高强铝合金预拉伸厚板残余应力场分层法建模研究
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摘要
高强铝合金厚板是航空、航天、国防、船舶、轻工等领域的重要结构材料。其作为整体部件材料,不仅可以增强机体强度,还能够减少飞机构件数量和装配工时,因此作为国家”大飞机”项目的主要用材。然而高强铝合金厚板通常需经固溶强化,以提升板材力学性能。强化处理工艺在板内形成高达100～300MPa的残余应力。若应力消减工艺不当,则残存的残余应力将使厚板在加工中发生变形,影响构件的疲劳强度和抗应力腐蚀开裂性能。预拉伸厚板在重大项目中的应用对板内残余应力水平控制提出了严格要求。因而开展高强铝合金厚板残余应力消减机理及数学建模研究,进一步优化工艺并降低板内应力水平具有十分重要的意义。
本文围绕淬火-预拉伸厚板残余应力的演化机理,针对残余应力实验测试、铝合金应变空间弹塑性本构建模、金属薄板平面变形下厚度建模、铝合金预拉伸厚板残余应力场分层法建模以及残余应力的宏观消减机理等开展研究,主要有以下几个方面：
1、研究了典型高强铝合金厚板在不同固溶强化工艺和预拉伸条件下的残余应力场分布规律。实验测定了2A12和7075两种铝合金淬火厚板在淬火-预拉伸工艺中的残余应力场。发现在阵列喷淋及水浴淬火方式下厚板内部都形成了“内拉外压”的残余应力场典型分布；喷淋方式的淬火强度相对较低,只在厚板靠近表层的地方形成了较大的残余应力；水浴方式淬火强度更大,在厚板整个厚度上形成了倒U形分布的残余应力；预拉伸使喷淋和水浴两种淬火板内的残余应力都大幅度消减。
2、针对淬火工艺在厚板内部形成的力学性能不均性开展研究,通过7075厚板的屈服强度和硬度测试结果的相互印证,表明沿板厚方向确实存在明显的强度和硬度不均匀性,强度值从厚板表层到芯部呈现逐渐降低的趋势；研究了7000系铝合金铝合金在淬火-预拉伸过程中的力学性能演化规律,并根据实验情况确定了7075厚板在淬火一预拉伸的多个关键时间节点处的力学性能。研究发现7075合金在淬火结束时屈服强度低于实验测得的残余应力水平,从而发现残余应力在时效过程中出现增长的现象。
3、从应变空间表述的塑性增量本构模型一般形式出发,根据铝合金等线性强化材料特性建立了应变空间弹塑性本构模型。以应变空间的形式建立材料的屈服准则、流动法则、内变量和塑性模量等准则及参量,建立起适合铝合金等线性强化材料应用的弹塑性增量模型。
4、研究了铝合金板材在平面应力且平面内变形条件下的厚度变化规律。以各向同性线性强化材料在应力空间的弹塑性本构模型为工具,推导出薄板在平面内变形已知时厚度方向应变的计算模型。建立了加载过程中应力分量间成恒定比例关系时用于求解厚度应变的η-η1线方程；建立了应变增量分量在屈服加载阶段为非线性比例关系时,计算板内应力和厚度的计算模型,通过与应力／应变空间弹塑性理论和MSC.Marc下有限元仿真之间的比较对模型进行了验证。
5、基于分层法建立了预拉伸厚板残余应力场力学模型,并以7075厚板实验结果进行了验证研究。建立了多层薄板贴合的厚板组合结构；基于应变空间增量本构关系研究了厚板各深度处材料在拉伸关键点处的应变及应力特征,从而建立起厚板整体的应力演化模型；通过导入7075厚板实验数据,研究该模型预测预拉伸厚板残余应力场的准确性；研究了力学性能沿板厚的不均匀分布对预拉伸厚板残余应力场的量化影响。
6、研究了厚板残余应力场的消减机理,揭示了厚板残余应力演化规律。通过分析厚板预拉伸过程中各深度处自由尺寸的变化情况,揭示了预拉伸消减残余应力的机理是各深度处的自由尺寸差异减小；研究发现在拉伸过程中,厚板内轧制和横向残余应力的消减不同步,导致在拉伸率不同时两者的消减程度不一；研究还揭示了预拉伸导致的厚板不均匀塑性应变分布规律。
本文研究受到国家重点基础研究发展规划(973)课题：大规格铝材非均匀多相组织和内应力场的产生与演变(课题编号：2005CB623708)和大型薄壁构件塑变与去除成形及其内应力与表面完整性主动控制(课题编号：2010CB731703)资助。
Aluminum alloy thick plate is an important material in the fields of airplane, aerospace, shipbuilding and other industries. Structure made of thick plate is stronger and lighter, and it is then applied in the large military and civil aircraft of our country. However, there is high level residual stress, usually100-300MPa, caused by quenching in the plate. When stress-relief process is not designed well, the residual stresses left are sufficient to cause distortion and weaken the fatigue strength and the stress-corrosion-cracking resistance in aircraft components machined from this material. Meanwhile, lower residual stresses are required for the thick plate used in the large aircraft. Therefore, it is important to study the mechanism and establish the analytical model for pre-stretch in order to improve the process and lower the residual stress in the plate.
The thesis focuses on the mechanism and modeling of stress-evolution of the residual stress during quench-stretch process by stress experiment, strain-based modelling of elasto-plasticity, analysis on in-plane deformation of thin plate and multi-layer method modeling of residual stress in thick plate:
1. Residual stresses in quenched and pre-stretched thick plates of2A12and7075aluminum alloy were measured by layer removal method. The thick plates were quenched in spray and immersion to get different quenching intensities. The results show that plate was cooled down in shorter term under the immersion-quenching than that of the spray-quenching and residual stress caused under the former circumstance was higher than that of the latter. Spraying process caused high level residual stress close to the surface and nearly zero stress around the midplane, while immersion bringing inverted U-shape of stress in the plate. Besides, pre-stretch process significantly reduced the residual stresses in quenched plates.
2. The evolution of mechanical properties of7000series aluminum alloy during quench-stretch process and values of properties at key stages were determined according to the test condition. It was found that the yield strength is lower than residual stress of as-quenched plate, indicating that residual stress is increasing during aging process. The through-thickness inhomogeneity was confirmed in the quenched-stretched7075plate by uniaxial tension test and hardness test. Material close to the surface has the higher strength than that near the midplane in the thick plate.
3. Based on general form of strain-space incremental plasticity relation, a new model for linear hardening materials was proposed. The model, suitable for isotropic hardening materials like aerospace aluminum alloy, was carried out by determining yield criteria, flow rule, hardening function and plastic modulus in strain space.
4. A calculation model for strain in the thickness-direction of isotropic linear hardening plate was proposed, based on the theory of stress and strain space elastic-plastic constitutive model and analysis of stretching process of aerospace aluminum alloy thick plate. It was found that when ratio of stress fractions is constant during in-plane loading, ratios of strain components under various loading conditions are linearly related and these points of ratios form an η-η line. Under these simple loadings, strains in thickness direction can be easily calculated by the η-η line equation without integral and differential work. When the plate is under more complicated loading conditions, the thickness can be computed by the proposed optimization and piecewise calculation model. The model was then verified against the results of proved theories and FE simulation in MSC.Marc.
5. A mathematical model is developed to calculate the residual stress in stretched aluminum alloy thick plate. It is based on multi-layer method, balance of stresses, two-dimensional plasticity and a conception of free size. The model was verified against the experiments performed on7075aluminum plate. It was found that the computed residual stress basically express the stress level of the stretched plate under the given stretching ratio and that through-thickness inhomogeneity plays an important role in residual stress.
6. The mechanism of stress-relief during stretch was studied. The stress was reduced by narrowing of differences of free sizes at various depths of the plate. Study showed that residual stress in the transverse direction is higher than that of the rolling direction when the tension ratio is relatively small and the latter is larger than the former when tension ratio reaches a certain level. Non-uniform plastic deformation caused by stretching was also studied.
This work was funded by the State Key Fundamental Research Program of China (Grant No.2005CB623708and No.2010CB731703).
本文围绕淬火-预拉伸厚板残余应力的演化机理,针对残余应力实验测试、铝合金应变空间弹塑性本构建模、金属薄板平面变形下厚度建模、铝合金预拉伸厚板残余应力场分层法建模以及残余应力的宏观消减机理等开展研究,主要有以下几个方面：
1、研究了典型高强铝合金厚板在不同固溶强化工艺和预拉伸条件下的残余应力场分布规律。实验测定了2A12和7075两种铝合金淬火厚板在淬火-预拉伸工艺中的残余应力场。发现在阵列喷淋及水浴淬火方式下厚板内部都形成了“内拉外压”的残余应力场典型分布；喷淋方式的淬火强度相对较低,只在厚板靠近表层的地方形成了较大的残余应力；水浴方式淬火强度更大,在厚板整个厚度上形成了倒U形分布的残余应力；预拉伸使喷淋和水浴两种淬火板内的残余应力都大幅度消减。
2、针对淬火工艺在厚板内部形成的力学性能不均性开展研究,通过7075厚板的屈服强度和硬度测试结果的相互印证,表明沿板厚方向确实存在明显的强度和硬度不均匀性,强度值从厚板表层到芯部呈现逐渐降低的趋势；研究了7000系铝合金铝合金在淬火-预拉伸过程中的力学性能演化规律,并根据实验情况确定了7075厚板在淬火一预拉伸的多个关键时间节点处的力学性能。研究发现7075合金在淬火结束时屈服强度低于实验测得的残余应力水平,从而发现残余应力在时效过程中出现增长的现象。
3、从应变空间表述的塑性增量本构模型一般形式出发,根据铝合金等线性强化材料特性建立了应变空间弹塑性本构模型。以应变空间的形式建立材料的屈服准则、流动法则、内变量和塑性模量等准则及参量,建立起适合铝合金等线性强化材料应用的弹塑性增量模型。
4、研究了铝合金板材在平面应力且平面内变形条件下的厚度变化规律。以各向同性线性强化材料在应力空间的弹塑性本构模型为工具,推导出薄板在平面内变形已知时厚度方向应变的计算模型。建立了加载过程中应力分量间成恒定比例关系时用于求解厚度应变的η-η1线方程；建立了应变增量分量在屈服加载阶段为非线性比例关系时,计算板内应力和厚度的计算模型,通过与应力／应变空间弹塑性理论和MSC.Marc下有限元仿真之间的比较对模型进行了验证。
5、基于分层法建立了预拉伸厚板残余应力场力学模型,并以7075厚板实验结果进行了验证研究。建立了多层薄板贴合的厚板组合结构；基于应变空间增量本构关系研究了厚板各深度处材料在拉伸关键点处的应变及应力特征,从而建立起厚板整体的应力演化模型；通过导入7075厚板实验数据,研究该模型预测预拉伸厚板残余应力场的准确性；研究了力学性能沿板厚的不均匀分布对预拉伸厚板残余应力场的量化影响。
6、研究了厚板残余应力场的消减机理,揭示了厚板残余应力演化规律。通过分析厚板预拉伸过程中各深度处自由尺寸的变化情况,揭示了预拉伸消减残余应力的机理是各深度处的自由尺寸差异减小；研究发现在拉伸过程中,厚板内轧制和横向残余应力的消减不同步,导致在拉伸率不同时两者的消减程度不一；研究还揭示了预拉伸导致的厚板不均匀塑性应变分布规律。
本文研究受到国家重点基础研究发展规划(973)课题：大规格铝材非均匀多相组织和内应力场的产生与演变(课题编号：2005CB623708)和大型薄壁构件塑变与去除成形及其内应力与表面完整性主动控制(课题编号：2010CB731703)资助。
Aluminum alloy thick plate is an important material in the fields of airplane, aerospace, shipbuilding and other industries. Structure made of thick plate is stronger and lighter, and it is then applied in the large military and civil aircraft of our country. However, there is high level residual stress, usually100-300MPa, caused by quenching in the plate. When stress-relief process is not designed well, the residual stresses left are sufficient to cause distortion and weaken the fatigue strength and the stress-corrosion-cracking resistance in aircraft components machined from this material. Meanwhile, lower residual stresses are required for the thick plate used in the large aircraft. Therefore, it is important to study the mechanism and establish the analytical model for pre-stretch in order to improve the process and lower the residual stress in the plate.
The thesis focuses on the mechanism and modeling of stress-evolution of the residual stress during quench-stretch process by stress experiment, strain-based modelling of elasto-plasticity, analysis on in-plane deformation of thin plate and multi-layer method modeling of residual stress in thick plate:
1. Residual stresses in quenched and pre-stretched thick plates of2A12and7075aluminum alloy were measured by layer removal method. The thick plates were quenched in spray and immersion to get different quenching intensities. The results show that plate was cooled down in shorter term under the immersion-quenching than that of the spray-quenching and residual stress caused under the former circumstance was higher than that of the latter. Spraying process caused high level residual stress close to the surface and nearly zero stress around the midplane, while immersion bringing inverted U-shape of stress in the plate. Besides, pre-stretch process significantly reduced the residual stresses in quenched plates.
2. The evolution of mechanical properties of7000series aluminum alloy during quench-stretch process and values of properties at key stages were determined according to the test condition. It was found that the yield strength is lower than residual stress of as-quenched plate, indicating that residual stress is increasing during aging process. The through-thickness inhomogeneity was confirmed in the quenched-stretched7075plate by uniaxial tension test and hardness test. Material close to the surface has the higher strength than that near the midplane in the thick plate.
3. Based on general form of strain-space incremental plasticity relation, a new model for linear hardening materials was proposed. The model, suitable for isotropic hardening materials like aerospace aluminum alloy, was carried out by determining yield criteria, flow rule, hardening function and plastic modulus in strain space.
4. A calculation model for strain in the thickness-direction of isotropic linear hardening plate was proposed, based on the theory of stress and strain space elastic-plastic constitutive model and analysis of stretching process of aerospace aluminum alloy thick plate. It was found that when ratio of stress fractions is constant during in-plane loading, ratios of strain components under various loading conditions are linearly related and these points of ratios form an η-η line. Under these simple loadings, strains in thickness direction can be easily calculated by the η-η line equation without integral and differential work. When the plate is under more complicated loading conditions, the thickness can be computed by the proposed optimization and piecewise calculation model. The model was then verified against the results of proved theories and FE simulation in MSC.Marc.
5. A mathematical model is developed to calculate the residual stress in stretched aluminum alloy thick plate. It is based on multi-layer method, balance of stresses, two-dimensional plasticity and a conception of free size. The model was verified against the experiments performed on7075aluminum plate. It was found that the computed residual stress basically express the stress level of the stretched plate under the given stretching ratio and that through-thickness inhomogeneity plays an important role in residual stress.
6. The mechanism of stress-relief during stretch was studied. The stress was reduced by narrowing of differences of free sizes at various depths of the plate. Study showed that residual stress in the transverse direction is higher than that of the rolling direction when the tension ratio is relatively small and the latter is larger than the former when tension ratio reaches a certain level. Non-uniform plastic deformation caused by stretching was also studied.
This work was funded by the State Key Fundamental Research Program of China (Grant No.2005CB623708and No.2010CB731703).
引文
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