Computer Prediction on Stress Distribution During Laser Quenching

IntroductionInprocessofindustry,theproblemscoupIedwiththermaIandfOrceareusuaIIymet.LaserqueIlchinginvolvingphasetransformationisoneofthem.HowtosetupafitmatheInatica1modeltosimulatetl1elaserquenchingprocessandhowtocalculateandanalyzenumericallythestresgdistributionarefolIowedwithinterestbymanyresearchersIl'2'3J.Thoseeffol'tsareimportanttooPtilnizethetechnologyparametersandprovideareliablebasisforimprovingthesyntheticallymechanicspropertiesandtheuseagesofmaterials.Alongwithdevelopmentofcomp…     

Computer modeling and validations of steel gear heat treatment processes using commercial software DANTE

The heat treatment process of a gear made of AISI 9310 carburized steel is modeled using the commercial heat treatment simulation software DANTE. Both carburization and quenching processes affect the residual stress distribution and distortion of heat-treated parts, which are important to service quality and fatigue life. DANTE/VCARB is used to design the boost/diffuse schedule of a vacuum carburization process. Oil quenching is modeled following the vacuum carburization process. Thermal gradient and phase transformation are two main sources of distortion and residual stresses in quenched parts. The relation of the carbon distribution, thermal gradient, and phase transformations during quenching is studied through the gear modeling example. Because of geometry, the residual stress distribution after quenching is non-uniform along the gear surface. In general, the root fillet has higher residual compression than either the root or tooth face locations after traditional oil quenching of carburized gears. The predicted residual stresses from the oil quenching model are imported into a single tooth fatigue bending model. The gear stresses under bending load indicate the possible cracking locations during the bending fatigue test. The importance of heat treatment residual stresses during gear design is pointed out, and it is commonly ignored in the gear design and manufacturing industry.     

Computer Predictions and Experimental Verification of Residual Stresses and Distortion in Carburizing-Quenching of Steel

IntroductionInordertoobtainimprovedmechanicalpropertiesandfatiguestrengthofmachinecomponents,stlchasgears,shaftsandsoon,carburizing-quenchingprocessasamethodofstirfacehardeningisoftenusedinindustry.Howevef,carbtirizing-quenchingisusuallyaccompaniedwithcarbonconcentrationandleadtodistortion,residualstressesandhardnessofsteelparts.Theeffectofcarboncontentisspeciallysignificantonphasetransformationbel1aviorThispaPerwillpresentthesimulationresultsoftheresidualstressfieldanddistortionofasteelcylin…     

Integrated fluid-thermal-structural numerical analysis for the quenching of metallic components

The quenching of a metal component with a channel section in a water tank is numerically simulated. Computational fluid dynamics (CFD) is used to model the multiphase flow and the heat transfer in film boiling, nucleate boiling and convective cooling processes to calculate the difference in heat transfer rate around the component and then combining with the thermal simulation and structure analysis of the component to study the effect of heat transfer rate on the distortion of the U-channel component. A model is also established to calculate the residual stress produced by quenching. The coupling fluid-thermal-structural simulation provides an insight into the deformation of the component and can be used to perform parameter analysis to reduce the distortion of the component.     

Transformation Plasticity─The Effect on Metallo-Thermo-Mechanical Simulation of Carburized Quenching Process

IntroductionInelashcorhaersiblestrainaccompaniedbyslidingofcrystalsduetothermalandphasetransformationdilatationiswellknowntointensivelythethedistonionofworkpieceunderqUopching,andsomanynumericalsimulatonsll-7]havebeencAnedoutintheframeworkofmotallochermo-mechwhcsl1].Transformationplasticity(TP),anothekindofbeversiblestrain,isalsorecognizedasoneofdominantparwtersthechngthestr6ssanddistorton,andsomenumcricalcalculationaremadebytakingtheeffectintoconsideration.Figurelschematicallyillustraresthe…     

Generalization of Results of Computations and Natural Experiments at Steel Parts Quenching

IntroductionThepaPerpresentsthegenera1izationofresultsofnumericalcomputationsandnaturalexperimentsbasedonthesimilaritytheoryandtheoryofregularthermalconditions.Thenumericalcomputationshasbeenmadeonthebasisofsolvingequationsofnon-stationarythermalconductivityandthermoplaSticity.Thegeneralizationofresultsliesinthefactthatwefoundadimensionlessformulaforthedeterminationofthetimeofreachingthemaximumcompressionstressesonthesurfaceofp8rtstobequenched.ThepatstobequenchedaredividedintothreegrouPs:pla…     

AN FEM MODEL OF BUCKLING DISTORTION DURING WELDING OF THIN PLATE

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单向短纤维复合材料中热残余应力研究

基于单向短纤维增强金属基复合材料的单纤维模型,利用轴对称弹塑性有限元分析方法,研究了该类复合材料中热残余应力的大小和分布情况以及各种微结构参数的变化对它的影响,同时还讨论了热残余应力的存在对基体与纤维之间应力传递的影响。研究表明,热应变的不匹配导致纤维受压、基体受拉,界面法向受压。热残余应力的存在降低了基体与纤维间的应力传递,不利于复合材料整体性能的提高。     

厚钢板对接焊缝残余应力的数值模拟

基于ABAQUS及其子程序DFLUX,采用热力间接耦合法,对不同厚度尺寸的Q345B厚钢板的对接焊缝进行了三维模拟分析,得到了焊接的温度场分布和最终焊接残余应力分布.结果表明：构件表面焊接残余应力大于中间面;表面纵向和横向残余应力都有一定的规律;对接焊缝沿纵向焊接残余应力随着板厚度的增加而增加,这种增加的趋势对厚度小于70 mm的钢板很明显,对70～80 mm的钢板不明显;而横向残余应力随钢板厚度的增加变化不显著.     

车轴表面应力分析

为了提高车轴寿命,使车轴表面产生较大压应力,分析了50钢车轴表面残余应力变化规律,采用X射线法检测了车轴表层经过低温淬火和滚压后的轴向、周向和径向应力。测试结果表明,采用此方法后,车轴表面的残余应力大幅提高,最大增幅为556MPa,且应力分布均匀,说明此方法能够有效提高车轴的疲劳寿命。     

300MW锅炉汽包的三维瞬态应力有限元分析

采用某电厂300MW锅炉机组多次试验和事故工况下的实测数据作为锅炉汽包三维有限元模型的边界条件,计算并分析比较了该锅炉汽包模型在8种工况下的瞬态热应力、机械应力、总应力和位移,结果表明:壁面温差对汽包总应力的影响不大,汽包内部蒸汽压力是影响汽包总应力的主要因素;当汽包压力较大时,汽包总应力与蒸汽压力成近似定比值关系.     

热障涂层应力场的微拉曼光谱技术测试研究

采用等离子体喷涂工艺制备了热障涂层实验样品,在不同高温下进行热循环氧化实验。再应用微拉曼光谱法测量了热障涂层样品内残余应力场大小,并分析了试样尺寸、热处理温度和陶瓷涂层厚度对残余应力的影响。经历20次热循环氧化实验后,测得陶瓷涂层内残余应力由初始压缩应力值(-30~-20 MPa)逐渐变化到(-15~15 MPa),与文献[3~7]结果比较一致。最后,用扫描电镜观察了试样截面形貌的变化。     

非稳态载荷对二维轮轨纯滚动接触应力和变形的影响

为了揭示轮轨波状表面与非稳态载荷的内在联系,利用有限元法,建立了二维弹塑性轮轨纯滚动接触计算模型,分析法向接触载荷波动值对钢轨残余应力、应变和变形的影响。模型中材料本构采用考虑棘轮效应的Jiang-Sehitoglu模型,非稳态仅考虑法向接触载荷的简谐变化,用弹塑性无限半空间表面上重复移动赫兹法向压力分布模拟反复纯滚动接触过程。发现非稳态法向接触载荷作用下产生同样波长的波状接触表面;随滚动次数的增加,残余应力增大,但很快趋于稳定,而残余应变也增大,但增大速率衰减;载荷波动值越大,波谷和波峰处的纵向残余应力越大,波谷处的轴向残余应力、残余剪应变和表面纵向位移越大,而波峰处的轴向残余应力、残余剪应变和表面纵向位移越小,波深越大。     

Research on a new type of precision cropping method with variable frequency vibration

Aiming at the cropping operations widely applied in practical industry production, a new method of bar cropping is presented. The rotational speeds of actuating motor of eccentric blocks are controlled by a frequency changer, and the shearing die provides the bar with the controllable force, frequency and amplitude of vibration. By utilizing the stress concentration at the bottom of V shape groove on the bar, the low stress bar cropping is realized. The bar cropping experiments of duralumin alloy and steel show that the shear surface has no radial distortion and deviation angle, the cutting force is lower and the die life is longer compared with the common bar cropping method. According to the special feature of cutting surface obtained by the new method, a new method of measurement is proposed and applied to assess the cutting surfaces obtained by the different control curves of frequency. The results show that the linear decrease control method is the best.     

Forging penetration efficiency of steel H13 stepped shaft radial forging with GFM forging machine

The numerical thermal mechanical simulation of radial forging process of steel H13 stepped shaft with GFM (Gesellschaft fur Fertigungstechnik und Maschinenbau) forging machine was carried out by three-dimensional finite element code DEFORM 3D. According to the effective plastic strain, the mean stress and the mean plastic strain distribution of the radial forging, the forging penetration efficiency (FPE) was studied throughout each operation. The results show that the effective plastic strain in the center of the forging is always greater than zero for the desirable larger axial drawing velocity. The mean stress in the center of the workpiece is proposed to describe hydrostatic pressure in this paper. There is compressive strain layer beneath the surface of the workpiece to be found, while there is tensile strain core in the center of the workpiece. These results could be a valuable reference for designing the similar forging operations.     

复合碾压混凝土路面温度应力分析

采用ANSYS有限元分析软件,建立了弹性地基上由碾压混凝土面层和水泥稳定碎石基层双层板三维路面结构模型;分析了复合碾压混凝土路面在温度曲线分布情况下的温度翘曲应力,包括曲线温度场,不同时刻,层间接触状态,碾压混凝土面层厚度、温度膨胀系数、模量和板平面尺寸等影响因素。分析结果表明:曲线温度场下的温度应力明显低于折线性温度场下的温度应力;随着板厚的增加,出现最大温度应力的时间推迟;层间接触状态对温度应力的影响不显著;面层厚度、温度膨胀系数及模量对温度应力的影响较显著。     

Finite Element Method Analysis of Stress Field Considering Thermal Coupled Force During Laser Process

IntroductionLaserphasetransformationhardeningisanewtechnologyduringwhichlaserheatresourceactsdirectlyonsurfaceofmaterialandcompositionscharacteristicofmaterialischanged.Thetechnologyproce8sesacharacterofrapidheatvelocity,highheattempelatureandquickcoolingspeed(l0'col0'aC/s).Thecompositionandcharacteristicofmaterialvariedwithvariousinnertemperaturewillleadtothermalresidualstress.Itiswellknownthattheresidualstressaffectssignificantlyoncharacteristicofmaterial,suchasimProvingstrengthoffatigUere…     

X65管线厚板控制冷却时的相变效应

为明确相变效应对X65管线厚板控制冷却的影响,通过开发线性混合热膨胀模型、拓展Avrami相变动力学模型和应用Leblond模型建立了热力耦合有限元模型.用该模型研究了X65管线厚板在上下层流冷却系数分别为3和1 kW/(m2.K)的非对称控制冷却时,相变效应对温度、残余应力和应变的影响.结果表明:相变期间,潜热减缓心部和下表面的冷却速度达50%、25%;潜热和TRIP效应分别产生峰值为89、-89 MPa,并且130、-170 MPa的应力可减小整体残余应力;相变膨胀产生峰值为723、-479 MPa的组织应力决定了整体残余应力大小及分布.     

混凝土箱梁桥沥青混凝土铺装层温度应力分析

为了探求混凝土箱梁桥沥青混凝土铺装层在温度变化条件下引起开裂的破坏机理,采用现场监测与理论仿真模拟相结合的手段研究了沥青混凝土铺装层在低温、高温季节,以及夏季阵雨引起大幅降温等情况下的温度场分布及引起的温度应力,并与车辆荷栽作用下的沥青混凝土铺装层力学响应进行了对比分析．计算结果表明,沥青混凝土铺装层在大幅降温条件下产生的拉应力要明显大于日变化条件下的计算结果;由实测温度场得到的拉应力峰值出现在沥青混凝土铺装层表面;大幅降温引起的铺装层拉应力要大于车载作用下的计算结果;在沥青混凝土铺装层的设计中要重点考虑温度荷载的作用．     

High temperature indentation test to improve constitutive model for welding simulation

The high temperature gradients experienced during fusion welding lead to a local dilatation and metallurgical transformations that generate inhomogeneous plastic deformation, residual stresses and distortions in the welded parts which can affect the service life of the structures. To predict such residual stresses and distortions, finite element analysis is nowadays widely used. This work reports a 3D finite element model for welding simulation. The proposed model is based on semi coupled thermo-mechanical analysis using a double ellipsoidal model of heat source. Firstly, a disk heated in its central zone is investigated. Secondly the validation concerns the simulation of a fully 3D two pass butt weld. The idea in this work concerns the calibration of the heat source parameters with the help of the inverse analysis to improve the heat flow predictions. For the stress analysis, an annealing temperature is introduced to force the material to lose its hardening memory above a given temperature. The predicted residual stresses as well as the predicted distortions are found to be sensitive to the annealing temperature.