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基于7075鋁厚板銑削加工的初始?xì)堄鄳?yīng)力釋放與再分布模型
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1.南京航空航天大學(xué) 機(jī)電學(xué)院;2.南昌航空大學(xué) 航空制造工程學(xué)院;3.成都飛機(jī)工業(yè)集團(tuán)有限責(zé)任公司 數(shù)控加工廠

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國(guó)家自然科學(xué)基金(項(xiàng)目號(hào)51465045)、江西省主要學(xué)科學(xué)術(shù)和技術(shù)帶頭人資助計(jì)劃(大型航空整體結(jié)構(gòu)件加工變形的“性能-應(yīng)力-變形”一體化分析方法)、航空科學(xué)基金(項(xiàng)目號(hào)2016ZE56011)、江西省自然科學(xué)基金(20161BAB206114)資助


Model of Release and Redistribution of Initial Residual Stresses for the Milling Process of 7075 Aluminum Alloy Thick Plate
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College of Mechanical & Electrical Engineering, Nanjing University of Aeronautics and Astronautics

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    摘要:

    在7075鋁合金厚板的制造過程中,材料塑性變形和力學(xué)性能的非均勻性,勢(shì)必導(dǎo)致毛坯內(nèi)產(chǎn)生殘余應(yīng)力。而在后續(xù)的高速切削加工過程中,殘余應(yīng)力隨著材料去除的釋放與再分布,是引起飛機(jī)結(jié)構(gòu)件加工變形的關(guān)鍵因素。因此,研究殘余應(yīng)力釋放與再分布的解析方法能夠更為清晰地了解加工變形的演變機(jī)理,是進(jìn)行加工質(zhì)量控制的核心環(huán)節(jié),對(duì)于實(shí)現(xiàn)加工過程的高效化和精密化至關(guān)重要。通過材料的切削去除轉(zhuǎn)化為殘余應(yīng)力的釋放,利用靜力平衡條件將作用于飛機(jī)結(jié)構(gòu)件的殘余應(yīng)力等效為外力后,依據(jù)小變形理論創(chuàng)新性地建立加工變形的分析模型。通過全面地考慮拉壓、彎曲、以及轉(zhuǎn)角引起的飛機(jī)結(jié)構(gòu)件的厚向位置變化,利用疊加原理建立了殘余應(yīng)力再分布的力學(xué)模型。本文建立的解析模型,不僅能夠準(zhǔn)確地計(jì)算飛機(jī)結(jié)構(gòu)件的加工變形,還能夠分析毛坯殘余應(yīng)力的再分布狀態(tài),通過與有限元仿真值、實(shí)驗(yàn)測(cè)量值進(jìn)行比較,結(jié)果表明:無論是幅值還是變形曲線,解析值都與仿真值具有高度一致性,而與測(cè)量值相比,盡管在變形曲線上具有很好的吻合性,但由于殘余應(yīng)力的測(cè)量誤差使得兩者在幅值上亦存在一定誤差。

    Abstract:

    In the process of manufacturing 7075 aluminimun alloy thick plate, the non homogeneity of plastic deformations and mechanical properties of the material will generate residual stresses. During the following high speed machining process, the release and redistribution of residual stresses are key to deformations of aeronautical monolithic component with the removal of material. Therefore, the study of the analytical method on the residual stress release and redistribution can more clearly understand the evolution mechanism of machining deformation, which is the core link of controlling the machining quality. This is because it is very important for the realization of machining process with high efficiency and precise. Through equaling the removal of materials to the release of residual stresses, the residual stresses remained in the aeronautical monolithic component are converted into the external force according to the static equilibrium conditions, the analysis model is deduced for machining deformations based on the small deformation theory. Because the overall consideration on position variation is done by the tension/compression of neutral surface, bending of neutral surface, and rotation of end surface, the superposition principle can be used to formulize the mechanical model of residual stress redistribution. The proposed analytical model can be suitable for the accurate calculation of the machining deformations of aeronautical monolithic component, in addition to the analysis of the residual stress redistribution. The comparison among the model calculations, the simulated values and the experimental measurement data shows that, both the amplitude and deformation curve, the model calculations are good agreement with the simulated values. Moreover, the measurement error of residual stresses causes the little difference of the amplitude of the model calculations with the experimental measurement data, though the deformation curves of the two have a good agreement with each other.

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葉海潮,秦國(guó)華,林鋒,左敦穩(wěn),吳竹溪,羅育果.基于7075鋁厚板銑削加工的初始?xì)堄鄳?yīng)力釋放與再分布模型[J].稀有金屬材料與工程,2019,48(1):123~132.[Ye Haichao, Qin Guohua, Lin Feng, Zuo Dunwen, Wu Zhuxi, Luo Yuguo. Model of Release and Redistribution of Initial Residual Stresses for the Milling Process of 7075 Aluminum Alloy Thick Plate[J]. Rare Metal Materials and Engineering,2019,48(1):123~132.]
DOI:10.12442/j. issn.1002-185X.20170356

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  • 收稿日期:2017-05-02
  • 最后修改日期:2017-08-08
  • 錄用日期:2017-08-18
  • 在線發(fā)布日期: 2019-02-18
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