金属表面超声滚压加工理论及表层力学性能研究
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摘要
超声表面滚压加工(USRP)是一种新兴的表面纳米化技术，可以提高金属材料表面的综合性能。
本文首先在考虑应变、应变率和循环加载特性的基础上修正了非线性各向同性-随动硬化本构模型用以描述金属材料在超声表面滚压加工过程中的应力应变关系，并针对轴类用供货态和调质态40Cr钢进行了不同应变幅和不同应变速率下的对称应变控制低周疲劳试验，以获取其材料参数。
其次，建立了基于压电效应原理的USRP动力监测系统，以40Cr钢为载体，研究了超声表面滚压的动力响应，获得了按正弦函数变化的动态冲击力的频率和幅值，结果发现随着静压力和振幅的增加，冲击力有所增加，相对于静压力，振幅的影响更为显著。据此对超声表面滚压过程进行有限元模拟，得到了加工过程中工作头的运动状态，从而进一步对工作头冲击40Cr钢表面的弹塑性球面应力波问题进行了求解。通过特征线法给出了弹塑性球面波传播的任意质点在任意时刻的应力应变状态和运动速度。
再次，用有限元手段分析了超声表面滚压过程中整体模型的能量分布，定义并求得了超声表面滚压加工的效率和功率，获得了表面纳米化工艺中关注的表面特征参量随USRP加工参数的变化规律。模拟结果表明：经过超声表面滚压处理后，表层残余应力分布比较均匀，表面各方向的应力分量均为压应力，随着深度的增加压应力先增大后减小。随着车床主轴转速、加工头径向进给速率的降低和静压力、振幅和加工遍数的增加，最大残余压应力的数值和深度以及残余压应力范围均有不同程度的增加。表面粗糙度随着主轴转速和进给速率的增加而增加，随静压力和振幅的增加先减小后增大。通过等效塑性应变表征了材料的加工硬化程度。
最后，采用纳米压痕技术测试了超声滚压后材料表层的力学性能，包括弹性模量、纳米硬度、以屈服强度和应变硬化指数表征的材料塑性参数和残余应力。弹性模量、纳米硬度和屈服强度由材料的表面向内部逐渐减小，并随USRP静压力、振幅和加工遍数的增加显著提高，应变硬化指数呈相反趋势。在距离表面500μm以内，40Cr钢表层残余应力均为压应力，随着距表面距离的增加，残余压应力值不断减小。
Ultrasonic surface rolling processing (USRP) is a newly developed surfacenanocrystallization technology, which can greatly improve the comprehensiveperformance of metal surface.
This paper first chooses the nonlinear isotropic-kinematic hardening constitutivemodel to describe the stress-strain relation of material subjected to ultrasonic surfacerolling and then carries out symmetrical strain controlled low cycle fatigue tests underdifferent strain amplitude and strain rate for as-supplied, quenched and tempered40Crsteel for the sake of drawing material parameters. Meanwhile, the nonlinearisotropic-kinematic hardening constitutive model is revised considering strain, strainrate and cyclic loading characteristics.
Secondly, the dynamic response of40Cr suffered by ultrasonic surface rolling isinvestigated. In this connection, dynamic monitoring system based on the principle ofpiezoelectric effect is established and the frequency and amplitude of dynamic impactforce which varies according to sine function are obtained. It is found that the impactforce increases as static pressure and vibration amplitude increase. Compared withstatic pressure, the influence of vibration amplitude is more significant. The motionstate of processing tip is obtained by finite element simulation, and further used forsolving the elastic-plastic spherical stress wave problem generated in dynamic impactprocess. The stress-strain state and velocity of any mass point at any time are providedthrough characteristic method.
Energy distribution during ultrasonic surface rolling process is studied using finiteelement analysis, as well as definition and calculation of USRP efficiency and power.Also, effects of USRP parameters on surface characteristics are discussed. Simulationresults show that residual stress distribution in surface layer is evener after USRPtreatment and the surface residual stress is compressive. Compressive stress firstincreases and then decreases with the increase of depth. The magnitude and depth ofmaximum residual stress and residual stress range increase as spindle speed and feedrate decrease and static pressure, vibration amplitude, processing times increase.Surface roughness rises as spindle speed and feed rate increase and first decrease andthen increase with the increase of static pressure and vibration amplitude. Workhardening is characterized through the equivalent plastic strain.
Finally, nanoindentation experiments are performed on the surface layer of40Crtreated by USRP to obtain the mechanical properties, including elastic modulus, nanohardness, yield strength, strain hardening exponent and residual stress. Elasticmodulus, nano hardness and yield strength gradually reduce from surface to interior,and are significantly improved with the increase of static pressure, amplitude andprocessing times, whereas strain hardening exponent presents a contrary trend. Within500μm from the surface, residual stresses are compressive and reduce with theincrease of distance from the surface.
本文首先在考虑应变、应变率和循环加载特性的基础上修正了非线性各向同性-随动硬化本构模型用以描述金属材料在超声表面滚压加工过程中的应力应变关系，并针对轴类用供货态和调质态40Cr钢进行了不同应变幅和不同应变速率下的对称应变控制低周疲劳试验，以获取其材料参数。
其次，建立了基于压电效应原理的USRP动力监测系统，以40Cr钢为载体，研究了超声表面滚压的动力响应，获得了按正弦函数变化的动态冲击力的频率和幅值，结果发现随着静压力和振幅的增加，冲击力有所增加，相对于静压力，振幅的影响更为显著。据此对超声表面滚压过程进行有限元模拟，得到了加工过程中工作头的运动状态，从而进一步对工作头冲击40Cr钢表面的弹塑性球面应力波问题进行了求解。通过特征线法给出了弹塑性球面波传播的任意质点在任意时刻的应力应变状态和运动速度。
再次，用有限元手段分析了超声表面滚压过程中整体模型的能量分布，定义并求得了超声表面滚压加工的效率和功率，获得了表面纳米化工艺中关注的表面特征参量随USRP加工参数的变化规律。模拟结果表明：经过超声表面滚压处理后，表层残余应力分布比较均匀，表面各方向的应力分量均为压应力，随着深度的增加压应力先增大后减小。随着车床主轴转速、加工头径向进给速率的降低和静压力、振幅和加工遍数的增加，最大残余压应力的数值和深度以及残余压应力范围均有不同程度的增加。表面粗糙度随着主轴转速和进给速率的增加而增加，随静压力和振幅的增加先减小后增大。通过等效塑性应变表征了材料的加工硬化程度。
最后，采用纳米压痕技术测试了超声滚压后材料表层的力学性能，包括弹性模量、纳米硬度、以屈服强度和应变硬化指数表征的材料塑性参数和残余应力。弹性模量、纳米硬度和屈服强度由材料的表面向内部逐渐减小，并随USRP静压力、振幅和加工遍数的增加显著提高，应变硬化指数呈相反趋势。在距离表面500μm以内，40Cr钢表层残余应力均为压应力，随着距表面距离的增加，残余压应力值不断减小。
Ultrasonic surface rolling processing (USRP) is a newly developed surfacenanocrystallization technology, which can greatly improve the comprehensiveperformance of metal surface.
This paper first chooses the nonlinear isotropic-kinematic hardening constitutivemodel to describe the stress-strain relation of material subjected to ultrasonic surfacerolling and then carries out symmetrical strain controlled low cycle fatigue tests underdifferent strain amplitude and strain rate for as-supplied, quenched and tempered40Crsteel for the sake of drawing material parameters. Meanwhile, the nonlinearisotropic-kinematic hardening constitutive model is revised considering strain, strainrate and cyclic loading characteristics.
Secondly, the dynamic response of40Cr suffered by ultrasonic surface rolling isinvestigated. In this connection, dynamic monitoring system based on the principle ofpiezoelectric effect is established and the frequency and amplitude of dynamic impactforce which varies according to sine function are obtained. It is found that the impactforce increases as static pressure and vibration amplitude increase. Compared withstatic pressure, the influence of vibration amplitude is more significant. The motionstate of processing tip is obtained by finite element simulation, and further used forsolving the elastic-plastic spherical stress wave problem generated in dynamic impactprocess. The stress-strain state and velocity of any mass point at any time are providedthrough characteristic method.
Energy distribution during ultrasonic surface rolling process is studied using finiteelement analysis, as well as definition and calculation of USRP efficiency and power.Also, effects of USRP parameters on surface characteristics are discussed. Simulationresults show that residual stress distribution in surface layer is evener after USRPtreatment and the surface residual stress is compressive. Compressive stress firstincreases and then decreases with the increase of depth. The magnitude and depth ofmaximum residual stress and residual stress range increase as spindle speed and feedrate decrease and static pressure, vibration amplitude, processing times increase.Surface roughness rises as spindle speed and feed rate increase and first decrease andthen increase with the increase of static pressure and vibration amplitude. Workhardening is characterized through the equivalent plastic strain.
Finally, nanoindentation experiments are performed on the surface layer of40Crtreated by USRP to obtain the mechanical properties, including elastic modulus, nanohardness, yield strength, strain hardening exponent and residual stress. Elasticmodulus, nano hardness and yield strength gradually reduce from surface to interior,and are significantly improved with the increase of static pressure, amplitude andprocessing times, whereas strain hardening exponent presents a contrary trend. Within500μm from the surface, residual stresses are compressive and reduce with theincrease of distance from the surface.
引文
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