CN107607372B - Brittle material fatigue crack prefabrication testing machine - Google Patents
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Abstract
本发明提出了一种脆性材料疲劳裂纹预制试验机，试验机包括基座、电机、传动轴、撞击球、压头、支撑架、支撑板、激光计数器、压力传感器，激光信号控制器，报警器，PLC控制系统、压缩弹簧、限位筒、夹具等部分。通过压力传感器、调整撞击球连接杆和限位筒的位置实现不同大小载荷的加载，预制裂纹长度达到要求尺寸，PLC控制系统根据激光探头反馈的信号信息，会切断电机的电源，同时报警器会发出警报，提示该试件的疲劳裂纹已经预制完成。实现整个裂纹预制过程中的无人看守。应用本发明预制脆性材料的疲劳裂纹可以很大程度上节约人力、物力，同时提高裂纹制备的精度。
The invention provides a prefabricated testing machine for fatigue cracks of brittle materials. The testing machine includes a base, a motor, a transmission shaft, an impact ball, an indenter, a support frame, a support plate, a laser counter, a pressure sensor, a laser signal controller, and an alarm. , PLC control system, compression springs, limit cylinders, fixtures and other parts. Through the pressure sensor, adjusting the position of the impact ball connecting rod and the limit cylinder, different loads can be loaded, and the length of the prefabricated crack reaches the required size. The PLC control system will cut off the power of the motor according to the signal information fed back by the laser probe, and the alarm will An alarm is issued, indicating that the fatigue crack of the specimen has been prefabricated. Achieve unattended throughout the crack prefabrication process. The application of the invention to prefabricate the fatigue crack of the brittle material can save manpower and material resources to a great extent, and at the same time improve the precision of crack preparation.
Description
技术领域technical field
本发明涉及材料断裂韧度的测试领域，具体涉及一种脆性材料疲劳裂纹预制试验机。The invention relates to the field of testing the fracture toughness of materials, in particular to a fatigue crack prefabrication testing machine for brittle materials.
技术背景technical background
疲劳理论研究具有很大的工程实用价值。它的第一个作用是解决定寿问题,即精确地估算或预测构件的疲劳寿命,预防结构发生灾难性的失效,避免生命和财产的巨大损失。第二个作用是解决延寿问题,即优选材料和优化工艺,延长构件的疲劳寿命,也为研制新的抗疲劳材料提供依据。众所周知,实验测定材料的疲劳性能,要耗费大量的人力、物力和财力；尤其是构件以至全尺寸结构在服役载荷下的疲劳试验,耗费更大。因此,疲劳理论研究的第三个重要作用是,用简单的力学性能参量,如拉伸性能,估算材料的疲劳性能,简化以至取代疲劳试验；尤其是缩短构件以至全尺寸结构疲劳试验的周期,以节约人力、物力和财力。过量变形、开裂和复合材料的层间开裂是机械零件和工程构件的主要失效形式。其中,开裂会导致构件的断裂,是最具危害性的失效方式。由于断裂的突然性,不仅会造成重大的经济损失,而且经常导致灾难性事故的发生。传统的经典强度理论认为,断裂是瞬间发生的,断裂受控于由断面尺寸计算出的名义断裂应力和断裂应变。然而,对实际构件而言,其材料内部是不均匀和非连续的,并可能存在微观和宏观的裂纹或类似于裂纹的缺陷,而这些缺陷对材料和构件的服役性能会产生重大的影响。早在15世纪,人们在测量铁丝的强度时就发现,当铁丝直径相同时,其抗拉强度与铁丝长度成反比,因而推测铁丝中的缺陷控制其强度,铁丝愈长,则体积愈大,存在较大缺陷的可能性也愈大,强度也愈低。材料和构件中的裂纹或类似于裂纹的缺陷,可能是在外加载荷和环境介质的共同作用下于服役过程中萌生,也可能是在材料制造的过程中产生,如铸件、锻件及焊接结构中的各种冶金缺陷等。实际的带缺陷构件在初次正常工作加载时就发生断裂的情况并不多见,因为导致构件发生一次性断裂的缺陷一般是较大的,这种较大的缺陷在无损探伤时易被发现。而存在于实际构件材料中的无损探伤未能探到的小缺陷或裂纹,在长期的服役过程中,会因为疲劳、应力腐蚀和蠕变等原因而扩展,并最终在正常工作应力一般是低于屈服应力下发生突然断裂。因为断裂前不发生塑性变形,无征兆可见,断裂具有突发性。因此,将这种十分危险的断裂称为低应力脆性断裂。Fatigue theory research has great engineering practical value. Its first function is to solve the problem of life determination, that is, to accurately estimate or predict the fatigue life of components, prevent catastrophic failure of the structure, and avoid huge loss of life and property. The second function is to solve the problem of life extension, that is, to optimize the material and optimize the process, prolong the fatigue life of the component, and also provide the basis for the development of new anti-fatigue materials. As we all know, it takes a lot of manpower, material and financial resources to test the fatigue properties of materials; especially the fatigue tests of components and full-scale structures under service loads are more expensive. Therefore, the third important role of fatigue theory research is to use simple mechanical properties parameters, such as tensile properties, to estimate the fatigue properties of materials, simplify or even replace fatigue tests; To save manpower, material and financial resources. Excessive deformation, cracking and interlaminar cracking of composite materials are the main failure modes of mechanical parts and engineering components. Among them, cracking will lead to the fracture of components, which is the most harmful failure mode. Due to the suddenness of the rupture, it will not only cause significant economic losses, but also often lead to catastrophic accidents. The traditional classical strength theory holds that fracture occurs instantaneously, and the fracture is controlled by the nominal fracture stress and fracture strain calculated from the section size. However, for actual components, the interior of the material is inhomogeneous and discontinuous, and there may be microscopic and macroscopic cracks or defects similar to cracks, and these defects will have a significant impact on the service performance of materials and components. As early as the 15th century, when measuring the strength of iron wire, it was found that when the diameter of the iron wire is the same, its tensile strength is inversely proportional to the length of the iron wire, so it is speculated that the defects in the iron wire control its strength, the longer the iron wire, the larger the volume. The greater the possibility of larger defects, the lower the strength. Cracks or defects similar to cracks in materials and components may be initiated during service under the combined action of external loads and environmental media, or may be generated in the process of material manufacturing, such as castings, forgings and welded structures. various metallurgical defects, etc. It is rare for the actual defective component to break during the initial normal working loading, because the defect that causes the component to break at one time is generally large, and this large defect is easy to be found during non-destructive testing. However, small defects or cracks that cannot be detected by non-destructive testing existing in actual component materials will expand due to fatigue, stress corrosion and creep in the long-term service process, and eventually the normal working stress is generally low. Sudden fracture occurs at yield stress. Because there is no plastic deformation before fracture, no signs are visible, and the fracture is sudden. Therefore, this very dangerous fracture is called low stress brittle fracture.
断裂韧度是材料一个重要的力学性能指标，材料断裂韧度的测试通常需要实验含有预制裂纹，对于金属等非脆性材料其预制裂纹的预制通常需要通过疲劳实验机进行预制，预制裂纹在预制过程中，疲劳试验机通常需要实验人员进行看守，通过目测观察预制裂纹是否达到要求，精度控制比较低。而对于脆性材料，其预制裂纹通常通过两种方式进行预制：一种是利用锋利的刀片和小锤子通过手动敲击使试样产生疲劳裂纹，但手动敲击不能保证每一次敲击都有相同的力，所制备的预制裂纹方向会有较大的偏差，而且在敲击过程中极易导致试件破坏报废；另一种是利用疲劳试验机通过疲劳实验室的交变载荷进行裂纹预制，但疲劳实验机的夹具的振动更易使试样在裂纹预制过程中发生破坏失效，而且在裂纹预制过程中，需要有人一直看守，操作人员的疏忽易导致预制裂纹过长，试件成为无效试件。Fracture toughness is an important mechanical property index of materials. The test of fracture toughness of materials usually requires experiments to contain prefabricated cracks. For non-brittle materials such as metals, prefabrication of prefabricated cracks usually needs to be prefabricated by a fatigue testing machine. Prefabricated cracks are prefabricated during the prefabrication process. Among them, the fatigue testing machine usually needs to be guarded by experimental personnel, and the prefabricated cracks are visually observed to meet the requirements, and the precision control is relatively low. For brittle materials, prefabricated cracks are usually prefabricated in two ways: one is to use a sharp blade and a small hammer to generate fatigue cracks in the specimen by manual knocking, but manual knocking cannot guarantee that each knock will have the same effect. The force of the prepared prefabricated cracks will have a large deviation, and it is easy to cause the specimen to be destroyed and scrapped during the knocking process; However, the vibration of the fixture of the fatigue testing machine is more likely to cause the sample to fail during the crack prefabrication process, and during the crack prefabrication process, someone needs to be guarded all the time. The operator's negligence can easily lead to the prefabricated crack being too long, and the specimen becomes an invalid specimen. .
发明内容SUMMARY OF THE INVENTION
基于技术背景中所存在的问题，本发明提出了一种脆性材料疲劳裂纹预制试验机。Based on the problems existing in the technical background, the present invention proposes a fatigue crack prefabrication testing machine for brittle materials.
本发明提出的试验机主要是用于脆性材料疲劳裂纹的预制，利用电机、激光计数仪，压力传感器、激光信号控制器，整体结构简单，易组装实现，通过PLC控制器可实现裂纹预制过程中载荷的小幅变化，底座的低振动，降低了脆性材料的疲劳裂纹预制过程中的破坏失效的概率，并且在设定好相应的载荷后，无需操作人员看守，当裂纹扩展到指定长度时，激光信号控制器会将信号传输到PLC控制器，控制台会自动关闭电机，发出警报，提示操作人员该试件的疲劳裂纹制备完成，在减少裂纹预制过程中操作人员的精力投入的同时，提高了脆性材料疲劳预制裂纹制备的精度和合格试样的成功率。The testing machine proposed by the invention is mainly used for the prefabrication of fatigue cracks of brittle materials. It uses a motor, a laser counter, a pressure sensor and a laser signal controller. The overall structure is simple, and it is easy to assemble. The small change of the load and the low vibration of the base reduce the probability of failure during the fatigue crack prefabrication of brittle materials, and after setting the corresponding load, there is no need for operators to guard, when the crack expands to the specified length, the laser The signal controller will transmit the signal to the PLC controller, and the console will automatically turn off the motor and issue an alarm to remind the operator that the fatigue crack preparation of the specimen is completed. Accuracy and success rate of qualified specimens for fatigue pre-crack preparation in brittle materials.
一种脆性材料疲劳裂纹预制试验机，所述的试验机包括底座及支撑系统、动力输出系统、控制系统、限位保护、试样夹具系统；所有设备固定于底座上，电机固定在与底座连接的支撑架上，通过螺纹连接到传动轴上，传动轴固定在支撑架顶端的轴承上，传动轴中间焊接带撞击球的螺纹连接杆；控制系统包括电机开关、压力传感器、激光计数器、PLC控制器和PLC 终端，除PLC终端外的设备通过与电机相同的固定方式、上下水平的与电机固定于同一根支撑杆上；撞击球通过螺纹连接杆固定于转动轴上，与限位筒保持垂直；激光计数器控制终端固定在支撑架连接的含绝缘层的铝合金面板上，电机开关、压力传感器控制终端和激光计数器控制终端通过PLC控制器连接到PLC终端，同时PLC控制器连接监测裂纹扩展的激光信号探头、报警器。A brittle material fatigue crack prefabrication testing machine, the testing machine includes a base and a support system, a power output system, a control system, a limit protection, and a sample fixture system; all equipment is fixed on the base, and the motor is fixed on the base. It is connected to the drive shaft through threads, the drive shaft is fixed on the bearing at the top of the support frame, and the threaded connecting rod with impact ball is welded in the middle of the drive shaft; the control system includes motor switch, pressure sensor, laser counter, PLC control The equipment other than the PLC terminal is fixed on the same support rod as the motor, vertically and horizontally, on the same support rod as the motor; the impact ball is fixed on the rotating shaft through the threaded connecting rod, and is vertical to the limit cylinder ;The laser counter control terminal is fixed on the aluminum alloy panel with insulation layer connected to the support frame, the motor switch, pressure sensor control terminal and laser counter control terminal are connected to the PLC terminal through the PLC controller, and the PLC controller is connected to the monitoring crack propagation. Laser signal probe, alarm.
所述的底座及支撑系统具体包括：The base and support system specifically include:
所述的传动轴通过轴承固定在支撑架的上部，传动轴中间焊接一根长度可变的螺纹连接杆，螺纹连接杆上通过螺纹连接丁晴橡胶撞击球；电机固定底座采用合金钢板，通过螺栓连接；两个激光探头、PLC控制器均通过螺栓连接在支撑架上，并且在支撑架之间放置绝缘橡胶垫，两种不同作用的激光探头分别通过螺栓连接在钢架上的指定位置，并可以进行上下位置的调节；支撑板与支撑架通过法兰连接，电机与支撑板通过螺栓连接。The drive shaft is fixed on the upper part of the support frame through a bearing, a threaded connecting rod with variable length is welded in the middle of the drive shaft, and the threaded connecting rod is threaded to connect the NBR impact ball; the motor fixing base is made of alloy steel plate, and the bolts Connection; the two laser probes and the PLC controller are connected to the support frame by bolts, and insulating rubber pads are placed between the support frames. The upper and lower positions can be adjusted; the support plate and the support frame are connected by flanges, and the motor and the support plate are connected by bolts.
所述的控制系统具体包括：The control system specifically includes:
电机手动开关控制压力传感器控制终端；当试样裂纹长度达到指定长度时，裂纹长度监测激光探头反馈给PLC控制器的信号，PLC控制器会切断电机电源，同时控制压力传感器输出单周期加载过程中载荷-时间数据，计数器停止计数。The motor manual switch controls the pressure sensor control terminal; when the crack length of the sample reaches the specified length, the crack length monitoring laser probe feeds back the signal to the PLC controller, the PLC controller will cut off the motor power, and at the same time control the pressure sensor output during the single-cycle loading process Payload-time data, the counter stops counting.
所述的限位保护系统具体包括：The limit protection system specifically includes:
所述的限位筒可水平和上下调整，撞击球撞击板，压力弹簧、固定支座、压力传感器、压头均需安装在限位筒内，限位筒内表面需要涂有润滑油；所述的压力传感器利用强力胶粘结在压头和固定支座之间；所述的压头的材质为具有较大刚度的轻质合金钢。The limit cylinder can be adjusted horizontally and up and down, the impact ball hits the plate, the pressure spring, the fixed support, the pressure sensor and the pressure head must be installed in the limit cylinder, and the inner surface of the limit cylinder needs to be coated with lubricating oil; The pressure sensor is bonded between the indenter and the fixed support by using super glue; the material of the indenter is light alloy steel with high rigidity.
所述的试样夹具系统具体包括：The sample fixture system specifically includes:
所述的试样跨距支撑杆固定在试样基座上，两端设有可移动的限位栓；支撑架焊接在试验机基座，试样基座通过螺栓固定在试验机基座上。The sample span support rod is fixed on the sample base, and the two ends are provided with movable limit bolts; the support frame is welded on the testing machine base, and the sample base is fixed on the testing machine base by bolts .
所述的不同大小疲劳载荷的施加通过调整撞击球所连接的杆的长度和限位筒的位置实现。The application of the fatigue loads of different magnitudes is achieved by adjusting the length of the rod to which the impact ball is connected and the position of the limiting cylinder.
相对与现有技术本发明具有以下优点：Compared with the prior art, the present invention has the following advantages:
1.本发明在脆性材料疲劳裂纹预制过程中无需操作员长时间看守，当预制裂纹达到指定长度，试验机会自动停止并发出警报，可以节省操作人员的大量的精力同时节约实验操作成本。1. The present invention does not require an operator to guard for a long time during the prefabrication of fatigue cracks in brittle materials. When the prefabricated crack reaches a specified length, the test machine will automatically stop and an alarm will be issued, which can save a lot of energy of the operator and save the cost of experimental operation.
2.本发明可以很有效提高脆性材料预制裂纹的制备精度和预制裂纹预制的成功率，提高脆性材料断裂实验结果的有效性，并有效节约试样制备的成本。2. The present invention can effectively improve the preparation precision of brittle material prefabricated cracks and the success rate of prefabricated crack prefabrication, improve the effectiveness of brittle material fracture test results, and effectively save the cost of sample preparation.
3.本实验机构简单，组装成本较低，具有更加广泛的应用前景。3. The experimental mechanism is simple, the assembly cost is low, and it has a wider application prospect.
附图说明Description of drawings
图1本发明实施的结构示意图。Figure 1 is a schematic structural diagram of the implementation of the present invention.
具体实施方式Detailed ways
下面结合附图和具体实施例进行详细说明。The following describes in detail with reference to the accompanying drawings and specific embodiments.
撞击球撞击到压缩弹簧连接的钢板上，钢板向下运动使弹簧发生变形，压力传感器控制终端会显示出相应的压力值，同时压头会将该压力传递至脆性材料，使脆性材料处于三点弯曲的状态，通过调节撞击球14的螺纹连接杆11的长度和限位筒的高度实现不同载荷的疲劳加载。The impact ball hits the steel plate connected to the compression spring, the steel plate moves downward to deform the spring, the pressure sensor control terminal will display the corresponding pressure value, and the indenter will transmit the pressure to the brittle material, so that the brittle material is at three points In the bent state, fatigue loading of different loads can be achieved by adjusting the length of the threaded connecting rod 11 of the
限位筒通过螺栓固定在在支撑架上，限位筒会防止加载过程的过载造成试样在裂纹预制过程中发生破坏。The limit cylinder is fixed on the support frame by bolts, and the limit cylinder will prevent the overload of the loading process from causing damage to the sample during the crack prefabrication process.
试样跨距支撑杆23固定在试样基座24上，实现不同跨距脆性材料试样的加载，试样基座两端设计可移动的限位栓，防止试样在加载过程中发生移动。The sample span support rod 23 is fixed on the
支撑架焊接在试验机基座，试样基座通过螺栓固定在试验机基座上，两个激光探头、PLC 控制器均通过螺栓连接在支撑架上与支撑架之间放置绝缘橡胶垫。The support frame is welded on the base of the testing machine, the sample base is fixed on the base of the testing machine by bolts, and the two laser probes and PLC controller are connected by bolts on the support frame and an insulating rubber pad is placed between the support frame.
实施例：Example:
脆性材料裂纹预制试验机整体结构示意图如图1所示，整体包括底座26及支撑系统、动力输出系统、控制系统、限位保护、试样夹具系统。支撑架采用高强度钢，轴承9及传动轴 10固定在支撑架12的顶端，轴承两端保持水平后，将左端轴承的传动轴与电机8相连接，电机固定在支撑架相连接的支撑板7上。支撑板与支撑架通过法兰连接，电机与支撑板通过螺栓连接。两种不同作用的第一激光探头13、第二激光探头25分别通过螺栓连接在支撑架上的指定位置，并可以进行上下位置的调节。The schematic diagram of the overall structure of the brittle material crack prefabrication testing machine is shown in Figure 1, which includes a
限位筒18采用可上下调节的螺栓连接在支撑架上。限位筒18与支架连接的采用可左右调整位置的螺纹连接杆。钢块15、压缩弹簧16、压头-弹簧固定支座19通过焊接连接、压力传感器17利用高强度胶连接在压头20和弹簧固定支座中间。在限位筒四周涂上一定量的润滑油后，将钢块15、压缩弹簧16、压力传感器17、压头-弹簧固定支座19、压头20放入到限位筒中，将限位筒调节至指定位置，固定。The limiting cylinder 18 is connected to the support frame by bolts that can be adjusted up and down. The limit cylinder 18 is connected with the bracket using a threaded connecting rod whose position can be adjusted left and right. The steel block 15, the
电机手动开关1、压力传感器终端2、激光计数器终端3利用螺栓连接在固定板上后固定在支撑架后，将以上三者、报警器6、第二激光探头25、分别接到PLC控制器4，电机转动正常、PLC控制器正常工作可进行脆性材料预制裂纹制备实验。The motor manual switch 1, the pressure sensor terminal 2, and the laser counter terminal 3 are connected to the fixing plate by bolts and then fixed on the support frame, and the above three, the alarm 6, and the second laser probe 25 are respectively connected to the PLC controller 4 , the motor rotates normally and the PLC controller works normally, and the prefabricated crack preparation experiment of brittle materials can be carried out.
试验开始前，在夹具上放置钢块试样，先调整限位筒及连接撞击球螺纹连接杆的高度，手动旋转螺纹连接杆，观察压力传感器终端压力值的大小，根据实际材料试验要求压力值的大小选择不同质量的撞击球，调节螺纹连接杆及限位筒的高度，压力值满足试验要求即可进行下一步。Before the test starts, place a steel block sample on the fixture, first adjust the height of the limit cylinder and the threaded connecting rod connecting the impact ball, manually rotate the threaded connecting rod, observe the pressure value of the pressure sensor terminal, and request the pressure value according to the actual material test. The size of the impact balls of different masses is selected, the height of the threaded connecting rod and the limit cylinder is adjusted, and the pressure value meets the test requirements to proceed to the next step.
将脆性材料试样22置于支撑夹具上，通过试样限位栓21对试样进行限位，防止在裂纹预制过程中试样发生左右、前后滑动，将压头调整到试样中间位置。The brittle material sample 22 is placed on the support fixture, and the sample is limited by the
调整第二激光探头25的位置，激光打到裂纹预制长度的最大位置，当裂纹扩展到要求尺寸，根据激光信号强度的变化，PLC控制器会关闭电机。Adjust the position of the second laser probe 25, and the laser hits the maximum position of the prefabricated length of the crack. When the crack expands to the required size, the PLC controller will turn off the motor according to the change of the laser signal intensity.
调整第一激光探头13的位置，手动转动含撞击球的螺纹连接杆，保证撞击球转到指定位置激光计数器都有示数的变化。Adjust the position of the first laser probe 13 and manually rotate the threaded connecting rod containing the impact ball to ensure that the laser counter changes when the impact ball rotates to the designated position.
打开PLC终端5的电源总开关，打开压力传感器17 、第一激光探头13开关，以上都正常工作时，打开电机开关，通过PLC终端调整电机的转速，进行脆性材料疲劳预制裂纹的制备。Turn on the main power switch of the PLC terminal 5, turn on the switch of the
当裂纹扩展到指定长度，第二激光探头25的激光信号强度会发生变化，PLC控制器会自动切断电机电源，报警器6发出警报，提示操作员该试样的预制裂纹制备完成。When the crack expands to the specified length, the laser signal intensity of the second laser probe 25 will change, the PLC controller will automatically cut off the motor power, and the alarm 6 will issue an alarm to remind the operator that the prefabricated crack preparation of the sample is completed.
操作员记录激光计数器终端的疲劳次数，通过压力传感器输出一个疲劳周期疲劳载荷随时间的变化数据。更换试样，即可进行下一个试样疲劳裂纹的预制过程。The operator records the fatigue times of the laser counter terminal, and outputs the change data of the fatigue load with time in a fatigue cycle through the pressure sensor. When the sample is replaced, the prefabrication process of the next sample fatigue crack can be carried out.
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