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Identification of deformations of cylindrical specimens by optical method using the technique of digital image correlation 利用数字图像相关技术的光学方法识别圆柱形试样的变形
Pub Date : 1900-01-01 DOI: 10.18323/2782-4039-2022-2-74-83
D. Rastorguev, K. Semenov
A provision of location tolerances and their retention in the postoperative period is one of the main hard-hitting process tasks when producing long-length low-rigidity shaft-type parts. Mixed treatment – tensile straightening or thermal-power treatment is one of the technological methods intended to provide this group of geometrical indicators, including axle linearity. The efficiency improvement of this technology is impossible without knowing the features of the formation of plastic deformations distribution along the length of long-length blank parts. The paper considers the application of an optical method for controlling deformation on the surface using the method of digital image correlation at axial deformation of cylindrical parts. The work describes an experimental device for optic control of deformations when loading a specimen using digital cameras. The authors studied the influence of various modes of paint deposition to a sample (deposition rate, distance, deposition mode – continuous or pulsed) on the features of a produced speckle in the form of random distribution of mixed-size paint spots over the specimen surface; obtained histograms of the intensity distribution of various speckles. The authors carried out the experiments to identify deformations based on the technology of the local gradient digital image correlation method for the specimens of polymer tubes with different speckle types. The study identified the distribution of the deformation over the length of samples within the deformable area selected for analysis with the specified degree of smoothing provided by choice of correlation kernel size and the choice of its displacement step for fixing deformation processes with a precise error. The authors obtained distributions of axial deformations along the length of specimens and errors of deformations determination depending on a speckle nature. The study specifies necessary speckle parameters ensuring minimal error for long-length samples up to 200 mm in length and appropriate technology for paint depositing. It is a speckle with a wide range of spot sizes rarefied with their locations and the Gaussian filter image smoothing before the analysis.
在生产长长度低刚性轴型零件时,提供位置公差及其在术后期间的保持是主要的硬冲击工艺任务之一。混合处理-拉伸矫直或热动力处理是旨在提供这组几何指标,包括轴线性的技术方法之一。如果不了解长毛坯件沿长度方向塑性变形分布的形成特征,就不可能提高该工艺的效率。本文研究了一种利用数字图像相关方法控制圆柱形零件轴向变形的光学方法。该工作描述了一个实验装置,用于光学控制变形时,使用数码相机加载试样。作者研究了不同的涂料沉积模式对样品的影响(沉积速率、距离、沉积模式-连续或脉冲)对产生的斑点特征的影响,其形式是样品表面上混合大小的涂料斑点的随机分布;获得了各种散斑的强度分布直方图。基于局部梯度数字图像相关技术,对不同散斑类型的聚合物管试件进行了变形识别实验。通过选择相关核大小和选择其位移步长提供指定的平滑程度,确定了所选分析的可变形区域内的变形在样本长度上的分布,以精确的误差固定变形过程。作者得到了沿试样长度轴向变形的分布,以及根据散斑性质确定变形的误差。该研究规定了必要的斑点参数,确保长度达200毫米的长样品误差最小,并规定了适当的涂料沉积技术。它是一个斑点大小范围很广的斑点,在分析前对其位置进行高斯滤波和图像平滑。
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引用次数: 0
Simulation of the processes of drilling polymer composite blanks using digital twins 基于数字孪生体的聚合物复合材料毛坯钻孔过程模拟
Pub Date : 1900-01-01 DOI: 10.18323/2782-4039-2023-2-64-1
M. Ilyushkin, E. Kiselev
Polycrystalline composite materials made of carbon fiber reinforced plastics have more and more widespread application in mechanical engineering and become the main material for the production of modern types of high-speed transport. Thus, their share has already reached 35–45 % in the structural design of passenger aircrafts. However, the technology of machining surfaces of parts made of these materials, in particular, holes, is characterized by insufficient knowledge, the absence of regulatory standards for cutting modes and is most often based on the production experience of enterprises. When changing the processing conditions and the material, the pre-production engineering duration causes a significant increase in the cost of manufacturing parts due to the need for experimental selection of the cutting mode rational elements. To exclude the empirical selection of rational elements of the machining equipment cutting mode, the authors considered the possibility of using digital twins for studying the processes of drilling holes in the blanks made of composite materials, including those with the ultrasonic field energy introduction into the new surface shaping zone (to improve the processing quality and productivity). When modeling, the LS-DYNA program was used. The authors prepared the models and processed the results using the LS-PrePost 4.8 program. During the study, an explicit modeling method was used with preliminary validation and calibration of the results of tests of composites. The authors carried out calibration on test operations of tension, three-point bending, and interlaminar shear of the ВКУ-39 polymer composite material based on carbon fibers (carbon fiber reinforced plastic) widely used in domestic engineering. The developed finite element computer models allow simulating drilling procedures without carrying out rather complicated and expensive field tests. As a result of modeling, a simulation file was obtained, which reflects the process of drilling holes in a polymer composite material blank, as close as possible to the real-life situation with chip removal.
碳纤维增强塑料制成的多晶复合材料在机械工程中的应用越来越广泛,已成为生产现代各类高速运输工具的主要材料。因此,它们在客机结构设计中的份额已经达到35 - 45%。然而,这些材料制成的零件的表面加工技术,特别是孔的加工技术,其特点是知识不足,缺乏对切削方式的监管标准,而且往往是基于企业的生产经验。在改变加工条件和材料时,由于需要对切削方式合理元件进行试验选择,生产前的工程工期导致零件制造成本显著增加。为了排除机械加工设备切削方式合理要素的经验选择,作者考虑了利用数字孪生体研究复合材料毛坯的钻孔过程的可能性,包括将超声场能量引入新的表面成形区(以提高加工质量和生产率)。建模时采用LS-DYNA程序。作者利用LS-PrePost 4.8程序建立模型并对结果进行处理。在研究过程中,采用了显式建模方法,并对复合材料的试验结果进行了初步验证和标定。对国内工程中广泛应用的以碳纤维(碳纤维增强塑料)为基础的ВКУ-39高分子复合材料的拉伸、三点弯曲、层间剪切试验操作进行了标定。开发的有限元计算机模型可以模拟钻井过程,而无需进行相当复杂和昂贵的现场测试。通过建模得到仿真文件,该文件反映了聚合物复合材料毛坯的钻孔过程,尽可能接近真实的切屑去除情况。
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引用次数: 0
The influence of a workpiece shape on residual stresses during linear friction welding 工件形状对直线摩擦焊接过程中残余应力的影响
Pub Date : 1900-01-01 DOI: 10.18323/2782-4039-2022-4-102-112
A. N. Pautov, A. Medvedev, V. R. Galimov, O. Kolenchenko
Linear friction welding is an advanced technology for manufacturing titanium blisks for gas-turbine engine compressors, which are subjected to stringent requirements for cyclic strength and dimensional accuracy. Substitution of conventional butt joints with more technological T-shape joints is a promising area, which provides reducing of the pre-welding machining costs. The introduction of T-form joints requires additional research of thermal distribution specifics and strain-stress state formation in the welding process and after its end. Therefore, the study of residual stresses in titanium alloy T-shape joints produced by linear friction welding is topical. The paper investigates the residual stresses in imitating welded blisk joints. The authors consider the results of welding where the blade imitator has a reamed relief of a smaller section. The finite element model covering forging, cooling, and disassembly of welded specimens is offered. The authors developed the model in ANSYS Workbench to describe the strain-stress state of welded specimens, which allows for estimating the residual stress levels and spreading. The main distinctive feature of the model is an accounting of asymmetric temperature distribution obtained by finite-difference solving of a T-shape joint thermal problem and weld shape simulation obtained as a result of welded joints metallographic research. The presented model allows the evaluation of the residual stresses in joints. The distribution of residual stresses in T-shaped welded joints is specific – compressive stresses existing in a weld are balanced by tensile stresses acting at a distance of 1 mm from the joint. The formation of compressive stresses in a weld is caused by plastic deformation due to the forging force action.
直线摩擦焊是制造燃气涡轮发动机压气机用钛片的一种先进工艺,对循环强度和尺寸精度有严格的要求。用技术含量更高的t形接头代替传统的对接接头是降低焊前加工成本的一个有前景的领域。引入t型接头需要进一步研究焊接过程中及结束后的热分布特性和应变-应力状态形成。因此,对直线摩擦焊接钛合金t形接头残余应力的研究是当前研究的热点。研究了模拟焊盘接头的残余应力。作者考虑了焊接的结果,其中叶片模拟器有一个较小的截面的扩孔救济。给出了涵盖焊接试样锻造、冷却和拆卸的有限元模型。作者在ANSYS Workbench中建立了描述焊接试样应变-应力状态的模型,可以估计残余应力水平和分布。该模型的主要特点是考虑了t形接头热问题有限差分求解得到的非对称温度分布和焊接接头金相研究得到的焊缝形状模拟结果。所提出的模型允许对节点的残余应力进行评估。t形焊接接头残余应力的分布是特殊的——焊缝中存在的压应力被作用在距离接头1mm处的拉应力所平衡。焊缝中压应力的形成是由锻压力作用下的塑性变形引起的。
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引用次数: 0
Optimizing the layout of a CNC lathe 数控车床布局优化
Pub Date : 1900-01-01 DOI: 10.18323/2782-4039-2022-2-17-27
A. Denisenko, R. Grishin
A reasonable choice of machine layout is one of the ways to improve the quality of CNC machines and the result of a comprehensive analysis and consideration of many frequently conflicting requirements: accuracy, design feasibility, processability, productiveness, efficiency, safety, etc. The complexity of the choice of machine layout is associated with their diversity depending on the fact that machines with different designs of assembly units can have the same arrangement and, conversely, lathes with the same designs of main elements can have different layouts. Due to the multiple effects of layout on the accuracy characteristics of a machine, the optimal layout solution choice is the priority problem of machine building. The study covers the development of a technique for selecting a layout solution for the CNC lathes, which considers the random location of cutting zones and the existence of power factors related to the design and layout of a spindle unit. In the developed technique, as a criterion for choosing an optimal arrangement, the authors suggest using an accuracy layout criterion evaluated by the elastic deformations of a spindle in the cutting zone. The study resulted in analytical expressions for an objective function depending on two design variables: angles determining the location of a spindle pre-drive gear and a tool-holding group. The authors note that for the precision lathes when identifying spindle bearing radial stiffness, one should take into account the stiffness anisotropy of a housing bore for the spindle front support. For two specified design variables, the study shows the performance of a scanning method (complete enumeration for 322 points). Using this method and processing with Mathcad software, the authors obtained a possible variation range of values of specified angles for five standard layouts of spindle support bearings and limitations related to the minimization of elastic deformations of the tooling system.
合理选择机床布局是提高数控机床质量的途径之一,也是对精度、设计可行性、可加工性、生产率、效率、安全性等许多经常相互冲突的要求进行综合分析和考虑的结果。机床布局选择的复杂性与它们的多样性有关,这取决于具有不同设计的装配单元的机床可以具有相同的布置,相反,具有相同设计的主要部件的车床可以具有不同的布置。由于布局对机床精度特性的影响是多方面的,因此最优布局方案的选择是机床制造中的优先问题。该研究涵盖了一种选择数控车床布局解决方案的技术开发,该技术考虑了切割区域的随机位置以及与主轴单元设计和布局相关的功率因素的存在。在已开发的技术中,作为选择最佳布置的标准,作者建议使用由切削区主轴弹性变形评估的精度布置准则。该研究得出了目标函数的解析表达式,该函数取决于两个设计变量:确定主轴预驱动齿轮和刀具夹紧组位置的角度。作者指出,对于精密车床,在确定主轴轴承径向刚度时,应考虑主轴前支承轴承座孔的刚度各向异性。对于两个指定的设计变量,研究显示了扫描方法的性能(完全枚举322个点)。利用该方法并结合Mathcad软件进行处理,得到了主轴支承轴承五种标准布局的指定角度值的可能变化范围,以及与刀具系统弹性变形最小化相关的限制条件。
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引用次数: 0
The influence of aging on microhardness and electrical conductivity of Cu–2 wt. % Be alloy 时效对Cu-2 wt. % Be合金显微硬度和电导率的影响
Pub Date : 1900-01-01 DOI: 10.18323/2782-4039-2022-3-1-69-75
L. Zaynullina, E. Sarkeeva, I. Alexandrov, R. Valiev
Goods made of beryllium bronzes got widespread use in the industry due to the complex of properties: high heat conductivity, strength, hardness, wear resistance, and corrosion resistance. They are not magnesium-based and do not spark on impact; therefore, they are essential for the production of non-sparking tools. The alloys of this system are used in the electrical engineering industry; consequently, it is necessary to pay attention to the improvement of the material’s electrical conductivity. The paper studies the microstructure, microhardness, and electrical conductivity of the Cu–2 wt.% Be alloy exposed to high-pressure torsion (HPT). The authors investigated the microstructure and fine structure of the alloy in various states. The study showed that HPT leads to the formation of an ultrafine-grained nanostructured (UFG NS) state with an average size of grains/subgrains of 22±1 mmn. Additional ageing of samples after HPD led to a slight increase in the grains/subgrains size up to 31±1 mmn. In both states, the authors observed nanosized deformation twins. The authors studied the dependences of microhardness and electrical conductivity of the alloy after HPD on the time of further ageing. The study identified that the microhardness increases from 122±3 HV in the initial state up to 525±8 HV after HPD and ageing. The investigation shows that the electrical conductivity substantially better recovers after ageing of the UFG NS state compared to the initial state. The electrical conductivity of the UFG NS state increased from 14.5±0.1 % IACS up to 27.5±0.6 % IACS in conditions similar to the initial state ageing. Therefore, resulting from such processing, the Cu–2 wt.% Be alloy is characterized by its advanced strength properties and electrical conductivity.
由于铍青铜具有高导热性、强度、硬度、耐磨性和耐腐蚀性等综合性能,在工业上得到了广泛的应用。它们不是镁基的,撞击时不会产生火花;因此,它们对于生产无火花工具是必不可少的。该系统的合金用于电气工程行业;因此,有必要注意提高材料的导电性。本文研究了Cu-2 wt.% Be合金在高压扭转(HPT)下的显微组织、显微硬度和电导率。研究了合金在不同状态下的显微组织和微观组织。研究表明,高温热处理可形成晶粒/亚晶粒平均尺寸为22±1 mmn的超细晶纳米结构(UFG NS)。HPD后,样品的进一步老化导致晶粒/亚晶粒尺寸略有增加,可达31±1 mmn。在这两种状态下,作者都观察到了纳米级变形孪晶。研究了HPD后合金的显微硬度和电导率与进一步时效时间的关系。研究发现,HPD和时效后的显微硬度从初始状态的122±3 HV增加到525±8 HV。研究表明,与初始状态相比,UFG - NS状态老化后的电导率恢复得更好。在与初始状态老化相似的条件下,UFG NS状态的电导率从14.5±0.1% IACS增加到27.5±0.6% IACS。因此,经过这种加工,Cu-2 wt.% Be合金具有先进的强度和导电性。
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引用次数: 0
Investigation of heat release in nanomodified elastomers during stretching and torsion under the action of electric voltage 纳米弹性体在电压作用下拉伸和扭转过程中的热释放研究
Pub Date : 1900-01-01 DOI: 10.18323/2782-4039-2022-2-121-132
A. Shchegolkov, A. Shchegolkov, N. Zemtsova
The authors studied the elastomers modified with carbon nanotubes (MWCNTs) with a mass concentration from 1 to 8 % wt. and investigated the modes of heat release of nanomodified elastomers within the range between 30 and 260 V (of alternating current) at different levels of stretching and torsion. Samples of elastomers with the MWCNT concentration from 1 to 5 % wt. in the supply voltage range up to 260 V did not generate heat. The study showed that heat release when feeding composites of elastomers with MWCNTs was observed at a mass concentration of 6 % wt. of MWCNTs and a supply voltage of 70 V. The maximum voltage for an elastomer sample with 6 % wt. of MWCNTs reaches 260 V. An increase in concentration to 7 % wt. causes the increase in the heat release power and the decrease in the maximum supply voltage level to 180 V when the initial heat release voltage is 40 V. At the 8 % wt. concentration, the power increases, and the limiting voltage drops to 100 V, while the initial voltage becomes 36 V. The study identified that when twisting elastomer by 360°, the areas with an increased temperature on the right and in the central zone of the sample (49.5 °C) are formed. The temperature at the bend point increases up to 50.2° С when twisting elastomer by 540°. An increase in the twisting angle to 1080° leads to the formation of areas with the elevated temperature near the right-side current-carrying clamp. It is worth noting the possibility of using the produced samples of elastomers with MWCNTs as sensitive elements of strain sensors, which will allow obtaining the information on physical and chemical parameters according to the principles of measuring the change in electrical resistance that occurs during stretching and torsion.
作者研究了质量浓度为1 ~ 8% wt的碳纳米管(MWCNTs)改性弹性体,并研究了在30 ~ 260 V(交流电)范围内不同拉伸和扭转水平下纳米改性弹性体的放热模式。在高达260 V的电源电压范围内,MWCNT浓度为1%至5% wt的弹性体样品不产生热量。研究表明,在MWCNTs质量浓度为6% wt.,电源电压为70 V时,添加MWCNTs的弹性体复合材料有放热现象。含有6% wt的MWCNTs的弹性体样品的最大电压达到260 V。当初始放热电压为40v时,当浓度增加到7% wt时,放热功率增加,最大电源电压降至180v。在8% wt浓度下,功率增大,极限电压降至100v,初始电压变为36v。研究发现,当将弹性体扭转360°时,在样品的右侧和中心区域(49.5°C)形成温度升高的区域。当扭转弹性体540°时,弯曲点的温度增加到50.2°С。当扭转角度增加到1080°时,在右侧载流钳附近形成了温度升高的区域。值得注意的是,有可能使用含有MWCNTs的弹性体样品作为应变传感器的敏感元件,这将允许根据测量拉伸和扭转过程中电阻变化的原理获得物理和化学参数的信息。
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引用次数: 2
THE INFLUENCE OF CHEMICAL COMPOSITION ON SOLID SOLUTION AND STRAIN HARDENING OF SINGLE CRYSTALS OF FCC HIGH-ENTROPY ALLOYS 化学成分对FCC高熵合金单晶固溶及应变硬化的影响
Pub Date : 1900-01-01 DOI: 10.18323/2782-4039-2022-1-15-23
A. Vyrodova
A characteristic feature of high-entropy alloys is high strength at maintaining plasticity, wear and corrosion resistance, and fracture toughness at cryogenic temperatures. Currently, CoCrFeNiMn is the best-investigated high-entropy compound. However, its application is limited in the high-temperature region due to the low values of the deforming stress level at the plasticity breaking point at T>296 K. One of the common ways to improve the material durability is the addition of substitution atoms of larger atomic radius, and Al, Ti, and Mo are some of these atoms. The paper presents the analysis of the mechanical behavior of single crystals of CoCrFeNiMn and CoCrFeNiMо FCC high-entropy alloys (at. %) oriented along the [001] direction: the author studied the temperature dependence of critical shear stresses τcr(T) within the temperature range of T=77–973K, the type of dislocation structure, strain hardening coefficient θII, plasticity and fracture at Т=296 K under tension. The study shows that the alloying with Mo atoms 4 at. % of the CoCrFeNi system (at. %) causes the solid solution hardening, and critical shear stresses τcr increase within the entire studied temperature range. The onset of plastic deformation is associated with slip at all temperature tests. At T=296 K, the author identified a planar dislocation structure with flat dislocation pile-ups and dislocation networks in CoCrFeNiMo while in equiatomic CoCrFeNiMn, at such test temperature, a uniform distribution of dislocations was observed in several systems without flat pile-ups. Work hardening coefficient, plasticity, and the level of stresses before fracture turn out to be similar in [001]-crystals of CoCrFeNiMo and CoCrFeNiMn high-entropy alloys, which are determined by the development of slip deformation simultaneously in several systems. Crystals are destroyed viscously at 296 K at the same level of stress.
高熵合金的一个特征是在低温下保持塑性、耐磨损、耐腐蚀和断裂韧性的高强度。目前,CoCrFeNiMn是研究得最好的高熵化合物。但在T>296 K时塑性断裂点处变形应力水平较低,限制了其在高温区域的应用。提高材料耐久性的常用方法之一是加入原子半径较大的取代原子,Al、Ti、Mo就是其中的一些原子。本文对CoCrFeNiMn和cocrfenimim_ FCC高熵合金(at)单晶力学行为进行了分析。%)沿[001]方向取向:研究了T=77 ~ 973k温度范围内的临界剪应力τcr(T)、位错组织类型、应变硬化系数θII、拉伸Т=296 K时的塑性和断口与温度的关系。研究表明,与Mo原子的合金化过程中,%的CoCrFeNi系统(在。%)引起固溶硬化,临界剪切应力τcr在整个研究温度范围内增大。在所有温度试验中,塑性变形的开始都与滑移有关。在T=296 K时,作者在CoCrFeNiMo中发现了位错平面堆积和位错网络的平面位错结构,而在等原子CoCrFeNiMn中,在该测试温度下,几个体系的位错分布均匀,没有位错平面堆积。[001]- CoCrFeNiMo和CoCrFeNiMn高熵合金的加工硬化系数、塑性和断裂前应力水平相似,这是由多个体系同时发生滑移变形决定的。在296k时,在相同的应力水平下,晶体发生粘性破坏。
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引用次数: 0
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