热应力预制裂纹技术在低应力精密下料中的实验研究

针对棒料的精密下料问题,给出了一种热应力预制裂纹的新的下料方法,简述了热应力变频振动下料系统的组成。建立了新的激振频率控制曲线和专门针对这种下料所获断面质量的评价方法。20号钢棒料的下料实验结果表明,通过采用热应力预制棒料V型槽尖端区域微小裂纹的方法,下料时间减少了20%左右,且仍可获得高质量的断面平整度。     

共振诱导V形槽尖端萌生裂纹机构的研究

在低应力精密下料中,提出采用共振效应诱导棒料V形槽尖端萌生微裂纹的方法,并设计了相应的激振系统.利用Solidworks和ANSYS软件,简化了该激振系统的三维造型,并对其进行了模态分析.结果表明,调整振动电动机的偏心块质量,能够有效实现激振系统的整体性能,这为高效高质量精密下料打下了基础.     

双频振动载荷下带V形槽铝合金棒料的断裂行为

针对金属棒料低应力分离过程中裂纹萌生扩展速率低的问题,提出一种基于双频振动的加载方法,探究带V形槽7A09铝合金棒料的断裂行为。研究了双频振动对带V形槽金属棒料裂纹萌生扩展的作用机理,通过研发双频激振装置,对带V形槽7A09铝合金棒料进行了实验研究。实验结果表明,相对于单频振动加载方法,双频振动载荷能够大幅缩短带V形槽7A09铝合金棒料的分离时间,有效提高裂纹萌生扩展的速率与稳定性,棒料断面几何精度高。     

低周疲劳精密下料新工艺及试验研究

传统的金属棒料下料工艺存在着材料利用率低、能耗高、生产效率低以及下料断面质量差等问题。采用一种新的下料工艺-周向加载低周疲劳精密下料技术,利用V形槽的应力集中效应,促使棒料V形槽底尖端处疲劳裂纹的萌生及疲劳裂纹的快速扩展。描述周向加载低周疲劳精密下料机的工作原理。给出在低周疲劳下棒料V形槽根部裂纹是否起裂的判据。采用两种控制曲线对5种材料(20钢、H59、45钢、20Cr和LY12)的棒料进行试验研究,实现加速棒料裂纹的产生、扩展并获得良好的棒料断面质量。试验结果表明,V形槽的应力集中效应可以有效地减小棒料下料过程中的平均应力,在不断增加打击位移的同时减小冲击频率可以保证棒料裂纹的稳定扩展和断裂。     

气动人工肌肉驱动的定向传送振动盘设计

介绍了一种以单根气动人工肌肉为激振装置的定向传送振动盘设计方案.利用气动人工肌肉这种响应频率高、初始拉力大、自身重量轻、定位无摩擦阻力、安装空间小的柔性驱动器作为定向传送振动盘的激振装置,将此气动系统与机械料盘系统集成一体,组成一种新型气动振盘,该系统具有振幅和频率连续可调,输送的产品不受电磁场影响的优点.文中给出了该振动系统的结构和工作原理,为振动输送技术提供了一种新的驱动方法.     

锻造毛坯下料装置的改进

为了降低成本 ,获得质量较高、较稳定的锻件 ,必须有精度较高的料坯。料坯精度包括料坯重量误差和断面质量平整度。我厂下料工序采用中频感应加热、棒料剪切机等装备。在这种状况下 ,下料的质量情况较好。但仍存在重量相差较大 ,断面不平等影响锻件质量的问题。我厂现在的下料状况为 :( 1 )下刀板采用进料时的套筒 ,由于长期受循环载荷作用 ,套筒下面(底座 )易出现凹坑。剪切时 ,棒料翘起 ,影响料坯断面质量。 ( 2 )料坯长度定位采用螺杆调节 ,只顶住料头 ,下面悬空 ,影响断面质量。且螺杆受机床震动时易松动 ,造成下料重量的不均匀。 ( 3)…     

径向预压紧热切下料装置

本文介绍的带有自动送料机构的径向预压紧热切下料装置由切料机构、杠杆式径向预压紧机构、双滑块式送料机构和平行四边形托料机构等四部分组成。使用这种装置下料时,棒料压紧可靠,料段质量有很大提高,下料重量误差由原来的2.9～3.4%减少到1.3～1.6%。     

3 MN棒料剪断机液压系统设计

金属棒料下料是机械行业中应用量很大的一项工作,如齿轮、轴承、锻压件等的备料都是用棒料下料,用锯切方式下料其形状精度好,但效率低、成本高,而剪断方式下料则有较高的生产效率且生产成本较低。本文论述用于金属棒料剪切下料的３ＭＮ棒料剪断机的液压系统设计与分析...     

新型电液激振试验台的高频特性研究

电液激振试验台是在振动机架上安装电液激振器,由激振器产生激振力,作用在实验对象的某一局部区域,使其产生强迫振动。该文根据液压马达的大功率、大扭矩的特点,提出了一种由马达驱动高频激振阀的新型电液激振试验台研究方法。该方法主要是通过液压马达对2D激振阀阀芯的旋转进行驱动,采用流量阀控制进入马达的流量达到控制阀芯转速的目的。应用流体动力学和系统动力学理论建立电液激振试验台数学模型,对建立的试验台进行实验研究,同时测得液压缸活塞输出的激振力波形。实验表明:该试验台可以大幅度地提高激振频率,达到1200Hz以上的激振频率,激振输出波形近似为一正弦波。马达驱动2D阀的新型电液激振试验台是提高液压振动的激振频率的有效途径。     

某型飞机翼梁振动时效参数化工艺测试分析

为了测量飞机翼梁振动时效处理时残余应力的量值,提出了用相应结构动态参数的变化来进行监测的方法.本文介绍了翼梁振动时效处理的工艺流程,并对测试激振频率、激振时间、激振力和试件固有频率、振后频率等动态参数进行了取样测试分析,试验表明动态参数的变化规律与残余应力的下降规律相对应.     

Research of effects of bar geometric parameters on initial external force in precision cropping

In precise cropping of the metal bars with different geometrical parameters, it is very important to obtain the reasonable initial external forces required by the bars rapidly and accurately. Stress concentration factor and stress intensity factor are proposed to calculate the initial external force accurately in this paper according to geometrical sizes of metal bars. By means of numerical simulation and linear fitting method, the correctional expressions of stress concentration factor and stress intensity factor of V-shaped notch tip, which include the geometric parameters of the bar, are obtained respectively and the error analyses are also performed. The ratio of the depth of V-shaped notch to the diameter of the bar is presented to be a condition parameter. The numerical analytical results show that the method of stress concentration factor can be used to calculate the initial external force accurately when the ratio of the depth of V-shaped notch to the diameter of the bar is more than 0.05, and the method of the stress intensity factor can be used when the ratio is less than 0.05. The calculating formulas of reasonable initial external forces for the bars with different geometrical parameters are also given. The cropping experimental results have confirmed that it is feasible that the reasonable initial external forces required by the bars with different geometrical parameters are calculated effectively by using the stress concentration factor or the stress intensity factor in precision cropping.     

Investigation on a new type of low-stress cropping system with variable frequency vibration

This paper presents a new type of precision cropping system with variable frequency vibration by which the high-quality cutting surface can be obtained. On the basis of D’Alembert’s principle, the approximate relationship between the exciting force and the excited frequency in the cropping is acquired through computation. Five types of excited frequency control curves are designed and applied in the cropping experiments and the influences of these control curves on the cropping cross-section and the cropping time are investigated by experiment in details. According to the special feature of the cross-section obtained in the course of variable frequency vibration cropping, a new measurement method is proposed and applied to assess the quality of the cross-section. The theoretic and experimental results show that the exciting force acted on the bar in the vertical direction is larger than that in the horizontal direction and the linear decrease control curve, by which the high quality cross-section is obtained and the cropping time is reduced, is an ideal control mode compared with other control modes mentioned in the paper. The experiment also proves that the width of the bar instantaneous fracture region is decreased by reducing the value of every step frequency change, and the cropping time is also shortened by reducing the durative time of every step variable frequency under the action of the linear decrease frequency curve.     

304不锈钢棒气动式可控旋弯下料工艺及试验

针对金属棒料传统下料工艺存在断面质量差、材料利用率低、能耗高等问题,提出一种综合利用预制环状V型槽缺口效应、起裂微裂纹及扩展宏观裂纹裂尖应力集中效应的新型气动式棒料可控旋弯下料工艺,详细介绍了该下料工艺的工作原理。基于该工作原理研制了金属棒料气动式旋弯下料试验装置,利用材料力学强度理论与线弹性断裂力学理论,建立了弯矩载荷作用下金属棒料下料过程的力学模型,获得了环状“V”型槽根部微裂纹萌生载荷、扩展裂纹起裂载荷及瞬断载荷的理论计算公式。采用三种不同恒应力强度因子幅水平载荷控制曲线对φ30 mm直径的304不锈钢棒料进行下料试验研究,结合所提出的坯料断面评价方法及其评价指标,对下料所得坯料质量进行了量化评价。结果表明,保持裂尖处于恒应力强度因子幅水平,可以实现金属棒料的可控精密下料,断面质量和下料时间随幅值水平提高而降低,当裂尖处△K=0.7K_c时,坯料最终瞬断区最小。该下料工艺利用断裂力学理论建立旋弯下料机理,可以指导实际下料试验,为后续下料工艺数据库的建立提供理论支撑。     

金属棒料精密下料新工艺及实验研究

提出了一种能获得高质量断面的金属棒料下料新工艺——旋转锻打疲劳下料技术,探讨了旋转锻打疲劳下料技术的机理,描述了旋转锻打疲劳下料新工艺的实验情况,展示了成功的实验结果,还根据下料断面特点提出一种新的断面质量评价方法。实践证明,研制的新型旋转锻打疲劳下料机能对不同直径的不同材料进行快速精密下料,下料后的形态能完全满足精密塑性加工要求,能直接进行下一步工序加工。     

The experimental and theoretical analysis of plastic flow during the closed-die cropping of rectangular bars

Plastic flow during the closed-die cropping of rectangular bars is analysed by the method of visio-plasticity. A velocity field satisfying the limiting conditions is described. Calculated flow lines and cropping force are close to experimental results. Work-hardening appears to be the most important parameter in cropping.     

高固有频率构件分频共振时效的分析计算

利用力学、线性和非线性振动理论,对高固有频率构件进行振动时效的新方法－－分频共振的原理和应用进行了讨论。指出对同一构件进行振动时效处理,要达到相同的时效效果。分频共振方法所用的激振力比直接共振方法所用的激振力要大些。从理论上说明了分频的方法是行之有效的方法。     

Investigation of a new-type precision cropping system with variable-frequency vibration

To investigate a new-type precision cropping system with variable-frequency vibration, it is necessary to obtain the characteristics of vibrating force and displacement of shearing die in different exciting frequencies. The model and equations of a six-degree-of-freedom vibrating system are established, and the six natural frequencies of the system are achieved by means of classical analysis method, the amplitude-frequency characteristics are described according to Cramer's rule, and the theoretical analysis results are verified by experiments. The approximate relationship between the vibrating force and exciting frequency are achieved and the experimental results show that crack will propagate along z direction, which is in agreement with the theoretical results. The work-piece cross-section obtained by the experiments has no radial distortion and deviation angle, moreover, the cutting force is lower and the die lifetime is longer compared with common bar cropping method. A new cross-section quality assessment method is proposed for the work-piece obtained under the control of different frequency-time characteristic curves. The assessment results show that the linear decrement control mode is better for producing good-quality work-piece.     

Research of stress intensity factor of V-shaped notch tip in precision cropping

For carrying out the precise cropping of metal bar with different geometrical sizes, it is very important to obtain the reasonable stress intensity factor of V-shaped notch tip rapidly and accurately. At first, a new precise cropping method, which is the high-speed peripheral low-stress bending fracture cropping is presented in the paper, and its working mechanism is also given in detail. The stress field near V-shaped notch tip is analyzed, and the stress extrapolation method is presented to compute the stress intensity factor of V-shaped notch tip. Based on it, the correctional expression of theoretical stress intensity factor in a handbook of stress intensity factor is also given. The contrasts between stress intensity factor results obtained by means of the stress extrapolation method and the corresponding theoretical results in the handbook of stress intensity factor are also carried out in detail. The results show that the two errors are not more than 5 % and are within a reasonable engineering range. The cropping experimental results for initial loading force and crack propagation life have also confirmed that the correctional expression of theoretical stress intensity factor is feasible.     

A one-dimensional model for the prediction of residual stress and its relief in welded plates

The simulation of the welding process by means of continuum mechanics models has a very high cost both in input data preparation time and in computing time required for the integration of the complex thermoelastoplastic equations involved in solids with temperature dependent properties. For this reason, the plates in this study will be visualized as formed by a certain number of bars that can carry out elastoplastic behaviour and having temperature dependent properties. The thermal loads are simulated by analytical singular solutions, the thermomechanical problem being solved by means of an incremental algorithm of high efficiency. An excellent agreement has been found between the results numerically predicted and those previously obtained with an experimental technique and the Finite Element Method. Finally, the one-dimensional model developed here is used to predict the effects of a local heat treatment on the residual stresses originated by the welding. The versatility and rapidity of the use of this model makes it specially suitable to be used as a tool to select among different stress relieving procedures.     

高频电液激振器的实验研究

电液激振器作为疲劳试验机的关键部件,其发展趋势是保证输出大激振力的同时,向着2000Hz以上工作频率段的方向发展,以适应新产品开发过程中的振动环境试验的需求,为此对高频电液激振器的研究显得尤为重要。高频电液激振器系统是由2D阀驱动液压缸活塞以某一振动中心位置作周期性往复运动。根据流体力学和系统动力学的理论对该系统进行数学建模。通过实验研究与分析发现,在2000Hz至3000Hz高频电液激振器所采集的激振波形比较光滑,且波形失真度不大,趋近于正弦波。同时,实现了激振频率3000Hz的重大突破。