镁合金轧制变形及边裂机制研究
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摘要
镁合金作为最轻的金属之一,被广泛的应用到各种交通工具和移动产品上。轧制是镁板生产最主要的方式。但是由于金属镁固有的晶体结构和物理性质,在镁合金的塑性变形及镁板轧制的过程中很容易出现裂纹等缺陷。为了研究镁板轧制裂纹产生的原因,本文运用有限元技术,结合损伤理论,以及Gleeble热塑性物理模拟、实验室轧制、XRD等织构分析手段、SEM、金相分析等实验手段,系统的研究了镁合金塑性变形的特点,尤其是各向异性对镁合金弹塑性变形的影响;镁合金塑性变形中的损伤行为,以及影响镁板轧制边裂和轧板组织的诸多因素;并制定了镁板轧制边裂预测和改进的方案。
镁合金塑性变形及损伤行为的研究表明:(1)塑性变形过程中,镁合金的各向异性行为非常显著。初始织构将严重影响镁合金变形后的形状,及变形过程中的应力-应变特征。当加载方向垂直于密排六方晶格的c轴,将出现明显的屈服现象;且变形将优先发生在沿着c轴的方向,使圆柱形试样的截面形状呈椭圆形。
(2)镁合金塑性变形的各向异性具有强烈的温度和应变速率依赖性。温度越低,应变速率越高,各向异性越明显。且即使在400℃的较高温度,如果应变速率很大,则依然有很强烈的各向异性。(3)建立了考虑各向异性因素的镁合金弹塑性变形的本构方程:σ= C_(ij)ε_e+σlcosxcosλ。(4)镁合金的初始晶体取向、变形温度、应变速率等对塑性损伤有很大的影响,尤其初始织构将决定裂纹的扩展方向,使标准拉伸断口呈现取向性的椭圆形。(5)建立了综合考虑温度、应变速率,及晶体取向的损伤本构方程: 0 maxd C1uexp(RQT)。
基于镁合金塑性变形本构和塑性损伤理论,用实验和有限元方法研究镁合金轧板边裂的结果表明:(1)初始织构对镁板轧制成形性有重大影响。当初始晶体结构的c轴垂直于镁板ND方向的时候,道次压下量62%未见边裂;而具有基面织构的镁板容易发生边裂。(2)镁板的形状对轧制边裂的影响可以用下面的方程预测,D=-0.124+0.09X-0.008X~2,X=宽/厚, 0 通过镁合金弹塑性变形和损伤的研究、轧制实验和有限元模拟,建立了基于温度、压下量和道次的轧制成型图、诸多经验方程、有限元模型,以指导镁合金的轧制,避免边裂。制订了能够实现少道次大压下量无边裂轧制的ND-TD-ND-TD镁板轧制工艺。
本研究发展的理论和制订的新工艺将很好的指导镁板的轧制,很大程度提高轧制成形性和生产效率,具有重大生产和学术的意义。由于镁合金的密排六方结构和塑性变形的各向异性,其塑性损伤的机制跟以往研究损伤的材料不同,所以对镁合金的损伤的研究还有很漫长的道路。
As one of the lightest metals, Mg alloys are used in many fields, especially transport and mobile equipment. Rolling is the most common process to produce Mg sheet. But it is prone to crack during deformation in particular rolling, for its crystal structure and properties. To investigate the reason for edge crack, the finite element method, damage theory, and lots of experiments including thermal-mechanical test, rolling, XRD, SEM, OM were all used. The characteristic of Mg plastic deformation, especially effects of anisotropy, damage behavior, and factors affecting edge crack were studied systematically. Some ways were found out to predict and eliminate edge crack.
Study of Mg deformation and damage behavior indicates, (1) anisotropy is obvious during Mg alloy deformation. Initial texture can impact the shape of samples and the stress- strain behavior. When loading direction is perpendicular to c-axis of HCP lattice, it turns out yielding clearly. Deformation would prefer along c-axis, and that make the section of sample oval. (2) the anisotropy of Mg deformation quite depends on temperature and strain rate. The lower temperature or higher strain rate, the more anisotropic. Even at 400℃anisotropy also exists when the strain rate is very high. (3) a constitutive equationσ= C_(ij)ε)e+σlcos xcosλconsidering crystal orientation was built. (4) initial crystal orientation, temperature, and strain rate play important role on damage. Initial texture can affect crack direction, and make the tensile fracture oval. (5) A damage constitutive equation, 0 maxd C1uexp(RQT)∫εfσε=εrelated with temperature, strain rate, and crystal orientation was established.
Based on constitutive of plastic deformation and damage theory, edge crack was studied by means of experiment and finite element method. Results show, (1) initial texture plays important role in Mg sheet rollability. When c-axis of HCP lattice is vertical to ND, the Mg sheet is quality even after a rolling with reduction of 62%, while cracks appear at the edge of sheet with initial basal texture. (2) equation D=-0.124+0.09X-0.008X2 can be used to predict edge crack and study the effects of sheet shape on crack. X=width/thickness, 0 According to the study of plastic deformation and damage of Mg alloy, rolling experiment, and finite element simulation, a rolling map considering temperature, reduction, and pass was built, as well as some experience equation and finite element model. All these can be used to direct rolling of Mg sheet and avoid edge crack. A new ND-TD-ND-TD process was invented, and it can produce quality Mg sheet within few passes and big reduction.
The new theories and processes developed in this work can be used to conduct rolling of Mg sheet. It can strongly improve rollabiltiy and production efficiency. As its HCP structure and deformation anisotropy, the damage mechanism of Mg alloy is different from the materials used to study damage before. Therefore, there is still a long way to investigate the damage of Mg alloys.
镁合金塑性变形及损伤行为的研究表明:(1)塑性变形过程中,镁合金的各向异性行为非常显著。初始织构将严重影响镁合金变形后的形状,及变形过程中的应力-应变特征。当加载方向垂直于密排六方晶格的c轴,将出现明显的屈服现象;且变形将优先发生在沿着c轴的方向,使圆柱形试样的截面形状呈椭圆形。
(2)镁合金塑性变形的各向异性具有强烈的温度和应变速率依赖性。温度越低,应变速率越高,各向异性越明显。且即使在400℃的较高温度,如果应变速率很大,则依然有很强烈的各向异性。(3)建立了考虑各向异性因素的镁合金弹塑性变形的本构方程:σ= C_(ij)ε_e+σlcosxcosλ。(4)镁合金的初始晶体取向、变形温度、应变速率等对塑性损伤有很大的影响,尤其初始织构将决定裂纹的扩展方向,使标准拉伸断口呈现取向性的椭圆形。(5)建立了综合考虑温度、应变速率,及晶体取向的损伤本构方程: 0 maxd C1uexp(RQT)。
基于镁合金塑性变形本构和塑性损伤理论,用实验和有限元方法研究镁合金轧板边裂的结果表明:(1)初始织构对镁板轧制成形性有重大影响。当初始晶体结构的c轴垂直于镁板ND方向的时候,道次压下量62%未见边裂;而具有基面织构的镁板容易发生边裂。(2)镁板的形状对轧制边裂的影响可以用下面的方程预测,D=-0.124+0.09X-0.008X~2,X=宽/厚, 0
本研究发展的理论和制订的新工艺将很好的指导镁板的轧制,很大程度提高轧制成形性和生产效率,具有重大生产和学术的意义。由于镁合金的密排六方结构和塑性变形的各向异性,其塑性损伤的机制跟以往研究损伤的材料不同,所以对镁合金的损伤的研究还有很漫长的道路。
As one of the lightest metals, Mg alloys are used in many fields, especially transport and mobile equipment. Rolling is the most common process to produce Mg sheet. But it is prone to crack during deformation in particular rolling, for its crystal structure and properties. To investigate the reason for edge crack, the finite element method, damage theory, and lots of experiments including thermal-mechanical test, rolling, XRD, SEM, OM were all used. The characteristic of Mg plastic deformation, especially effects of anisotropy, damage behavior, and factors affecting edge crack were studied systematically. Some ways were found out to predict and eliminate edge crack.
Study of Mg deformation and damage behavior indicates, (1) anisotropy is obvious during Mg alloy deformation. Initial texture can impact the shape of samples and the stress- strain behavior. When loading direction is perpendicular to c-axis of HCP lattice, it turns out yielding clearly. Deformation would prefer along c-axis, and that make the section of sample oval. (2) the anisotropy of Mg deformation quite depends on temperature and strain rate. The lower temperature or higher strain rate, the more anisotropic. Even at 400℃anisotropy also exists when the strain rate is very high. (3) a constitutive equationσ= C_(ij)ε)e+σlcos xcosλconsidering crystal orientation was built. (4) initial crystal orientation, temperature, and strain rate play important role on damage. Initial texture can affect crack direction, and make the tensile fracture oval. (5) A damage constitutive equation, 0 maxd C1uexp(RQT)∫εfσε=εrelated with temperature, strain rate, and crystal orientation was established.
Based on constitutive of plastic deformation and damage theory, edge crack was studied by means of experiment and finite element method. Results show, (1) initial texture plays important role in Mg sheet rollability. When c-axis of HCP lattice is vertical to ND, the Mg sheet is quality even after a rolling with reduction of 62%, while cracks appear at the edge of sheet with initial basal texture. (2) equation D=-0.124+0.09X-0.008X2 can be used to predict edge crack and study the effects of sheet shape on crack. X=width/thickness, 0
The new theories and processes developed in this work can be used to conduct rolling of Mg sheet. It can strongly improve rollabiltiy and production efficiency. As its HCP structure and deformation anisotropy, the damage mechanism of Mg alloy is different from the materials used to study damage before. Therefore, there is still a long way to investigate the damage of Mg alloys.
引文
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