strengthening process the movement simulation, through shot peening the stress, the strain field which the pill craft caused carries on the value simulation, the utilization limited unit law to the projectile hit rear spring material surface stress, the strain distribution has carried on the value computation and the statistical analysis. I have discussed the relations between the jet speed, spray angle, the projectile diameter, the residual stress and the strain. I choose several groups of typical parameters to compare, in the analysis different situationshot peening to the local distortion influence, then shot peening strengthening craft parameter to the chassis steel structure to carry on the optimized choice. To the optimized parameter which obtains has conducted the experimental study, mainly discussed the jet velocity and the angle to the steel structure surface strengthening effect influence rule.
Firstly I have establishedshot peening strengthening finite element model at the jet velocity as 40m/s, 60m/s, 80m/s, 100m/s, the spray angle for 45°, 60°, 75°, 90°, the projectile diameter ;0.8mm, 1.0mm,1.2mm,1.6mm,2.0mm, the impact identical goal steel plate single grain of the pill. I have carried on the movement simulation using the finite element software to the establishment each kind of finite element model, had discovered the goal steel plate receives the projectile attacks repeatedly when the stress and the strain change rule: The jet velocity and the projectile diameter counter stress, the strain influence are very big, but spray angle major effect strain.
Through to the projectile diameter, the jet velocity, the spray angle craft parameter optimizes, obtains: Regarding the 1mm diameter projectile, the spray angle for 90°, chooses 60～80m/s the speed to be possible to obtain the good comprehensive effect; Regarding the jet velocity is 80m/s, the projectile diameter for 1.0mm, spray angle for 60°appropriate; The jet velocity is 80m/s, the spray angle for 90°, the projectile diameter should take 1.0～1.2mm.
To the optimized craft parameter which determined has conducted the experimental study, mainly has analyzed the strengthened steel plate surface macroscopic roughness and hardness changed rule, I found: When other craft parameter same, the projectile speed is bigger, the surface roughness Ra ascension is bigger; The spray angle is bigger, the surface roughness is bigger. The speed is when 60m/s the surface hardness enhances 24.1%. The speed is when 80m/s the surface hardness enhances 38.6%.But when other craft parameter same, spray angle to degree of hardness influence basic consistent, angle for 60°when the surface hardness enhances 24.1%; Angle for 90°when the surface hardness enhances 27.6%. When speed certain, the angle for 60°compared to 90°can improve the steel plate surface quality well. When angle fixed, considered merely the speed to the steel plate surface roughness influence, the 60m/s speed is more appropriate. This conclusion is consistent with the optimized parameter which obtains with the analog computation.
On the one hand the experiment explained this topic will use the research technique feasibility, more importantly the result and the method apply in the railroad vehicles manufacturing industry, will be helpful to when will carry on the surface treatment chooses the appropriate craft parameter, thus will improve the chassis steel structure surface quality, will lengthen the vehicles service life.
首先建立了有限元模型,设定喷射速度分别为40m/s、60m/s、80m/s、100m/s,喷射角度分别为45°、60°、75°、90°,弹丸直径分别为φ0.8mm、φ1.0mm、φ1.2mm、φ1.6mm、φ2.0mm的情况下,进行单粒弹丸冲击同一目标钢板的喷丸强化过程仿真分析。分析结果表明目标钢板受到弹丸反复冲击时应力和应变的变化规律是:喷射速度和弹丸直径对应力、应变影响很大,而喷射角度主要影响应变。
通过对弹丸直径、喷射速度、喷射角度工艺参数优化,得出:对于弹丸直径为φ1.0mm,喷射角度为90°,选60～80m/s的速度可以获得较好的综合效果;对于喷射速度为80m/s,弹丸直径为1.0mm,喷射角度为60°较合适;喷射速度为80m/s,喷射角度为90°,弹丸直径应取φ1.0～φ1.2mm。
对所确定的优化工艺参数进行了试验研究,主要分析了强化钢板表面宏观粗糙度和硬度的变化规律,从中得出:在其它工艺参数相同时,弹丸速度越大,表面粗糙度Ra升高越大;喷射角度越大,表面粗糙度越大。速度为60m/s时表面硬度提高24.1%;速度为80m/s时,表面硬度提高38.6%;而在其它工艺参数相同时,喷射角度对硬度的影响基本一致,角度为60°时表面硬度提高24.1%;角度为90°时表面硬度提高27.6%。速度一定时,喷射角度为60°比90°。能更好地改善钢板表面质量。角度一定时,仅仅考虑速度对钢板表面粗糙度的影响,60m/s的速度更合适。这一结论与模拟计算得出的优化参数是一致的。
本课题的结果和研究方法应用于铁道车辆的生产与制造,将有助于材料表面处理时选择恰当的工艺参数,对提高车体钢结构表面质量,延长车辆使用寿命有重要的现实意义。
This topic researched on how to enhance its service life of the chassis steel structure urgently according to our actual demand. It carries on using the computer simulation technology to the chassis steel structure shot peening strengthening process the movement simulation, through shot peening the stress, the strain field which the pill craft caused carries on the value simulation, the utilization limited unit law to the projectile hit rear spring material surface stress, the strain distribution has carried on the value computation and the statistical analysis. I have discussed the relations between the jet speed, spray angle, the projectile diameter, the residual stress and the strain. I choose several groups of typical parameters to compare, in the analysis different situationshot peening to the local distortion influence, then shot peening strengthening craft parameter to the chassis steel structure to carry on the optimized choice. To the optimized parameter which obtains has conducted the experimental study, mainly discussed the jet velocity and the angle to the steel structure surface strengthening effect influence rule.
Firstly I have establishedshot peening strengthening finite element model at the jet velocity as 40m/s, 60m/s, 80m/s, 100m/s, the spray angle for 45°, 60°, 75°, 90°, the projectile diameter ;0.8mm, 1.0mm,1.2mm,1.6mm,2.0mm, the impact identical goal steel plate single grain of the pill. I have carried on the movement simulation using the finite element software to the establishment each kind of finite element model, had discovered the goal steel plate receives the projectile attacks repeatedly when the stress and the strain change rule: The jet velocity and the projectile diameter counter stress, the strain influence are very big, but spray angle major effect strain.
Through to the projectile diameter, the jet velocity, the spray angle craft parameter optimizes, obtains: Regarding the 1mm diameter projectile, the spray angle for 90°, chooses 60～80m/s the speed to be possible to obtain the good comprehensive effect; Regarding the jet velocity is 80m/s, the projectile diameter for 1.0mm, spray angle for 60°appropriate; The jet velocity is 80m/s, the spray angle for 90°, the projectile diameter should take 1.0～1.2mm.
To the optimized craft parameter which determined has conducted the experimental study, mainly has analyzed the strengthened steel plate surface macroscopic roughness and hardness changed rule, I found: When other craft parameter same, the projectile speed is bigger, the surface roughness Ra ascension is bigger; The spray angle is bigger, the surface roughness is bigger. The speed is when 60m/s the surface hardness enhances 24.1%. The speed is when 80m/s the surface hardness enhances 38.6%.But when other craft parameter same, spray angle to degree of hardness influence basic consistent, angle for 60°when the surface hardness enhances 24.1%; Angle for 90°when the surface hardness enhances 27.6%. When speed certain, the angle for 60°compared to 90°can improve the steel plate surface quality well. When angle fixed, considered merely the speed to the steel plate surface roughness influence, the 60m/s speed is more appropriate. This conclusion is consistent with the optimized parameter which obtains with the analog computation.
On the one hand the experiment explained this topic will use the research technique feasibility, more importantly the result and the method apply in the railroad vehicles manufacturing industry, will be helpful to when will carry on the surface treatment chooses the appropriate craft parameter, thus will improve the chassis steel structure surface quality, will lengthen the vehicles service life.
引文
1孙双进.开发生产不锈钢客车提高我国客车制造水平.铁道车辆.1998,36(6):18-21
2Vijay k.Garg.Dynamics of Railway Vehicle Systems,T F 550.G35,1984
3F Mang,O Cubak.Comparative Study on the behaviors of Steel and Aluminium Hollow Section Joints Subjected to static and Dynamic Lodaing.Aluminium Structures,I CSAS.Singpor,1991
4陈世和.车辆钢结构腐蚀与防护.北京:中国铁道出版社,1994
5杨松柏.铁路货车车体材料的现状和需求.铁道机车车辆.2006,26(1):1-3
6严隽耄.车辆工程.北京:中国铁道出版社,2006
7袁礼.喷丸强化工艺技术的研究与改进.成飞科技,2006,(2):22-26
8GAbul Fazal.Arif M.Numerical prediction of plastic deformation and residual stress induced by laser shock processing.Journal of Materials Procesing Technology,2003,136:120-138
9Graham Hammersley,etal.Surface prestressing to improve fatigue strength of component by laser shot peening.Optics and Laser in Engineering,2000,34:327-337
10Wenwu Zhang,Lawrence Yao.Micro scale laser shock processing of metallic component.Journal of Manufacturing Science Engineering,2002,24(5):369-378
11张兴权,戴亚春,杜为民,王广龙,汪邦富.金属零件表面改性的喷丸强化技术.电加工与模具.2005,(2):30-32
12陈志新.喷丸工艺的现状及其发展.凿岩机械气动工具.1997,(2):55-59
13储继影,关占群,李占杰.喷丸强化效果和质量的表征指标及影响因素.汽轮机技术.2003,45(4):255-256
14.GAbul Fazal,Arif M.NumeficM prediction of plastic deformation and residual stress induced by laser shock processing.Journal of Materials Processing Technology,2003,136:120-138
15戴达煌,周克崧,袁镇海.现代材料表面技术科学.北京:冶金工业出版社,2004
16倪红芳,凌祥,彭薇薇.玻璃喷丸处理提高304不锈钢焊接接头抗应力腐蚀性能的研究.中国腐蚀与防护学报,2005,25(3):152-156
17李雁淮,王飞,吕坚,徐可为.单丸粒喷丸模型和多丸粒喷丸模型的有限元模拟.西安交通大学学报.2007,41(3):349-352
18Iida K.Dent and affected layer produced by shot peening Fuchs H O.Proc 2nd Int Conf on Shot Peening.Chicago:The American Society for Shot Peening,1984:283-292.
19Edberg J,Lindgren L,Mori K.Shot peening simulated by two different finite element formulations Shen Shanfu,Dawson P.Simulation of Materials Processing:Theory,Methods and Applications.Rotterdam,Netherlands:Balkema,1995:425-430
20刘文泉.喷丸强化.吉林工学院学报.1992,13(3、4):35-40
21Meguid S A,Shagal G,Stranart J C.Three dimensional Dynamic Finite Element Analysis of Shot-peening Induced Residual Stresses.Finite Elements in Analysis and Design.1999(31):179-191
22凌祥,彭薇薇,倪红芳.喷丸三维残余应力场的有限元模拟.机械工程学报.2006,42(8):182-189
23吴钢,侯占忠.提高水力机械抗磨蚀性能的喷丸工艺数值分析.水电能源科学.2006,24(1):1-3
24Al-Hassani S T S.Mechanical Aspects of Residual Stress Development in Shot Peening.Proceeding of First International Conference on Shot Peening,Paris,1982
25A1-Hassani S T S.An Engineering Approach to Shot Peening Mechanics.Proceeding of the Second International Conference on Shot Peening,Chicago,1984
26Iida K.Dent and Affected Layer Produced by Shot Peening.Proceeding of the Second International Conference on Shot Peening,Chicago,1984
27Meguid S A,Shagal G,Stranart J C.Three-dimension dynamic Finite Element Analysis of Shot peening Induced Residual Stress.Finite Elements in Analysis and Design,1999,31:179-191
28Baragetti S,Gualiano M,Vergani L.A Numerical Procedure for Shot Peening Optimization by Means of Non-dimensional Factors.Inter.J.Mater.And Product Tech.2000,15:91-103
29Baragetti S,Terranova A.Nondimensional Analysis of Shot peening by Means of DOE.Intern J.Mater Product Tech.2000.15:131-141
30Baragetti S.Three dimensional Finite element Procedures for Shot Peening Residual Stress Field Prediction.Intern J.Computer Appl.in Tech.2001.14:51-63
31Vantuchene R D.Cramer E J.Numerical Modeling of a Wing Skin Peen Forming Process J.Mater Eng Perf.,1996,5(6):753-760
32Guagliano M,VerganiL.An Approach for Prediction of Fatigue Strength of Shot Peened Components.Engng Fract Mech.2004,71:501-512
33康小明.窄条喷丸成形的数值模拟.航空学报.2002,23(1):94-96
34康小明.有限元法在机翼整体壁板成形中的应用.中国机械工程,2002,13(2):134-136
35Gao Y K,Yao M,Li J K.An Analysis of Residual Stress Fields Caused by Shot Peening.Metal lurgical and Mater Trans.2002,A33:1775-1778
36姚枚,王声平,李金魁,等.表面强化件的疲劳强度分析及金属的内部疲劳极限.金属学报,1993,29(11):511-519
37栾伟玲,涂善东.喷丸表面改性技术的研究进展.中国机械工程.2003,16(15):1405-1409
38刘惠民.铁道车辆构造检修及装备.北京:中国铁道出版社,2000
39彭明镜.喷丸强化技术最新进展与装备.中国铸机,2004,(1):43-44
40方博武.受控喷丸与残余应力理论.济南:山东科学技术出版社,1991
41凌祥,彭薇薇,倪红芳.喷丸三维残余应力场的有限元模拟.机械工程学报.2006,42(8):182-188
42何涛,杨竞,金鑫.ANSYS10.0/LS-DYNA非线性有限元分析.北京:机械工业出版社,2007
43李裕春,时党勇,赵远.ANSYS10.0/LS-DYNA基础理论与工程实践.北京:中国水利水电出版社,2006
44胡凯征,吴建军,王涛,敖志强.基于温度场的喷丸成形数值模拟及参数优化.中国机械工程.2007,18(3):292-295
45Wang T,Platts M J.A Computer-aided Blank Design Method for the Peen Forming Process.Journal of Materials Processing Technology.2002,122:374-380
46Wang T,Platts M J,Levers A.A Process Model for Shot Peen Forming.Journal of Materials Processing Technology.2006,172:159-162
47Levers A,Prior A.Finite Element Analysis of Shot Peening.Journal of Materials Processing Technology.1998,80/81:304-308
48J.G.A.Biter.A study of erosion phenomena,Part l.Wear.1963,(6):5-21
49丁明伟.新型SiC/(W,Ti)C陶瓷喷砂嘴的研究开发及其应用.山东大学硕士学位论文.2006
2Vijay k.Garg.Dynamics of Railway Vehicle Systems,T F 550.G35,1984
3F Mang,O Cubak.Comparative Study on the behaviors of Steel and Aluminium Hollow Section Joints Subjected to static and Dynamic Lodaing.Aluminium Structures,I CSAS.Singpor,1991
4陈世和.车辆钢结构腐蚀与防护.北京:中国铁道出版社,1994
5杨松柏.铁路货车车体材料的现状和需求.铁道机车车辆.2006,26(1):1-3
6严隽耄.车辆工程.北京:中国铁道出版社,2006
7袁礼.喷丸强化工艺技术的研究与改进.成飞科技,2006,(2):22-26
8GAbul Fazal.Arif M.Numerical prediction of plastic deformation and residual stress induced by laser shock processing.Journal of Materials Procesing Technology,2003,136:120-138
9Graham Hammersley,etal.Surface prestressing to improve fatigue strength of component by laser shot peening.Optics and Laser in Engineering,2000,34:327-337
10Wenwu Zhang,Lawrence Yao.Micro scale laser shock processing of metallic component.Journal of Manufacturing Science Engineering,2002,24(5):369-378
11张兴权,戴亚春,杜为民,王广龙,汪邦富.金属零件表面改性的喷丸强化技术.电加工与模具.2005,(2):30-32
12陈志新.喷丸工艺的现状及其发展.凿岩机械气动工具.1997,(2):55-59
13储继影,关占群,李占杰.喷丸强化效果和质量的表征指标及影响因素.汽轮机技术.2003,45(4):255-256
14.GAbul Fazal,Arif M.NumeficM prediction of plastic deformation and residual stress induced by laser shock processing.Journal of Materials Processing Technology,2003,136:120-138
15戴达煌,周克崧,袁镇海.现代材料表面技术科学.北京:冶金工业出版社,2004
16倪红芳,凌祥,彭薇薇.玻璃喷丸处理提高304不锈钢焊接接头抗应力腐蚀性能的研究.中国腐蚀与防护学报,2005,25(3):152-156
17李雁淮,王飞,吕坚,徐可为.单丸粒喷丸模型和多丸粒喷丸模型的有限元模拟.西安交通大学学报.2007,41(3):349-352
18Iida K.Dent and affected layer produced by shot peening Fuchs H O.Proc 2nd Int Conf on Shot Peening.Chicago:The American Society for Shot Peening,1984:283-292.
19Edberg J,Lindgren L,Mori K.Shot peening simulated by two different finite element formulations Shen Shanfu,Dawson P.Simulation of Materials Processing:Theory,Methods and Applications.Rotterdam,Netherlands:Balkema,1995:425-430
20刘文泉.喷丸强化.吉林工学院学报.1992,13(3、4):35-40
21Meguid S A,Shagal G,Stranart J C.Three dimensional Dynamic Finite Element Analysis of Shot-peening Induced Residual Stresses.Finite Elements in Analysis and Design.1999(31):179-191
22凌祥,彭薇薇,倪红芳.喷丸三维残余应力场的有限元模拟.机械工程学报.2006,42(8):182-189
23吴钢,侯占忠.提高水力机械抗磨蚀性能的喷丸工艺数值分析.水电能源科学.2006,24(1):1-3
24Al-Hassani S T S.Mechanical Aspects of Residual Stress Development in Shot Peening.Proceeding of First International Conference on Shot Peening,Paris,1982
25A1-Hassani S T S.An Engineering Approach to Shot Peening Mechanics.Proceeding of the Second International Conference on Shot Peening,Chicago,1984
26Iida K.Dent and Affected Layer Produced by Shot Peening.Proceeding of the Second International Conference on Shot Peening,Chicago,1984
27Meguid S A,Shagal G,Stranart J C.Three-dimension dynamic Finite Element Analysis of Shot peening Induced Residual Stress.Finite Elements in Analysis and Design,1999,31:179-191
28Baragetti S,Gualiano M,Vergani L.A Numerical Procedure for Shot Peening Optimization by Means of Non-dimensional Factors.Inter.J.Mater.And Product Tech.2000,15:91-103
29Baragetti S,Terranova A.Nondimensional Analysis of Shot peening by Means of DOE.Intern J.Mater Product Tech.2000.15:131-141
30Baragetti S.Three dimensional Finite element Procedures for Shot Peening Residual Stress Field Prediction.Intern J.Computer Appl.in Tech.2001.14:51-63
31Vantuchene R D.Cramer E J.Numerical Modeling of a Wing Skin Peen Forming Process J.Mater Eng Perf.,1996,5(6):753-760
32Guagliano M,VerganiL.An Approach for Prediction of Fatigue Strength of Shot Peened Components.Engng Fract Mech.2004,71:501-512
33康小明.窄条喷丸成形的数值模拟.航空学报.2002,23(1):94-96
34康小明.有限元法在机翼整体壁板成形中的应用.中国机械工程,2002,13(2):134-136
35Gao Y K,Yao M,Li J K.An Analysis of Residual Stress Fields Caused by Shot Peening.Metal lurgical and Mater Trans.2002,A33:1775-1778
36姚枚,王声平,李金魁,等.表面强化件的疲劳强度分析及金属的内部疲劳极限.金属学报,1993,29(11):511-519
37栾伟玲,涂善东.喷丸表面改性技术的研究进展.中国机械工程.2003,16(15):1405-1409
38刘惠民.铁道车辆构造检修及装备.北京:中国铁道出版社,2000
39彭明镜.喷丸强化技术最新进展与装备.中国铸机,2004,(1):43-44
40方博武.受控喷丸与残余应力理论.济南:山东科学技术出版社,1991
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