用应变能密度法分析纤维金属层板的微动疲劳特性

为研究纤维金属层板的微动疲劳特性,首先,基于三维坐标系下的临界平面法求解了纤维金属层板铝层临界平面上的应力和应变分量,并进一步求解了Smith-Watson-Topper （SWT）和I型Nita-Ogatta-Kuwabara （NOK）应变能密度参数;然后,建立了应变能密度参数-微动疲劳寿命关系式,并通过实验数据得到了寿命预测公式中的待定参数;最后,采用I型NOK应变能密度准则分析了铝层厚度、纤维层厚度、各层相对厚度和桥足圆角半径等对微动疲劳损伤位置和寿命的影响,并为纤维金属层板抗微动疲劳设计提出了一些合理化建议。结果表明:增加铝层厚度可以延长微动疲劳寿命,但增加纤维层厚度和桥足圆角半径不会改善微动疲劳特性。提出的方法可为分析纤维金属层板铆接和螺栓连接中的微动疲劳问题提供理论依据。      

基于局部应变能密度法的缺口多轴疲劳寿命评估

本文提出了包括实验和数值工作在内的综合分析,阐明了缺口行为对比例多轴疲劳寿命的影响。方法对45钢和45QT钢进行了考虑缺口半径和开口角的多轴疲劳试验,基于平均应变能量密度理论的多轴疲劳分析的分析和计算框架进行了研究,以处理能量梯度。结果显示,大量新的疲劳数据首先通过法向应力和剪应力进行汇总,然后通过凹口尖端周围受控体积中的局部应变能密度重新分析。结论缺口角度对比例载荷下多轴疲劳数据的影响较小,而缺口半径是影响疲劳寿命的主要因素。     

残余压应力对45钢疲劳裂纹萌生寿命的影响

本文研究了４５钢不同缺口半径及经预压，喷丸处理后对试样弯曲疲劳裂纹萌生寿命的影响。研究结果表明：随着试样缺口根部半径的增大，试样的弯曲疲劳裂纹萌生寿命增加。     

DP800 双相高强钢折弯及回弹研究

目的针对高强度钢板成形过程中的回弹问题,研究工艺参数对回弹的影响规律,优选工艺参数组合,以获得回弹较小的V形件。方法采用dynaform软件对V形件进行成形及回弹的数值模拟,以摩擦因数、模具间隙、冲压速度、凹模圆角半径等工艺参数为自变量,以回弹前后水平距离差最大值为因变量,设计了四因素三水平的正交试验方案,研究多个工艺参数对回弹影响的规律。结果实验结果表明,V形件回弹值大小随着摩擦因数的增大呈现减小趋势;随着模具间隙、凹模圆角半径的增大,回弹值呈现增大的趋势;而冲压速度对V形件回弹的影响较小,且工艺参数影响V形件回弹大小的主次顺序为模具间隙、摩擦因数、凹模圆角半径、冲压速度。结论优选工艺参数组合为:摩擦因数为0.2、模具间隙为2.6 mm、冲压速度为1200 mm/s、凹模圆角半径为12 mm,此时回弹水平距离差最大值为0.566 mm,最大减薄率为1.40%;实际生产可以忽略冲压速度对回弹的影响,仿真结果对实际生产具有指导意义。     

多轴载荷下缺口件的疲劳寿命估算方法

提出了一种多轴载荷下缺口件的疲劳寿命估算方法。该方法基于临界平面理论,计算出缺口件各部位的多轴疲劳损伤参数,以损伤参数最大的部位为缺口件的多轴疲劳危险点。根据临界距离思想,提出了热点法和线法的临界距离的计算方法,采用热点法和线法考虑缺口件疲劳危险点附近损伤梯度的影响,以临界距离修正的损伤参数计算多轴载荷下缺口件的疲劳寿命。采用SAE1045钢缺口件的多轴疲劳试验对该文提出的寿命估算方法进行评估和验证,结果表明:该文所建立的寿命预测方法具有较好的预测能力,预测结果大部分分布在试验结果的3倍分散带之内。     

轴对称曲面零件侧壁皱纹形貌的表述及测算方法

在分析与评价几种表述皱纹形状参数的基础上，确定了适用于研究轴对称曲面类零件测壁坊皱问题的皱形参数，研制了适于测量轴对称曲面类零件侧壁皱纹形貌的测量装置，并提出了根据测量结果计算皱形参数的方法。     

基于单轴缺口试样的一种低周疲劳测试方法与应用

对于漏斗式小曲率半径的缺口圆棒与缺口薄片试样提出了一种采用轴向测量应变的低周疲劳测试方法.通过有限元分析建立小曲率半径的漏斗式缺口圆棒或薄片试样的轴向测试应变到缺口根部Tresca等效应变的应变转换模型,并由疲劳损伤等效假设建立基于缺口试样疲劳实验数据的材料低周疲劳寿命估算模型;完成了大曲率半径漏斗光滑试样和小曲率半径缺口试样的Ti-4Al-2V合金低周疲劳试验,基于缺口试样的疲劳试验所建立的材料低周疲劳寿命估算模型与基于大曲率半径漏斗试样的低周疲劳寿命估算模型有良好的符合度.新方法也方便应用于N18锫合金缺口薄片试样的材料高温单轴低周疲劳行为试验研究,可推荐于材料低周疲劳测试规范修订采用.文中获得的Ti-4Al-2V合金和N18锆合金的不同温度下单轴低周疲劳行为试验数据与寿命估算模型有宜于工程应用.     

具有圆角的空心圆轴拉伸时的局部应力计算

根据锥形截面假设 ,探讨了一种计算具有圆角的空心圆轴拉伸时局部应力的方法 .文中详细讨论了圆角的半径、圆轴的半径和圆角的深度系数对应力集中的影响 ,并推导出圆轴内、外半径和弹塑性交界面与弹塑性局部应力的关系     

热声激励下金属薄壁结构的随机疲劳寿命估算

金属薄壁结构在热声载荷作用下会发生复杂的大挠度非线性响应,结构内部快速变化的复杂应力严重降低了结构的疲劳寿命。在结构热声激振非线性响应分析基础上,采用雨流循环计数法对应力响应时间历程进行疲劳循环计数,通过Morrow TFS,SWT平均应力模型将疲劳循环进行零均值等效处理,结合Miner线性损伤累积理论,计算结构的热声疲劳寿命。以2024-T3型铝合金薄板为研究对象,计算得到了屈曲前后四种温度条件有限带宽高斯白噪声载荷作用下的非线性动态响应,并估算了疲劳寿命。分析结果表明,屈曲前结构的疲劳寿命随着温度升高下降,屈曲后结构持续跳变时的疲劳寿命持续下降直至最低,结构进入间歇跳变区域后疲劳寿命上升,结构热声疲劳寿命与非线性响应特征具有特定的对应关系。     

基于田口方法齿圈压板精冲模具参数优化

在精密冲裁过程中,精冲模具结构参数和板料的摩擦系数显著影响精冲剪切面质量.采用有限元模拟和田口方法,对齿圈压板精冲模具精冲H62黄铜板料过程中凹模圆角半径、V形齿齿高、V形齿齿边距和板料摩擦系数对剪切面撕裂比的影响进行了研究.结果表明:参数按照减小撕裂比能力由大到小排序依次是凹模圆角半径,V形齿齿高,板料-模具摩擦系数和V形齿齿边距.研究发现:采用优化参数可显著减小剪切面上撕裂比,撕裂比最大减小24.8%,并可抑制凹模刃口附近微裂纹萌生,使剪切带内裂纹由凸模单向扩展至凹模刃口,避免裂纹的双向扩展-贯通导致较大撕裂比剪切面的出现.     

A simplified fatigue assessment method for high quality welded cruciform joints

The primary goal of this study was to develop an equation relating the geometric parameters to fatigue strength which can be used is routine design assessment. To attain this, the influence of local geometrical weld variations on the fatigue strength of non-load-carrying cruciform fillet welded joints were systematically studied using plane strain linear elastic fracture mechanics (LEFM). The effects of weld toe radius, flank angle and weld size were considered. Both continuous weld toe cracks and semi-elliptical toe cracks with alternate pre-existing defect depths were considered. A previously developed experimental crack aspect ratio development curve was used for assessing the growth of the semi-elliptical cracks using 2D FE models. A total of 152 experimental fatigue data points from six published studies of welded cruciform joints were evaluated. Details of the actual weld toe radius, flank angle and weld size were available for these joints. For the high quality welds evaluated, an assumed initial crack depth of 0.05 mm was found to correlate best with the experimental data. Of all the geometric parameters considered analytically, weld toe radius was found to have the most dramatic influence on fatigue life. A simple equation is proposed which relates welded joint fatigue strength to the ratio weld toe radius/plate thickness for high quality welds.     

Effect of an asymmetrical V-notch on the load carrying capacity of eccentrically loaded columns

In this paper theoretical and experimental investigations have been carried out to determine the effect of an asymmetrical V-shaped notch on the load carrying capacity of eccentrically loaded columns. The depth of the notch was kept constant whereas the notch angle, notch root radius; eccentricity of loading and length of the column was varied. It has been concluded that an asymmetrically placed V-notch decreases the load carrying capacity of the column. The load carrying capacity is not affected appreciably upto a notch angle of approx. 90°, but beyond 90° it increases. The load carrying capacity of the column also increases as the notch root radius increases but it decreases as the eccentricity of load and slenderness ratio increase.     

The use of the JV parameter in welded joints: Stress analysis and fatigue assessment

This paper investigates the use of the J_V parameter, a path-independent integral, for the evaluation of the elastic local stress parameters in welded details and for the estimation of their fatigue life.First, the stress intensity factors (SIF) of an embedded crack lying along the bisector of a sharp V-notch is calculated by means of the J_V without modelling the crack and by keeping the same external load and boundary conditions of the cracked model. Furthermore, the notch stress intensity factors (NSIFs) of the welds can be calculated after a post processing procedure of FE analysis with the advantage of using coarse meshes.Second, a correlation between the fatigue life of welded details and the J_V parameter is shown. In fact, careful analysis of the fracture surface of fillet welds taken from literature and of new fatigued joints indicates that the first stage of fatigue crack propagation follows the bisector line of the local V-notch as only mode I would be present. Therefore, since the J_V evaluated on a suitable integration path represents the SIF of an embedded crack lying along the bisector, the J_V is used for the fatigue life assessment of welded details. The critical characteristic length of a suitable integration path for welded joints made of steel and aluminium alloys has been calculated. These critical characteristic lengths were used for the evaluation of two fatigue general scatter bands, mainly based on fatigue data of non-load-carrying cruciform joints characterised by a V-notch angle of 135°. Further, fatigue life data of steel and aluminium alloy welded connections have also been investigated when both mode I and mode II loadings are singular.     

Failure initiation at a blunt V-notch tip under mixed mode loading

A criterion to predict crack onset at a sharp V-notch tip in homogeneous brittle materials under a mixed-mode loading was presented and validated by experimental observations in a previous paper by the authors. This criterion slightly underestimates the experimental loads causing failure which is attributed to a small notch tip radius that blunts the sharp corner. This discrepancy is rigorously analyzed mathematically in this paper by means of matched asymptotics involving 2 small parameters: a micro-crack increment length and the notch tip radius. A correction is brought to the initial prediction and a better agreement is obtained with experiments on PMMA notched specimens.     

A notch stress intensity approach applied to fatigue life predictions of welded joints with different local toe geometry

In the Notch Stress Intensity Factor (N‐SIF) approach the weld toe region is modelled as a sharp V‐shaped corner and local stress distributions in planar problems can be expressed in closed form on the basis of the relevant mode I and mode II N‐SIFs. Initially thought of as parameters suitable for quantifying only the crack initiation life, N‐SIFs were shown able to predict also the total fatigue life, at least when a large part of the life is spent as in the propagation of small cracks in the highly stressed region close to the notch tip. While the assumption of a welded toe radius equal to zero seems to be reasonable in many cases of practical interest, it is well known that some welding procedures are able to assure the presence of a mean value of the weld toe radius substantially different from zero. Under such conditions any N‐SIF‐based prediction is expected to underestimate the fatigue life. In order to investigate the degree of conservatism, a total of 128 fillet welded specimens are re‐analysed in the present work by using an energy‐based N‐SIF approach. The local weld toe geometry, characterised by its angle and radius, has been measured with accuracy for the actual test series. The aim of the work is to determine if the N‐SIF‐based model is capable of taking into account the large variability of the toe angle, and to quantify the inaccuracy in the predictions due to the simplification of setting the toe radius equal to zero.     

FE‐Festwalzsimulation und Dauerfestigkeitsberechnung festgewalzter Bauteile mit Konzepten der Schwingbruchmechanik

FE‐Simulation of Fillet Rolling and Fatigue life Calculation based on Fracture Mechanics Concepts Fillet rolling is a method which significantly improves the fatigue strength of members. Residual stresses induced in the surface layer during the fillet rolling process are able to retard or prevent crack propagation. For fatigue strength prediction of fillet rolled notched members a fracture mechanics based concept is described. It consists of three parts: • Finite element simulation of the fillet rolling process to calculate the residual stresses • Simulation of residual stress redistribution due to cyclic load • Assessment of fatigue cracks starting from notch roots and propagating under compressive residual stresses by means of fracture mechanics.     

基于有限元的法兰轴结构件塑性成形工艺分析

目的 针对法兰轴结构件塑性成形过程复杂、工序繁琐、成形效率低、材料易折叠等问题,基于塑性成形理论,对汽车法兰轴零件进行工艺分析,提出2种冷镦成形方案,对法兰轴结构件进行塑性成形工艺研究。方法 分析汽车法兰轴的几何特征,采用有限元分析软件对2种冷镦成形方案的成形载荷进行模拟比较,确定较为合理的工艺方案,通过正交试验设计进一步进行工艺参数的优化,选取预成形角度A、摩擦因数B、冷镦速度C、终成形圆角直径R作为4个因素,每个因素对应3个水平,并以成形载荷大小作为考核指标。结果 通过有限元数值模拟技术,得到工艺1各工序载荷分别为403、521 kN,工艺2各工序载荷分别为226、518 kN。可知工艺2比工艺1效率高,模具使用寿命更长。最后通过正交试验法获得各因素对成形载荷影响大小的排序为：摩擦因数>冷镦速度>终成形圆角直径>预成形角度,最优工艺组合为：预成形角度19°,摩擦因数0.2,冷镦速度15 mm/s,终成形圆角直径3 mm。结论 工艺2的冷镦成形方案缩短了锻件生产试验过程和修模时间,能够满足设计要求,为实际生产金属零部件提供了理论依据。     

Failure of two overhead crane shafts

The failure analysis of two overhead crane shafts is presented: the failure of an overhead crane drive shaft and the failure of an overhead crane gearbox shaft, due to rotating-bending fatigue. The fracture of the overhead crane drive shaft originated in small radius fillet between two different diameters of the shaft. A new shaft was made with a larger-size fillet, resulting in reduced stress concentration in this region. The failure of the overhead crane gearbox shaft originated at the intersection of two stress raisers, at the change in shaft diameter and in the keyway corner. A new shaft was made with a larger-size fillet and a larger size radius of the keyways corner to minimize stress concentration in this section. In both cases the installed couplings were replaced by gear couplings in order to allow parallel and angular misalignment as well as to avoid additional load due to misalignment. The analysis shows that the fatigue life can be significantly increased with a simple change in the structural details.     

J-Integral for Deep and Shallow Notches Under Torsion

J-integral has been calculated along the free-of-stress border of deep and shallow rounded notches under torsion, under the hypothesis of a linear elastic behaviour of the material. Two exact closed-form solutions have been obtained which make it explicit the influence of the notch opening angle and the notch root radius. When the notch root radius tends to zero the proposed solution matches the expression for the corresponding pointed V-notch case.