韧/脆性材料裂解加工数值模拟
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摘要
裂解加工是随着发动机连杆裂解生产而发展起来的新工艺,作为一门新技术其具有广泛的应用领域,本文以同连杆有相似结构与加工原理的工件为研究对象,深入研究裂解加工工艺。分别分析韧/脆性材料的裂解起始位置,研究背压力对裂解加工质量的影响,优化选择裂纹槽工艺参数。以使这项技术能够充分应用在实际加工生产中,改进这类结构形式的零件的加工方法。
选取典型的韧性材料C70S6与脆性材料HT150,利用ABAQUS有限元分析软件分析,根据各自的起裂准则分别确定两种材料的起裂位置。
通过有限元分析的方法考察背压力对韧/脆性材料裂解加工的影响,得出施加背压后会增大裂解主动载荷但是可以减小材料断裂后的变形量,提高断裂面质量。
分析裂纹槽三参数:张角、曲率半径、深度与裂解力、断裂面质量的关系。科学合理的选择裂纹槽参数,使裂解加工在较低的经济成本下获得较高裂解质量。
Splitting process is a new technology developping along with engine connecting rod splitting production.It hasαgood manny adavantages for example:few procedures and inexpensive equipment investment, low costs, good-quality products, high assembly precision,strong loading capacity, etc. As a new technique it is in possession of wide application area. The subject investigated of this article is workpiece with similar structure and process institutional with connecting rod.The main work is studying the splitting processing technic ,individually analysising the splitting original positions of tough and brittle material, optimizly selecting the crack processing parameters,studying the influnce of back pressure to splitting crudy.The main purpos is that this technology could be applied in practice manufacturing activity sufficiently and improving the processing procedure of this type structural part. It is of far reaching importance to improve the quality of products, reduce the production costs, increase economic benefit and enhance competitiveness in international markets.In fracture analysis it is difficult to solve with compute numerically method because of the intricacy diversity of influencing factor,material nonlinearity and geometrical nonlinearity,etc.Although some datas could be measured by experiment it needs every respect fund of huge equipment,material,processing and consumption of human power and time. So finite element analogy method is the best of all methods of fracture analysis.It could get accuracy and systemic simulation results as well as save much experiment spending.This paper finish sevral aspect work adopting large finite element analysis software ABAQUS.
1. Select representative tough material C70S6 and brittle material HT150. Do static analysis by finite element analysis software ABAQUS.Fix the splitting original positions of two material according to respective fracture criterias.The splittin original position of brittle material is unique, it is in front of the crack groove of the centrally symmetry. The splittin original positions of tough material is not unique because of its complex fracture criteria. They are in front of the crack groove in the 1/4 and 3/4 positions in the thickniss direction. Taking brittle material HT150 as an example, simulate crack propagation course applying cohesive element method of abaqus,specialisly learn splitting course. Fracture surface of splitting is ragged,because of the stress,displacement and strain are different at all points of the fracture path.
2 Research the influence of back pressure to the normal stress, mises stress, equivalent plastic strain of the tough and brittle material through the medium of FEM. It is shown that separation force increases as backpressure becomes larger. Plastic deformation at fractured surface decreases with the increase of backpressure. Backpressure has no influnce to the splittin original position of brittle material whereas convergence tough material ' splittin original position,thereby its fracture surface is more level off..
3. Analyses how crack notch geometric parameter influence sepration force of tough and brittle material through the medium of finite element numerical simulation. Curvature radius r ranges from 0.1mm to 0.4mm, open angleαfrom 0°to 90°,notch depth h from 0.4mm to 0.7mm. To brittle material take failure criteria most normal stress criteria and three-dimensional stress degree as analysis standard. Tough material failure criteria has two criteria : crack incept criteriaε≥εf, crack propagation criteriaσyy>σf so tough material take equivalent plastic strain, normal stress and three-dimensional stress degree as standard.The analysis results is crack notch three parameters have the same influnce to the sepration force of the two material. Notch depth influences separation force most and curvature radius takes second place and open angle has little effect. The choice range of the crack groove three parametric of the two materals is basicly the same. Selecting 0.1mm as curvature radius is logical,The deeper of the notch depht the easier of fracture in adequate conditions generally taking 0.6mm is logical.The flunce of open angle is small .Among the anglesα=60 is better.
选取典型的韧性材料C70S6与脆性材料HT150,利用ABAQUS有限元分析软件分析,根据各自的起裂准则分别确定两种材料的起裂位置。
通过有限元分析的方法考察背压力对韧/脆性材料裂解加工的影响,得出施加背压后会增大裂解主动载荷但是可以减小材料断裂后的变形量,提高断裂面质量。
分析裂纹槽三参数:张角、曲率半径、深度与裂解力、断裂面质量的关系。科学合理的选择裂纹槽参数,使裂解加工在较低的经济成本下获得较高裂解质量。
Splitting process is a new technology developping along with engine connecting rod splitting production.It hasαgood manny adavantages for example:few procedures and inexpensive equipment investment, low costs, good-quality products, high assembly precision,strong loading capacity, etc. As a new technique it is in possession of wide application area. The subject investigated of this article is workpiece with similar structure and process institutional with connecting rod.The main work is studying the splitting processing technic ,individually analysising the splitting original positions of tough and brittle material, optimizly selecting the crack processing parameters,studying the influnce of back pressure to splitting crudy.The main purpos is that this technology could be applied in practice manufacturing activity sufficiently and improving the processing procedure of this type structural part. It is of far reaching importance to improve the quality of products, reduce the production costs, increase economic benefit and enhance competitiveness in international markets.In fracture analysis it is difficult to solve with compute numerically method because of the intricacy diversity of influencing factor,material nonlinearity and geometrical nonlinearity,etc.Although some datas could be measured by experiment it needs every respect fund of huge equipment,material,processing and consumption of human power and time. So finite element analogy method is the best of all methods of fracture analysis.It could get accuracy and systemic simulation results as well as save much experiment spending.This paper finish sevral aspect work adopting large finite element analysis software ABAQUS.
1. Select representative tough material C70S6 and brittle material HT150. Do static analysis by finite element analysis software ABAQUS.Fix the splitting original positions of two material according to respective fracture criterias.The splittin original position of brittle material is unique, it is in front of the crack groove of the centrally symmetry. The splittin original positions of tough material is not unique because of its complex fracture criteria. They are in front of the crack groove in the 1/4 and 3/4 positions in the thickniss direction. Taking brittle material HT150 as an example, simulate crack propagation course applying cohesive element method of abaqus,specialisly learn splitting course. Fracture surface of splitting is ragged,because of the stress,displacement and strain are different at all points of the fracture path.
2 Research the influence of back pressure to the normal stress, mises stress, equivalent plastic strain of the tough and brittle material through the medium of FEM. It is shown that separation force increases as backpressure becomes larger. Plastic deformation at fractured surface decreases with the increase of backpressure. Backpressure has no influnce to the splittin original position of brittle material whereas convergence tough material ' splittin original position,thereby its fracture surface is more level off..
3. Analyses how crack notch geometric parameter influence sepration force of tough and brittle material through the medium of finite element numerical simulation. Curvature radius r ranges from 0.1mm to 0.4mm, open angleαfrom 0°to 90°,notch depth h from 0.4mm to 0.7mm. To brittle material take failure criteria most normal stress criteria and three-dimensional stress degree as analysis standard. Tough material failure criteria has two criteria : crack incept criteriaε≥εf, crack propagation criteriaσyy>σf so tough material take equivalent plastic strain, normal stress and three-dimensional stress degree as standard.The analysis results is crack notch three parameters have the same influnce to the sepration force of the two material. Notch depth influences separation force most and curvature radius takes second place and open angle has little effect. The choice range of the crack groove three parametric of the two materals is basicly the same. Selecting 0.1mm as curvature radius is logical,The deeper of the notch depht the easier of fracture in adequate conditions generally taking 0.6mm is logical.The flunce of open angle is small .Among the anglesα=60 is better.
引文
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2. Kubota T, Iwasaki S, Isobe T. Fracture split method for connecting rod. United States Patent:2004/0025340(A1), 2004-2-12.
3. Hasegana T, Iida Z, Takada K. Non-heat treated connecting rod and method of manufacturing the same. United States Patent: 2006/0000088(A1), 2006-1-5.
4. 寇淑清,杨慎华,金明华.发动机连杆裂解加工技术及其应用.机械强度, 2004,26(5):538～541.
5. 杨慎华,寇淑清,谷诤巍等.发动机连杆裂解加工新技术.哈尔滨工业大 学学报,2000,32(3):129～131.
6. Liebowitz,H.Computational fracture mechanics research and application[J]. Engineering Fracture Mechanics,1995,50(5-6):653- 670.
7. Hagedorn,Karl Edgar.Some aspects of fracture mechanics research during the last 25 years[J].Steel Research,1998,69:206-213.
8. 王国强.实用工程数值模拟技术及其在 ANSYS 上的实践.西安:西北工业大学出版社.1999.77 一 91.
9. 高庆.工程断裂力学.重庆大学出版社,1986.
10. Kubota T, Iwasaki S, Isobe T. Development of fracture splitting method for case hardened connecting rods. SAE2004320064, 2004.
11. 范天佑 断裂动力学引论 北京:北京理工大学出版社.
12. 寇淑清,杨慎华,邓春萍等.裂解工艺-发动机连杆制造最新技术.中国 机械工程,2001,12(7):839～84.
13. 寇淑清,杨慎华,赵勇.发动机连杆裂解加工及其关键技术,吉林大学学报,2004,34(1);86.
14. Fukuda S. Development of fracture splitting connecting rod. JSAE Review,2002, 23(1):10l～104.
15. Cristinacce M, Milbourn D J, James D E. The future competitiveness of automotive forgings. In: Kuzman K. Proceedings of the International Conference on Forging and Related Technologies. Birmingham: ImechE Conference Transactions, 1998, 1～13.
16. Gu Z W, Yang S H, Ku S Q. Fracture splitting technology of automobile engine connecting rod. International Journal of Advanced Manufacturing Technology,2005, (25):883～887.
17. Hoffmann G, Geiman T, Marra M. Fracture splitting of powder forged connecting rods. SAE2002010609, 2002.
18. Park H, Ko Y S, Jung S C. Development of fracture split steel connecting rods.SAE2003011309, 2003.
19. Boucha F A. Method of manufacturing connecting rods. United States Patent:2553935, 1951-5-22.
20. Honda Motor Co Ltd. Method for producing connecting rod of reciprocating motion system. United States Patent:4802269, 1989-02-07.
21. Daimler Chrysler AG. Split connecting rod for an internal combustion engineand method of production.United States Patent:6357321, 2002-03-19.
22. 奇瑞汽车有限公司发动机二厂技术科. AVL 连杆加工工艺简介.雅虎搜索, 2006, 12.- 44-(44).
23. 王秋冰 马 鸣 卢震鸣 来建刚等。发动机连杆用材料与工艺的发展趋势,柴油机设计与制造;2007,1(15),40-43.
24. http://www.alfing.de/aksenglishpage/produkte/technologien/cracken.html
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31. 王铎.断裂力学(上册).哈尔滨工业大学出版社(第 1 版).1989.3.
32. Irwin G R. Analysis of stress and strains near the end of a crack traversing a plate[J]. Appl.Mech.,1957,24:361-364.
33. J.M.Barsom.The Development of AASHTO Fracture Toughness Require- ment for Bridge Steel ,Eng.Frac.Mech.Vol 7(No.3),Sept 1975,p 605-618.
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35. 洪起超. 工程断裂力学基础.上海交通大学出版社(第 1 版).1987.7.
36. 高庆.工程断裂力学.重庆大学出版社,1986.
37. Wells Α A. Application of fracture mechanics at/and beyond general yielding[J].British Welding Journal,1963.
38. 黄克智.弹塑性断裂力学的一个重要进展[J].力学与实践,1993,(1):1-7.
39. Hutchinson J W.Sigular behavior at the end of α tensile crack in α hardening material[J]. Mech. Phys. Solids,1968,16:13-31.
40. Rice J R, Rosengren G F. Plane strain deformation near α crack tip in α power law hardening material[J].Mech.Phys.Solids,1968,16:1-12.
41. 张俊彦,张淳源.裂纹扩展条件及其温度场研究[J].湘潭大学自然科学学报,1996,(1):102-105
42. 郑修麟.切口件的断裂力学,西北工业大学出版社,2005.
43. Kuwamura H,Fracture nof steel during an earthquake-State-of-the-art in Japan.Eng.Structure,1998,2094-6):310-322 .
44. XuY and Schulson E M.On the notch sensitivity of the ductile intermetallic Ni,containing boron.Acta Mter.,1996,44(4):1601-1612.
45. EI-Magd E and Brodmann M. Influnce of precipitates on ductile fracture of aluminum alloy AA7075 at high strain rates.Matet, Sci,2001,A307:143-150.
46. Dowling N E.Mechanical Behavior of Materials (2nd Edition),Prentice Hall,Upper River.New Jersey,1998.
47. 郑修麟.材料的力学性能.第二版.西安:西北工业大学出版社,2000.
48. 郑修麟.金属材料切口强度的近似计算.航空材料(专刊),1983,3(1):53-58.
49. Zheng X L.On an unified model for predicting notch strength and fracture toughness. Eng.Fract.Mech.,1989,33(5),685-695.
50. Sih.Methods of ananlysis and Solution ofCrack Problems[M].Leyden; Noorhof f international Publishing,1973.
51. G.C.Sih.Role of Fracture Mechanics in Modern Technology[C].Proceedings of the International Conference on the role of Fracture Mechanics Technology.Rukuoka Japan.1986.
52. 郭伟国,李玉龙等.起裂韧性测试过程的三维分析. 计算力学学报,1997;14(3):310 一 316.
53. 刘瑞堂,张晓欣等.三点弯曲试样应力强度因子动态响应的有限元分析[J] 哈尔滨工程大学学报,2000;21(3):49 一 52.
54. 贾建军,彭颖红,阮雪榆. 一种有限元裂纹扩展仿真的网格技术[J]模具技术,2001;5:4.
55. 王国凡,汤爱君等 ,HT250 灰口铸铁的退火工艺和性能试验,《金属热处理》2004 年第 29 卷第 9 期.
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2. Kubota T, Iwasaki S, Isobe T. Fracture split method for connecting rod. United States Patent:2004/0025340(A1), 2004-2-12.
3. Hasegana T, Iida Z, Takada K. Non-heat treated connecting rod and method of manufacturing the same. United States Patent: 2006/0000088(A1), 2006-1-5.
4. 寇淑清,杨慎华,金明华.发动机连杆裂解加工技术及其应用.机械强度, 2004,26(5):538～541.
5. 杨慎华,寇淑清,谷诤巍等.发动机连杆裂解加工新技术.哈尔滨工业大 学学报,2000,32(3):129～131.
6. Liebowitz,H.Computational fracture mechanics research and application[J]. Engineering Fracture Mechanics,1995,50(5-6):653- 670.
7. Hagedorn,Karl Edgar.Some aspects of fracture mechanics research during the last 25 years[J].Steel Research,1998,69:206-213.
8. 王国强.实用工程数值模拟技术及其在 ANSYS 上的实践.西安:西北工业大学出版社.1999.77 一 91.
9. 高庆.工程断裂力学.重庆大学出版社,1986.
10. Kubota T, Iwasaki S, Isobe T. Development of fracture splitting method for case hardened connecting rods. SAE2004320064, 2004.
11. 范天佑 断裂动力学引论 北京:北京理工大学出版社.
12. 寇淑清,杨慎华,邓春萍等.裂解工艺-发动机连杆制造最新技术.中国 机械工程,2001,12(7):839～84.
13. 寇淑清,杨慎华,赵勇.发动机连杆裂解加工及其关键技术,吉林大学学报,2004,34(1);86.
14. Fukuda S. Development of fracture splitting connecting rod. JSAE Review,2002, 23(1):10l～104.
15. Cristinacce M, Milbourn D J, James D E. The future competitiveness of automotive forgings. In: Kuzman K. Proceedings of the International Conference on Forging and Related Technologies. Birmingham: ImechE Conference Transactions, 1998, 1～13.
16. Gu Z W, Yang S H, Ku S Q. Fracture splitting technology of automobile engine connecting rod. International Journal of Advanced Manufacturing Technology,2005, (25):883～887.
17. Hoffmann G, Geiman T, Marra M. Fracture splitting of powder forged connecting rods. SAE2002010609, 2002.
18. Park H, Ko Y S, Jung S C. Development of fracture split steel connecting rods.SAE2003011309, 2003.
19. Boucha F A. Method of manufacturing connecting rods. United States Patent:2553935, 1951-5-22.
20. Honda Motor Co Ltd. Method for producing connecting rod of reciprocating motion system. United States Patent:4802269, 1989-02-07.
21. Daimler Chrysler AG. Split connecting rod for an internal combustion engineand method of production.United States Patent:6357321, 2002-03-19.
22. 奇瑞汽车有限公司发动机二厂技术科. AVL 连杆加工工艺简介.雅虎搜索, 2006, 12.- 44-(44).
23. 王秋冰 马 鸣 卢震鸣 来建刚等。发动机连杆用材料与工艺的发展趋势,柴油机设计与制造;2007,1(15),40-43.
24. http://www.alfing.de/aksenglishpage/produkte/technologien/cracken.html
25. 沈成康.断裂力学〔M].上海:同济大学出版社,1996.
26. 陈兴周,常亮,刘杰;关于常用断裂判据;西北水力发电;2005,21(2):24-27.
27. Hyounsoo Park, Young Sang Ko. Development of Fracture Split Steel . Connecting Rods, SAE World Congress Detroit, Michigan March 3-6,2003.
28. 寇淑清,杨慎华,金文明;连杆裂解加工新技术与装备;机械工人;2002.11,5-7.
29. 沈成康.断裂力学[M].上海:同济大学出版社,1996.
30. 朱永昌,浦素云.断裂力学.北京航空航天大学出版社(第 1 版).1988.11.
31. 王铎.断裂力学(上册).哈尔滨工业大学出版社(第 1 版).1989.3.
32. Irwin G R. Analysis of stress and strains near the end of a crack traversing a plate[J]. Appl.Mech.,1957,24:361-364.
33. J.M.Barsom.The Development of AASHTO Fracture Toughness Require- ment for Bridge Steel ,Eng.Frac.Mech.Vol 7(No.3),Sept 1975,p 605-618.
34. 范天佑.应用断裂动力学基础.北京理工大学出版社,1992,6.
35. 洪起超. 工程断裂力学基础.上海交通大学出版社(第 1 版).1987.7.
36. 高庆.工程断裂力学.重庆大学出版社,1986.
37. Wells Α A. Application of fracture mechanics at/and beyond general yielding[J].British Welding Journal,1963.
38. 黄克智.弹塑性断裂力学的一个重要进展[J].力学与实践,1993,(1):1-7.
39. Hutchinson J W.Sigular behavior at the end of α tensile crack in α hardening material[J]. Mech. Phys. Solids,1968,16:13-31.
40. Rice J R, Rosengren G F. Plane strain deformation near α crack tip in α power law hardening material[J].Mech.Phys.Solids,1968,16:1-12.
41. 张俊彦,张淳源.裂纹扩展条件及其温度场研究[J].湘潭大学自然科学学报,1996,(1):102-105
42. 郑修麟.切口件的断裂力学,西北工业大学出版社,2005.
43. Kuwamura H,Fracture nof steel during an earthquake-State-of-the-art in Japan.Eng.Structure,1998,2094-6):310-322 .
44. XuY and Schulson E M.On the notch sensitivity of the ductile intermetallic Ni,containing boron.Acta Mter.,1996,44(4):1601-1612.
45. EI-Magd E and Brodmann M. Influnce of precipitates on ductile fracture of aluminum alloy AA7075 at high strain rates.Matet, Sci,2001,A307:143-150.
46. Dowling N E.Mechanical Behavior of Materials (2nd Edition),Prentice Hall,Upper River.New Jersey,1998.
47. 郑修麟.材料的力学性能.第二版.西安:西北工业大学出版社,2000.
48. 郑修麟.金属材料切口强度的近似计算.航空材料(专刊),1983,3(1):53-58.
49. Zheng X L.On an unified model for predicting notch strength and fracture toughness. Eng.Fract.Mech.,1989,33(5),685-695.
50. Sih.Methods of ananlysis and Solution ofCrack Problems[M].Leyden; Noorhof f international Publishing,1973.
51. G.C.Sih.Role of Fracture Mechanics in Modern Technology[C].Proceedings of the International Conference on the role of Fracture Mechanics Technology.Rukuoka Japan.1986.
52. 郭伟国,李玉龙等.起裂韧性测试过程的三维分析. 计算力学学报,1997;14(3):310 一 316.
53. 刘瑞堂,张晓欣等.三点弯曲试样应力强度因子动态响应的有限元分析[J] 哈尔滨工程大学学报,2000;21(3):49 一 52.
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