铝合金厚板振动时效的微屈服机理探讨与试验研究
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摘要
振动时效在实践中被证实是一种有效消减残余应力的工艺,然而在应用中发现对于不同的材料和构件,其应力消减效果并不相同。为了更好地在生产过程中应用振动时效工艺,对振动时效的机理研究就变得十分迫切。本文主要通过试验研究,得到了铝合金厚板在交变应力作用下残余应力演变的一般规律,并对振动时效的机理进行了进一步的分析与探讨。
本文首先对X射线残余应力测量法应用于铝合金材料的电解抛光,电解剥除工艺,测量技术进行了研究和优化,并对淬火和预拉伸铝合金厚板表面残余应力进行了测量,得到了分布区间和规律。
其次,本文通过试验,对交变应力加载状态下的残余应力演变规律进行了研究。当加载应力与残余应力之和大于材料屈服强度时,残余应力可以得到消减,其消减规律符合塑性变形和强化机理；当小于屈服强度时有两种情况,当叠加应力小于门槛值时,交变应力加载不会对残余应力产生影响,当叠加应力大于此值时,经过一定周期交变应力加载,残余应力会得到消减,加载应力越大,应力消减产生的越早。另外,试验中表面喷砂试样比淬火试样残余应力消减效果显著,因此残余应力消减也与初始残余应力状态与应力梯度有关。
再次,本文对振动时效消减残余应力的机理进行了进一步的探讨和研究。分别基于包辛格效应和位错理论总结了振动时效消减残余应力的宏观和微观机理,得到了残余应力消减的数学模型和经验公式。基于蠕变理论提出了振动时效与循环蠕变在力学本质上的相关性,并对交变应力幅、温度和材料特性等共同影响因素进行了分析。基于应变能原理分析了残余应力场对应的能量状态,从能量转化的角度对振动时效消减残余应力的过程进行了研究。
最后,通过对比试验证明振动时效可以调整淬火铝合金厚板的峰值应力,均化残余应力分布对尺寸稳定性有很好作用,并对其机理进行了研究与探讨。
Vibration Stress Relief (VSR) has been proved to be an effective residual stress reduction technique in practice. However, it is found that the effects of stress reduction to different materials and components are not the same in applications, so it is necessary to study the mechanism of VSR to improve the application in production process. In this paper, through experimental researches, general laws of the evolution of residual stress in the aluminum alloy plate under cyclic loading were obtained, and the mechanism of VSR was analyzed and discussed.
In this paper, the electrolytic etching and polishing process and measurement technique of X-ray diffraction method for aluminum alloy plate were optimized. The surface residual stresses of aluminum alloy plate after quenching were measured and the distribution laws and range were obtained.
Secondly, by means of experiments, the surface residual stress evolutions in the following two conditions were studied:the sum of load stress and residual stress exceeded the local yield stress or not. When the stress exceeded the yield stress, the residual stress can be reduced, the evolution laws accord to plastic deformation mechanism and work hardening, then if not, there are two conditions. When less than a certain value, the cyclic loading can not affect the residual stress, when exceeded this value, after a certain period of cyclic loading, residual stress can be reduced, and the amplitude of the load stress is positively effect to the reduction. In addition, the residual stress in sand blasting samples can be significantly reduced than quenching samples, so the stress relief is also related to the initial residual stress condition and stress gradient.
Thirdly, the mechanisms of VSR were deeply discussed. Respectively based on the Bauschinger effect and dislocation theory, the macro and micro mechanisms of VSR were summarized, and the mathematical models and empirical formulas in the reduction of residual stress were presented. Based on the creep theory, the mechanical relationship of VSR and cyclic creep was discussed, and common factors such as stress amplitude, temperature and material properties were analyzed. Based on the principle of strain energy, the relationship between residual stress field and the energy state was discussed and the stress relaxation in VSR was studied from the perspective of energy conversion.
Finally, it is also found that VSR can relief the peak stress and have a good effect to the dimensional stability of quenching aluminum alloy plate in another comparing experiment, and the mechanism was discussed.
本文首先对X射线残余应力测量法应用于铝合金材料的电解抛光,电解剥除工艺,测量技术进行了研究和优化,并对淬火和预拉伸铝合金厚板表面残余应力进行了测量,得到了分布区间和规律。
其次,本文通过试验,对交变应力加载状态下的残余应力演变规律进行了研究。当加载应力与残余应力之和大于材料屈服强度时,残余应力可以得到消减,其消减规律符合塑性变形和强化机理；当小于屈服强度时有两种情况,当叠加应力小于门槛值时,交变应力加载不会对残余应力产生影响,当叠加应力大于此值时,经过一定周期交变应力加载,残余应力会得到消减,加载应力越大,应力消减产生的越早。另外,试验中表面喷砂试样比淬火试样残余应力消减效果显著,因此残余应力消减也与初始残余应力状态与应力梯度有关。
再次,本文对振动时效消减残余应力的机理进行了进一步的探讨和研究。分别基于包辛格效应和位错理论总结了振动时效消减残余应力的宏观和微观机理,得到了残余应力消减的数学模型和经验公式。基于蠕变理论提出了振动时效与循环蠕变在力学本质上的相关性,并对交变应力幅、温度和材料特性等共同影响因素进行了分析。基于应变能原理分析了残余应力场对应的能量状态,从能量转化的角度对振动时效消减残余应力的过程进行了研究。
最后,通过对比试验证明振动时效可以调整淬火铝合金厚板的峰值应力,均化残余应力分布对尺寸稳定性有很好作用,并对其机理进行了研究与探讨。
Vibration Stress Relief (VSR) has been proved to be an effective residual stress reduction technique in practice. However, it is found that the effects of stress reduction to different materials and components are not the same in applications, so it is necessary to study the mechanism of VSR to improve the application in production process. In this paper, through experimental researches, general laws of the evolution of residual stress in the aluminum alloy plate under cyclic loading were obtained, and the mechanism of VSR was analyzed and discussed.
In this paper, the electrolytic etching and polishing process and measurement technique of X-ray diffraction method for aluminum alloy plate were optimized. The surface residual stresses of aluminum alloy plate after quenching were measured and the distribution laws and range were obtained.
Secondly, by means of experiments, the surface residual stress evolutions in the following two conditions were studied:the sum of load stress and residual stress exceeded the local yield stress or not. When the stress exceeded the yield stress, the residual stress can be reduced, the evolution laws accord to plastic deformation mechanism and work hardening, then if not, there are two conditions. When less than a certain value, the cyclic loading can not affect the residual stress, when exceeded this value, after a certain period of cyclic loading, residual stress can be reduced, and the amplitude of the load stress is positively effect to the reduction. In addition, the residual stress in sand blasting samples can be significantly reduced than quenching samples, so the stress relief is also related to the initial residual stress condition and stress gradient.
Thirdly, the mechanisms of VSR were deeply discussed. Respectively based on the Bauschinger effect and dislocation theory, the macro and micro mechanisms of VSR were summarized, and the mathematical models and empirical formulas in the reduction of residual stress were presented. Based on the creep theory, the mechanical relationship of VSR and cyclic creep was discussed, and common factors such as stress amplitude, temperature and material properties were analyzed. Based on the principle of strain energy, the relationship between residual stress field and the energy state was discussed and the stress relaxation in VSR was studied from the perspective of energy conversion.
Finally, it is also found that VSR can relief the peak stress and have a good effect to the dimensional stability of quenching aluminum alloy plate in another comparing experiment, and the mechanism was discussed.
引文
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