超声喷丸设备设计及工艺效果研究
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摘要
超声喷丸设备是机械零件强化处理设备,是传统的气体喷丸和抛丸设备的更新换代设备。它广泛应用于对机械零部件的疲劳强度和寿命要求较高的航空、航天、汽车、核动力、兵器、石油、煤炭、化工、机车、工程机械、汽轮机、农机、塑料模具、电气开关等众多工业部门。
超声喷丸设备主要由超声波发生器、换能器和变幅杆组成,其中变幅杆在喷丸过程中占有极其重要的地位,它的主要作用是在其输出端将换能器输入的机械振动的质点位移或速度放大,将超声能量集中在较小的面积上。放大系数是变幅杆的重要性能参数,对于目前的超声喷丸加工过程,丸粒的速度还远没有达到能够破坏受喷件安定性的程度,因此,提高丸粒的冲击速度即提高变幅杆的放大系数成为目前超声喷丸设备开发的首要任务,而传统形状的单一变幅杆显然无法达到该要求。
本文以提高变幅杆的放大系数为根本目的,以解析法设计理论为基础,对级联式变幅杆进行设计,并通过有限元软件LS-DYNA对超声喷丸过程进行仿真分析。主要研究内容有:
1.根据解析法设计单一、复合变幅杆,通过比较,选定两节所需变幅杆做为级联式变幅杆的推动节和输出节,选择的原则是在形状因数满足级联式变幅杆要求的情况下,通过放大系数的比较,选定放大系数较大的变幅杆。
2.根据变幅杆端面直径和输入频率的确定,设计出符合超声喷丸实验设备的级联式变幅杆,主要是通过解析法求出其放大系数、节点位移和谐振长度等参数。
3.根据振动理论和有限元方法,借助于有限元软件ANSYS对所设计出的级联式变幅杆进行模态分析,提取其纵向振动固有频率。并与解析法设计的级联式变幅杆的共振频率对比,提高级联式变幅杆设计制造的可行性。
4.加工制造出所设计的级联式变幅杆,运用到超声喷丸实验设备当中,验证级联式变幅杆实际运用的可行性。
5.将超声喷丸过程简化为丸粒撞击试件的过程,应用LS-DYNA软件进行有限元仿真。得出丸粒垂直于试件喷射时,随着丸粒直径增加或速度增大,试件最大应力应变值增加,但直径和速度增加到一定程度的时候,试件的最大应力应变值将不在增加,趋于稳定值。并且试件所产生的最大横向残余压应力总是大于最大纵向残余压应力,在各个方向上的最大横向残余压应力基本相等。当丸粒的抛射角度大于60°时,试件所产生的最大等效应力和纵向压应力变化不大,但各方向的最大横向压应力不再是等值。两丸粒撞击同一区域时,丸粒的最大应力应变值和单个丸粒在相同情况下撞击相比有明显的增大;而丸粒以同一角度沿不同方向撞击试件的同一区域要比丸粒以同一角度沿同一方向撞击试件所产生的残余拉应力要小。
Ultrasonic shot peening equipment, which is important surface treatment equipment, is a replacement equipment of traditional shot peening equipment and shot blasting equipment. It is widely used in aviation, aerospace, automotive, nuclear power, weapons, oil, coal, chemical industry, motorcycle, engineering machinery, gas turbines, agricultural machinery, plastic mold, electrical switches, and etc. industrial sectors which require a higher life expectancy and fatigue strength of mechanical components.
Ultrasonic shot peening equipment is composed of the ultrasonic generator, transducer and the horn components. Among them, the horn is of extremely importance, and its primary role is to enlarge the particle displacement of the mechanical vibration or velocity that is inputted by transducer, and to concentrate the ultrasonic energy in a smaller area. Magnification factor of the horn is an important performance parameter. For the current ultrasonic shot penning process, the speed of shot is so small that can’t damage the stability of parts. Therefore, enhancing the impact speed of shot, namely improving the magnification factor of the horn, is the primary task under the current development of ultrasonic shot peening equipment. It is obviously that the single horn with traditional shape unable to meet the above request.
In this dissertation, to enhance the magnification factor of horn is the fundamental purpose. The design of combination horn is based on analytical method, and finite element software LS-DYNA is used for the simulation analysis of the ultrasonic shot peening process. The main contents are as follows:
1. The single horn and composite horn are designed based on analytical method. The driven horn section and output horn section of cascade horn is selected by comparing. The principle of selection is that under the requirements of the form factor the horn of large magnification factor is selected through the comparison of magnification factor.
2. Based on the determined the end-horn diameter and input frequency, the combination horn met the requirement of the ultrasonic shot peening is designed. The parameters such as magnification factor, the length of the node and the resonance length are mainly derived through the analytic method.
3. According to vibration theory and finite element method, modal analysis for the designed combination is carried out through the finite element software ANSYS11.0, and its natural frequency of vertical vibration is extracted. The extracted frequency by simulation is compared with the resonant frequency of the horn that is designed based on analytical method; hence the manufacturing feasibility of the designed combination horn is improved.
4. The designed combination horn is manufactured and used for the ultrasonic shot peening experimental equipment to validate the feasibility for combination horn in practical application.
5. Ultrasonic Shot peening process is simplified as the process of a shot strike against the sample. Finite element simulation software LS-DYNA is used to simulate this process. Following conclusions are obtained. The largest stress-strain values of specimen increases with the increasing of the shot speed and shot diameter, but the increases of the shot speed and shot diameter are limited. When they are greater than a certain value, the increases of them will not increase and become stable value. In addition, the maximum horizontal residual compressive stress is always greater than the maximum vertical one. And in all directions, the maximum horizontal residual compressive stress has the same value. When the spray angle of shot is greater than 60°, the largest equivalent stress and vertical compressive stress have little changes, but the maximum horizontal compressive stress in all directions is no longer equivalent. When two shots strike against the same region, the stress-strain values significantly increased compared with the single shot under the same conditions. Moreover, the shot impact to the same region of the specimen in different directions with the same angle generates smaller residual tensile stress than that under the same conditions but in the same direction.
超声喷丸设备主要由超声波发生器、换能器和变幅杆组成,其中变幅杆在喷丸过程中占有极其重要的地位,它的主要作用是在其输出端将换能器输入的机械振动的质点位移或速度放大,将超声能量集中在较小的面积上。放大系数是变幅杆的重要性能参数,对于目前的超声喷丸加工过程,丸粒的速度还远没有达到能够破坏受喷件安定性的程度,因此,提高丸粒的冲击速度即提高变幅杆的放大系数成为目前超声喷丸设备开发的首要任务,而传统形状的单一变幅杆显然无法达到该要求。
本文以提高变幅杆的放大系数为根本目的,以解析法设计理论为基础,对级联式变幅杆进行设计,并通过有限元软件LS-DYNA对超声喷丸过程进行仿真分析。主要研究内容有:
1.根据解析法设计单一、复合变幅杆,通过比较,选定两节所需变幅杆做为级联式变幅杆的推动节和输出节,选择的原则是在形状因数满足级联式变幅杆要求的情况下,通过放大系数的比较,选定放大系数较大的变幅杆。
2.根据变幅杆端面直径和输入频率的确定,设计出符合超声喷丸实验设备的级联式变幅杆,主要是通过解析法求出其放大系数、节点位移和谐振长度等参数。
3.根据振动理论和有限元方法,借助于有限元软件ANSYS对所设计出的级联式变幅杆进行模态分析,提取其纵向振动固有频率。并与解析法设计的级联式变幅杆的共振频率对比,提高级联式变幅杆设计制造的可行性。
4.加工制造出所设计的级联式变幅杆,运用到超声喷丸实验设备当中,验证级联式变幅杆实际运用的可行性。
5.将超声喷丸过程简化为丸粒撞击试件的过程,应用LS-DYNA软件进行有限元仿真。得出丸粒垂直于试件喷射时,随着丸粒直径增加或速度增大,试件最大应力应变值增加,但直径和速度增加到一定程度的时候,试件的最大应力应变值将不在增加,趋于稳定值。并且试件所产生的最大横向残余压应力总是大于最大纵向残余压应力,在各个方向上的最大横向残余压应力基本相等。当丸粒的抛射角度大于60°时,试件所产生的最大等效应力和纵向压应力变化不大,但各方向的最大横向压应力不再是等值。两丸粒撞击同一区域时,丸粒的最大应力应变值和单个丸粒在相同情况下撞击相比有明显的增大;而丸粒以同一角度沿不同方向撞击试件的同一区域要比丸粒以同一角度沿同一方向撞击试件所产生的残余拉应力要小。
Ultrasonic shot peening equipment, which is important surface treatment equipment, is a replacement equipment of traditional shot peening equipment and shot blasting equipment. It is widely used in aviation, aerospace, automotive, nuclear power, weapons, oil, coal, chemical industry, motorcycle, engineering machinery, gas turbines, agricultural machinery, plastic mold, electrical switches, and etc. industrial sectors which require a higher life expectancy and fatigue strength of mechanical components.
Ultrasonic shot peening equipment is composed of the ultrasonic generator, transducer and the horn components. Among them, the horn is of extremely importance, and its primary role is to enlarge the particle displacement of the mechanical vibration or velocity that is inputted by transducer, and to concentrate the ultrasonic energy in a smaller area. Magnification factor of the horn is an important performance parameter. For the current ultrasonic shot penning process, the speed of shot is so small that can’t damage the stability of parts. Therefore, enhancing the impact speed of shot, namely improving the magnification factor of the horn, is the primary task under the current development of ultrasonic shot peening equipment. It is obviously that the single horn with traditional shape unable to meet the above request.
In this dissertation, to enhance the magnification factor of horn is the fundamental purpose. The design of combination horn is based on analytical method, and finite element software LS-DYNA is used for the simulation analysis of the ultrasonic shot peening process. The main contents are as follows:
1. The single horn and composite horn are designed based on analytical method. The driven horn section and output horn section of cascade horn is selected by comparing. The principle of selection is that under the requirements of the form factor the horn of large magnification factor is selected through the comparison of magnification factor.
2. Based on the determined the end-horn diameter and input frequency, the combination horn met the requirement of the ultrasonic shot peening is designed. The parameters such as magnification factor, the length of the node and the resonance length are mainly derived through the analytic method.
3. According to vibration theory and finite element method, modal analysis for the designed combination is carried out through the finite element software ANSYS11.0, and its natural frequency of vertical vibration is extracted. The extracted frequency by simulation is compared with the resonant frequency of the horn that is designed based on analytical method; hence the manufacturing feasibility of the designed combination horn is improved.
4. The designed combination horn is manufactured and used for the ultrasonic shot peening experimental equipment to validate the feasibility for combination horn in practical application.
5. Ultrasonic Shot peening process is simplified as the process of a shot strike against the sample. Finite element simulation software LS-DYNA is used to simulate this process. Following conclusions are obtained. The largest stress-strain values of specimen increases with the increasing of the shot speed and shot diameter, but the increases of the shot speed and shot diameter are limited. When they are greater than a certain value, the increases of them will not increase and become stable value. In addition, the maximum horizontal residual compressive stress is always greater than the maximum vertical one. And in all directions, the maximum horizontal residual compressive stress has the same value. When the spray angle of shot is greater than 60°, the largest equivalent stress and vertical compressive stress have little changes, but the maximum horizontal compressive stress in all directions is no longer equivalent. When two shots strike against the same region, the stress-strain values significantly increased compared with the single shot under the same conditions. Moreover, the shot impact to the same region of the specimen in different directions with the same angle generates smaller residual tensile stress than that under the same conditions but in the same direction.
引文
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[3] Jack Champaigne.Shot Peening Overview[EB/OL]. Electronics Inc, 2001.
[4] Jack Champaigne.The Little Book on Shot Peening[EB/OL]. Electronics Incorporated,2001.
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