QP980板材边缘开裂的实验研究和数值模拟

目的 冲裁加工后的第3代先进高强钢QP980板材在成形中会因边缘开裂而显著影响汽车结构件安全性,针对这一问题,对QP980板材边缘开裂行为进行研究。方法 使用QP980板材通过钻孔和冲孔2种方法制备不同边缘状态的试样,并进行扩孔和中心孔拉伸试验。分析不同边缘状态试样的扩孔率和断裂应变演化规律。采用DF2015断裂模型对QP980板材的韧性断裂行为进行预测。结果 钻孔试样的扩孔率约为33%,冲孔试样的扩孔率约为24%。与钻孔试样的试验结果相比,DF2015断裂模型的模拟结果显示出了良好的预测性,但DF2015断裂模型无法准确预测冲孔试样的载荷–位移响应、扩孔率和断裂应变。结论 不同的预加工工艺导致QP980板材表现出不同的边缘开裂行为。中心孔拉伸试验结果与扩孔试验结果趋势一致,因此中心孔拉伸试验是研究边缘开裂的良好方法。钻孔预加工工艺可以保持板材的原始性能,而冲裁预加工工艺会导致板材边缘发生严重的预损伤。由于DF2015断裂模型未考虑预损伤,因此无法准确预测冲孔试样的边缘开裂行为。     

Experiments and modeling of edge fracture for an AHSS sheet

With the emergence of advanced high strength steels (AHSSs) and other light–weight materials, edge fracture has been one of the important issues evading reliable prediction using CAE tools. To study edge fracture behavior of AHSS, a comprehensive hole expansion test (HET) program has been carried out on a DP780 sheet. Specimen with three different edge conditions (milled edge, water jet cut edge and punched edge) are manufactured and tested. Results reveal that the hole expansion ratio (HER) of the present DP780 sheet is around 38 % for milled specimen and water jet cut specimen, and about 14 % for punched specimen. A novel method of a central hole specimen tension is also introduced for edge fracture study, showing a similar trend as found in HET. The paper briefly presents a procedure and the results for a full calibration of the DP780 sheet for plasticity and fracture, where a hybrid testing/simulation method is used to obtain parameters for Hill 48 plasticity model and modified Mohr–Coulomb fracture model. The finite element simulation gives an accurate prediction of HER, as well as the load displacement response and specimen deflection distribution in the hole expansion tests on uncracked material. The correlation between simulation and tests on central hole specimen also turns out to be very good. The paper also presents a very interesting insight of the initiation and propagation of cracks from the hole edge during a hole expansion test by numerical simulation in comparison with testing observation. The number of final cracks are accurately predicted. Other new aspects of the present paper include an improved 3D DIC measurement technique and a simplified analytical solution, from which a rapid estimation of displacement and hoop strain field can be made (see “Appendix 2”).     

超高强度钢DP1000液压成形A柱的关键技术

目的研究超高强度钢DP1000液压成形A柱仿真技术和试验效果,解决批量生产中DP100焊管技术和同步冲孔等关键技术。方法基于Autoform有限元模拟软件,仿真分析了DP1000液压成形A柱的可行性,试验了DP1000液压成形A柱零件。通过对比高频焊管和激光焊管的液压成形零件焊缝质量,解决量产零件开裂问题,开展了DP1000液压成形A柱的Cr12MoV、ASP30和SKH51不同材料的同步冲孔效果,解决DP1000材料冲头寿命和冲孔质量问题。结果采用DP1000材料可以获得液压成形A柱,具有制造可行性。与高频焊管相比,具有较小的热影响区和硬度变化较小的激光焊管,更适合DP1000液压成形A柱使用。结论 ASP30和SKH51比传统的Cr12MoV更适合于DP1000材料液压成形A柱同步冲孔,冲头寿命提高80多倍,冲孔质量良好。     

Edge Fracture Prediction Using Uncoupled Ductile Fracture Models for DP780 Sheet

This paper is a contribution to the prediction of edge fracture behavior using uncoupled ductile fracture models. A fully integrated simulation framework for the edge fracture prediction is proposed with the shear-induced pre-damage considered. User-defined material subroutines are coded with uncoupled ductile fracture models (Lou-Huh, Oh, Brozzo) incorporated, which are calibrated using the fracture strains of various loading paths. A series of 3D numerical simulations are performed and compared with the results of hole-expansion tests. The effects of pre-damage field and fracture models are analyzed and discussed.

     

Surface Degradation and Cracking in Combustion Turbine Blade Cooling Passages

The depth of internal oxidation and nitridation from the surface of the 16 cooling holes in a first-stage turbine blade was measured by optical microscopy after 32,000 hours of service. Maximum depth of penetration was 15.5 mils (0.4 mm) at the trailing edge hole. An effort was made to predict hole surface metal temperatures based on these measurements using the Arrhenius relationship between time and temperature with depth of oxidation assumed to be parabolic with time. Good correlations were obtained between the finite element analysis results and the predictions. In the thickest part of the airfoil, where metal temperature is minimum, intergranular cracks up to 1.2.6 mils (0.32 mm∥ in depth were found at the surface of the cooling holes. Measurable attack was only one to two mils (0.025-0.050 mm). Based on an approximate elastic-relaxation-local inelastic stress analysis, it was calculated that inelastic local strains of over one percent occur at the points of cracking. No cracking was observed in the hotter holes, but cracking did occur in a trailing edge tip cooling hole when weld repair of the tip squealer was attempted indicating that embrittlement had occurred from the environmental attack.     

Interaction between matrix cracking and edge delamination in composite laminates

Matrix cracking and edge delamination are two main damage modes in continuous-fibre composite laminates. They are often investigated separately, and so the interaction between two damage modes has not yet been revealed. In this paper, a simple parallel-spring model is introduced to model the longitudinal stiffness reduction due to matrix cracking and edge delamination together. The energy release rate of edge delamination eliminating the matrix crack effect and the energy release rate of matrix cracking in the presence of edge delamination are then obtained. Experimental materials include carbon- and glass-fibre-reinforced bismaleimide composite laminates under static tension. The growth of matrix cracks and edge delaminations was recorded by means of NDT techniques. Results show that matrix cracks may initiate before or after edge lamination. This depends on the laminate layup, and especially on the thickness of the 90° plies. Edge delamination may also induce matrix cracking. Matrix cracking has a significant effect on the stiffness reduction in GRP laminates. The present model can predict the stiffness reduction in a laminate containing both matrix cracks and edge delaminations. The mixed-mode delamination fracture toughness obtained from the present model shows up to 50% differences compared with O'Brien's model for GRP laminates. However, matrix cracking has a small effect on the mixed-mode interlaminar fracture toughness of the CFRP laminates.     

省煤器膨胀板冲压开裂原因分析

通过对冲压开裂的省煤器膨胀板进行理化和变形分析 ,认为膨胀板在材料代用方面存在一定的问题 ,材料的拉伸性能不合格是膨胀板冲压开裂的主要原因。建议膨胀板以选用含硅量较少的Q2 35AF材料为宜 ;对已下料但还未冲压的膨胀板进行退火处理以改善钢板性能 ,或改为两次冲压 ,以减小变形量     

Forming limit diagram of Advanced High Strength Steels (AHSS) based on strain-path diagram

Advanced High Strength Steels (AHSS) is a promising material for automotive applications due to its high strength-to-weight ratio compared to other steels. Recently third generation steels have been developed which show intermediate properties between first and second generation AHSS. Formability analysis was performed between first generation Transformation Induced Plasticity (TRIP) and second generation Quenched and Partitioned (Q&P) AHSS. The main objective of the study is to perform formability analysis of TRIP and Q&P AHSS. The chemical compositions of both the steels are almost similar but different processing conditions lead to microstructural variations. Experimental and simulated strain-path diagram (SPD) was plotted from drawing to stretching regions using Limit Dome Height (LDH) test and Finite Element Method (FEM) respectively. The formability of TRIP steel is higher when compared to Q&P steels. Stretching regions show large deviation between experimental and simulated SPD for both the steels. A new strain localization criterion is proposed to construct a forming limit curve (FLC) for both experimental and simulated SPD. The proposed failure criterion is compared with other failure criteria for FLC prediction. The FLC based on new strain localization criterion shows better agreement with experimental FLC compared to other failure criteria.     

Experimental and theoretical formability analysis using strain and stress based forming limit diagram for advanced high strength steels

In this study, experimental and numerical analyses of Forming Limit Diagram (FLD) and Forming Limit Stress Diagram (FLSD) for two Advanced High Strength Steel (AHSS) sheets grade DP780 and TRIP780 were performed. Initially, the forming limit curves were experimentally determined by means of the Nakazima forming test. Subsequently, analytical calculations of both FLD and FLSD were carried out based on the Marciniak–Kuczinsky (M–K) model. Additionally, the FLSDs were calculated using the experimental FLD data for both investigated steels. Different yield criteria, namely, von Mises, Hill’s 48, and Barlat2000 (Yld2000-2d) were applied for describing plastic flow behavior of the AHS steels. Both Swift and modified Voce strain hardening laws were taken into account. Hereby, influences of the constitutive yield models on the numerically determined FLDs and FLSDs were studied regarding to those resulted from the experimental data. The obtained stress based forming limits were significantly affected by the yield criterion and hardening model. It was found that the forming limit curves calculated by the combination of the Yld2000-2d yield criterion and Swift hardening law were in better agreement with the experimental curves. Finally, hole expansion tests were conducted in order to verify the different failure criteria. It was shown that the stress based forming limit curves could more precisely describe the formability behavior of both high strength steel sheets than the strain based forming limit curves.     

接装纸材质和激光打孔参数对卷烟的影响研究

目的 研究不同材质接装纸和激光打孔参数对在线激光打孔卷烟的影响。方法 应用扫描电镜检测卷烟样品的打孔微观结构,包括纸的表面形貌、打孔的大小、孔间距等指标,对相应接装纸的卷烟物理指标差异和烟气指标差异以及相关性进行研究。结果 激光打孔脉冲时间、打孔数量对激光打孔的微观形态有较大影响,打孔脉冲时间和打孔数量与卷烟烟支吸阻呈线性负相关,与总通风率呈线性正相关。在相同激光打孔参数下,不同接装纸材质纸张孔径和孔间距明显不同,单孔的形态差异较大;不同材质接装纸对卷烟物理指标影响较小,对卷烟烟气指标有一定影响。单孔打孔的高质量有利于提高卷烟物理指标和烟气指标的稳定。结论 不同材质接装纸的在线激光打孔应用效果不同,可以根据烟支设计需要进行选择接装纸材质。     

预应力钢绞线锈胀及混凝土开裂预测

针对钢绞线锈蚀导致混凝土开裂现象,开展了不同应力状态下混凝土的锈胀开裂试验,基于红外和热重分析研究了预应力钢绞线锈蚀产物的膨胀率,分析了预应力对保护层临界开裂时间和裂缝宽度的影响,综合考虑预应力、铁锈膨胀率和混凝土开裂损伤等因素,建立了开裂初始和发展全过程的锈胀裂缝预测模型,并通过试验结果进行了验证。结果表明:预应力会加速混凝土的锈胀开裂,在钢绞线抗拉强度75%的预应力水平下,保护层初始开裂时间降低了22%,裂缝扩展速率增加了9%;建立的模型具有较好的精度,可以合理地预测预应力混凝土的锈胀开裂。     

Perforation of a thick plate by rigid projectiles

Perforation of a thick plate by rigid projectiles with various geometrical characteristics is studied in the present paper. The rigid projectile is subjected to the resistant force from the surrounding medium, which is formulated by the dynamic cavity expansion theory. Two perforation mechanisms, i.e., the hole enlargement for a sharp projectile nose and the plugging formation for a blunt projectile nose, are considered in the proposed analytical model. Simple and explicit formulae are obtained to predict the ballistic limit and residual velocity for the perforation of thick metallic plates, which agree with available experimental results with satisfactory accuracy.     

Creep induced rate effects on radial cracks in multilayered structures

This paper considers foundation and epoxy creep induced loading rate effects on radial cracks in multilayered structures. These include top layers of glass or silicon that are bonded to polycarbonate foundations with epoxy. The creep properties of the epoxy join and the polycarbonate foundation are determined using compression experiments and spring-dashpot models. The measured creep parameters are then incorporated into an analytical mechanics model, and finite element simulations are used to predict the effects of creep on the critical loads for radial cracking at different loading rates. The models suggest that the combined effects of creep and slow crack growth must be considered in the predictions of the critical loads required for radial cracking in the systems containing glass top layers. Since slow crack growth does not occur in silicon, the model considering the creep effect is used to predict the critical loads for radial cracking in the systems containing silicon top layers. In both of the structures, analytical solutions are obtained for bi-layer structures and finite element simulations are used for tri-layer structures. Our results show that the analytical solutions obtained by bi-layer structures provide good estimations for tri-layer structures when the epoxy thickness is less than 100 μm. The predictions obtained for both systems are shown to provide improved predictions by comparing with experimental results reported by Lee et al. [J. Am. Ceram. Soc., 2002, 85(8), 2019–2024]. In both systems, the modeling of join/substrate creep is shown to be important for the accurate prediction of loading rate effects on radial cracking.     

Effect of expansion technique and plate thickness on near-hole residual stresses and fatigue life of cold expanded holes

Cold expansion of fastener holes is a common way of improving fatigue performance of airframes. Among the several techniques applicable, the split-sleeve method is the most accepted in creating beneficial compressive residual stresses around expanded holes. In the present work, residual stresses at expanded holes in several types of aluminium plates produced by two different techniques, split-sleeve and roller burnishing, have been evaluated by the novel destructive Sachs method and then compared. It was found that stress distribution particularly at the vicinity of the hole was sensitive to the method of expansion and plate thickness, due to differing characteristics of the plastic material flow. Thus, secondary reverse yielding after cold expansion found to reduce residual hoop stresses at the edge of the hole, and excessive expansion above a limit, was thought to increase reverse yielding. S–N data revealed that no benefit was gained from expanding beyond this limit. It was suggested that the reduction in the number of cycles to crack initiation or more often to crack growth was due to increased reverse yielding at the vicinity of the expanded hole.     

内柱孔和内锥孔圆柱形变幅杆

激光和水射流是对陶瓷等易碎材料进行辅助打孔的传统方法,其设备存在大而复杂等缺点。加工陶瓷等易碎材料时,利用超声振动的带孔变幅杆的设备比起传统的利用激光和水射流的的设备更简易和小型化,因此,超声加工受到了人们的重视。文章对中心孔分别为柱形和锥形、外形为圆柱形的超声杆件,基于解析法推导了这两种孔型变幅杆的频率方程及性能参数表达式,分析了不同参量对其性能参数的影响,并利用有限元法计算了在谐振状态下这两种变幅杆的应力及振动位移沿轴向分布的规律。结果表明,在相同谐振频率及面积系数下,带孔变幅杆的放大系数大于实心圆柱杆的放大系数;锥形孔变幅杆的放大系数小于柱形孔变幅杆的放大系数,但前者应力曲线光滑且应力极大值较小。     

超高强钢前纵梁零件冲压开裂分析与处理

目的解决780 MPa级别超强度钢板冷冲压生产汽车前纵梁时发生的冲压开裂问题。方法通过网格应变分析技术和仿真分析,研究该零件冲压开裂的原因,分析引起开裂的因素,基于CAE模型系统,研究压边力、模具间隙、坯料尺寸、材料性能对开裂的影响规律。结果降低压边力和增加模具间隙均能减轻开裂,但是无法消除冲压开裂;坯料尺寸缩小可以消除冲压开裂,但是优化坯料尺寸需要改变模具上的坯料定位器,同时增大起皱风险;通过提升材料性能可以消除开裂。结论考虑最终各方案成本,选择性能优异的材料进行生产,将冲压开裂率降低至0.6%,满足了冲压要求。     

A new approach to enhancement of fatigue life of rail-end-bolt holes

The object of this paper is bolted joint railroads as the accent is put on the material behaviour around the bolted holes. The fatigue failure around rail-end-bolt holes is particularly dangerous, since it leads to derailment of trains and consequently, to inevitable accidents. Moreover, the cracking at rail-ends, which starts from bolt hole surface, causes premature rails replacement. It is well-known that the presence of residual compressive hoop stresses around the bolted holes closes the existing first mode cracks and impedes the formation of new ones and thereby extends the fatigue life of the holed components. In this article a new approach to enhancement of fatigue life of rail-end-bolt holes has been developed on the basis of a novel method and tool for cold expansion (CE) of holes, patented by the authors. The major advantage of the method is in imparting around the holes of beneficial residual compressive hoop stresses which are symmetric toward the middle longitudinal plane of the rail and thus the axial stress gradient is minimum. The developed approach consists in setting and solving a multi-objective optimization task of the CE of the rail-end-bolt holes. Because of the specificity of the studied problem, the optimal solution has been found by finite element (FE) simulations. For that purpose generalized FE model of the object has been developed. Through this model the critical point around the outside holes has been localized and the cycle of variation of hoop stresses has been determined taking into consideration assembly stresses. On the basis of adapting the generalized FE model of the rail joint to simulating the CE process, a comparison between the cases with and without CE of rail-end-bolt holes has been made. On this basis the optimal degree of CE and the successive hole treatment have been found. After simulating the CE process by the determined optimal degree of CE, the beneficial effect of implementing the new approach has been proved.     

A global model for corrosion-induced cracking in prestressed concrete structures

A global model is proposed in this study to predict prestressed concrete (PC) cracking induced by strand corrosion. The proposed model considers the three stages: micro-crack formations, cover cracking initiation, and crack width growth. The prestress and geometric properties of the strand have been incorporated into the prediction. Six PC beams were designed and accelerated toward corrosion-induced cracking. Observing the strands supported visual evidence of pitting corrosion and crevice corrosion. The effects of corrosion-induced crack on the failure of beams are analyzed. The proposed model is verified by the experimental results and this work presents the effects of parameters on corrosion-induced cracking. The results show that prestress has an adverse effect on corrosion-induced cracking. Prestress leads to a decrease in the critical corrosion loss at the three stages. This decrement becomes more noticeable with increasing cover and decreasing concrete tensile strength, but shows no remarkable changes with an increasing strand diameter and rust expansion ratio.     

Synthesis of punching failure in reinforced concrete

A synthesis of punching failure in reinforced concrete is given here. First, some recent experimental results are presented allowing one to show the difference between flexural and punching failure. Second, the punching failure mechanism is discussed based on results obtained with numerical simulations demonstrating among others the influence of the concrete tensile strength. Then, using these results, an analytical model is derived for punching load prediction. The model allows a unified treatment of slabs with various types of reinforcement. Finally, the prediction's capabilities are discussed using extended databases as well as special experimental results.     

A computational continuum damage mechanics model for predicting transverse cracking and splitting evolution in open hole cross‐ply composite laminates

The present study focuses on a computational constitutive model which predicts the matrix cracking evolution and fibre breakage in cross‐ply composite laminates with open hole under in‐plane loading. To consider the effects of matrix cracking on the nonlinear response of laminates, a simplified crack density based model is applied which evaluates the representative damage parameters of matrix cracking. Furthermore, a developed subroutine based on continuum damage mechanics concepts is applied in ANSYS code which is capable to consider the transverse cracking/splitting evolution and predict the final failure load of mentioned laminate under monotonic loading in a progressive damage analyses. It is shown that the obtained stress–strain behaviours and the damage evaluation of considered laminates are in good agreement with the available experimental results.