反向钻孔法应用于工件内表面残余应力测量的研究
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摘要
针对现有应力测试难以准确获得工件内壁应力的问题,该文提出于内壁贴片测应变,由外壁钻入的反向钻孔法。应用有限元数值模拟反向钻孔过程,借助生死单元技术获得反向钻孔法测试所需要的应变释放系数a,b;对比反向钻孔法、盲孔法和X射线衍射法对不同厚度钢板的同一测点测得的残余应力结果,以验证反向钻孔法的可行性和可靠度。模拟结果发现,a,b系数与样品壁厚、孔径、剩余钻深均有关系,对此进一步归纳出适用于标准ASTM E837中A、B型应变片的a,b系数赋值表。实验结果显示,不同测试方法间虽由于测试范围不同而存在差异,但大部分测试结果保持一致。综合模拟与实验结果,通孔法可以改善原先工件内壁应力测试难的问题,并提高内壁应力的测试精度。
It is difficult to measure the stress on the inner surface of the workpiece by the hole-drilling straingage method. This paper puts forward a new test method of drilling called inverse hole-drilling method, from the outer wall and releasing the stress layer by layer till the inner surface. Ansys is used to simulate the process by method of life-and-death element, the calibration factors a, b needed for test is obtained at the same time. In order to verify the validity of this drilling process, both X-ray and drilling method were used to determine residual stress of the same measure point. FEM results show that factors a, b are influenced by both wall thicknesses and hole's diameters while the drilling depth. To clarify this connection, the numerical values of coefficient a, b were drawn for the inverse hole-drilling method mentioned, both type A and B rosette mentioned in ASTM E837 were included. The experimental results show that although there are differences between the results, which may be due to each specific test range, most of the test results show consistency. In summary, inverse hole-drilling method applied on inner surface is proved to be an effective and accurate way.
It is difficult to measure the stress on the inner surface of the workpiece by the hole-drilling straingage method. This paper puts forward a new test method of drilling called inverse hole-drilling method, from the outer wall and releasing the stress layer by layer till the inner surface. Ansys is used to simulate the process by method of life-and-death element, the calibration factors a, b needed for test is obtained at the same time. In order to verify the validity of this drilling process, both X-ray and drilling method were used to determine residual stress of the same measure point. FEM results show that factors a, b are influenced by both wall thicknesses and hole's diameters while the drilling depth. To clarify this connection, the numerical values of coefficient a, b were drawn for the inverse hole-drilling method mentioned, both type A and B rosette mentioned in ASTM E837 were included. The experimental results show that although there are differences between the results, which may be due to each specific test range, most of the test results show consistency. In summary, inverse hole-drilling method applied on inner surface is proved to be an effective and accurate way.
引文
[1]刘一华,贺赟晖,詹春晓,等.盲孔法中释放系数的数值计算方法[J].机械强度,2008,30(1):33-36.
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[3]C ABRAHAM,GS SCHAJER.Hole-drilling residual stress measurement in an intermediate thickness specimen[C]//Proceeding of the 2012 annual conference on experimental and applied mechanics,2013.
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[6]YOUNG W,BUDYNAS R,SADEGH A.Roark’s Formulas for stress and strain[M].8th ed.New York:McGraw-Hill,2011:121-158.
[7]Standard test method for determining residual stresses by the hole-drilling strain gage method:ASTM E837-08e2.[S].2013.
[8]李世芸,肖正明.弹性力学及有限元[M].北京:机械工业出版社,2016:75-102.
[9]杨立权,杨立专,吕青青,等.平板孔口应力集中的数值模拟及理论分析[J].煤矿机械,2012,33(2):65-67.
[10]付连宇,厉学广,郭强.高厚径比微型钻头开发[J].印制电路信息,2010(s1):440-445.
[11]任建华,付学中,付宇明,等.激光熔覆45钢复合材料力学性能实验[J].塑性工程学报,2012(4):99-102.
[12]MIYAZAKI T,SASAKI T.A comparison of X-ray stress measurement methods based on the fundamental equation[J].Journal of Applied Crystallography,2016,49(2):426-432.
[13]徐顺飞.静态应变测量的误差分析[J].直升机技术,2010(1):47-51.
[14]陈惠南.盲孔法测量残余应力A,B系数计算公式讨论[J].机械强度,2009(2):31-36.
[2]闫鹏飞.高强铝合金厚板取样切割过程残余应力场演变的研究[D].长沙:中南大学,2010.
[3]C ABRAHAM,GS SCHAJER.Hole-drilling residual stress measurement in an intermediate thickness specimen[C]//Proceeding of the 2012 annual conference on experimental and applied mechanics,2013.
[4]SMITH D J,FARRAHI G H,ZHU W X,et al.Experimental measurement and finite element simulation of the interaction between residual stresses and mechanical loading[J].Int JFatigue,2001,23:293-302.
[5]BUCHMANN M,GADOW R,TABELLION J.Experimental and numerical residual stress analysis of layer coated composites[J].Mater Sci Engng,2000,288(2):154-159.
[6]YOUNG W,BUDYNAS R,SADEGH A.Roark’s Formulas for stress and strain[M].8th ed.New York:McGraw-Hill,2011:121-158.
[7]Standard test method for determining residual stresses by the hole-drilling strain gage method:ASTM E837-08e2.[S].2013.
[8]李世芸,肖正明.弹性力学及有限元[M].北京:机械工业出版社,2016:75-102.
[9]杨立权,杨立专,吕青青,等.平板孔口应力集中的数值模拟及理论分析[J].煤矿机械,2012,33(2):65-67.
[10]付连宇,厉学广,郭强.高厚径比微型钻头开发[J].印制电路信息,2010(s1):440-445.
[11]任建华,付学中,付宇明,等.激光熔覆45钢复合材料力学性能实验[J].塑性工程学报,2012(4):99-102.
[12]MIYAZAKI T,SASAKI T.A comparison of X-ray stress measurement methods based on the fundamental equation[J].Journal of Applied Crystallography,2016,49(2):426-432.
[13]徐顺飞.静态应变测量的误差分析[J].直升机技术,2010(1):47-51.
[14]陈惠南.盲孔法测量残余应力A,B系数计算公式讨论[J].机械强度,2009(2):31-36.
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