CN108256192B - Low-cycle fatigue-based thermomechanical fatigue life prediction method for metal material - Google Patents
Low-cycle fatigue-based thermomechanical fatigue life prediction method for metal material Download PDFInfo
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Abstract
The invention discloses a thermal mechanical fatigue life prediction method of a metal material based on low cycle fatigue, belonging to the technical field of material science and engineering application. The method comprises the steps of firstly establishing a quantitative relation between the thermal mechanical fatigue hysteresis energy of a metal material and the constant-temperature (thermal mechanical fatigue upper limit temperature) low-cycle fatigue hysteresis energy of the same material, namely, a linear relation between the difference value of the two fatigue hysteresis energies and mechanical strain, and then predicting the service life by an energy method. The method can realize accurate prediction of the thermal mechanical fatigue life of different mechanical strains through a small amount of low cycle fatigue and thermal mechanical fatigue test. The method effectively reduces the experimental amount required by thermal mechanical fatigue life prediction, greatly saves time, money and labor cost, has high accuracy, and can be widely applied to thermal mechanical fatigue life prediction of high-temperature alloys and heat-resistant metal materials such as gas turbine blades, gas turbine cylinder covers and pistons.
Description
Technical Field
The invention relates to the technical field of material science and engineering application, in particular to a thermal mechanical fatigue life prediction method of a metal material based on low cycle fatigue.
Background
Metal materials, especially high temperature alloy and heat resistant materials, are widely used for high temperature bearing members such as cylinder covers of internal combustion engines, pistons, blades of internal combustion engines and the like, and in the working process of the engines, the metal materials bear the changes of temperature load and mechanical load at the same time. Therefore, failure is liable to occur. According to failure analysis, the most dominant failure form is thermomechanical fatigue. If the thermal mechanical fatigue life prediction cannot be reasonably carried out, the service cost of the component is greatly increased, the service safety of the component is reduced, and the damage which is difficult to recover is generated.
At present, the traditional prediction of the thermal mechanical fatigue life can be divided into two categories: or a fitting method based on a large amount of thermal mechanical fatigue experimental data, although the prediction precision is higher, the required experimental amount is large, and the method has great limitation in application due to the complex process, strong unpredictability and higher time, labor and money costs; or according to the physical and mechanical properties of the material, the calculation is carried out through complex theoretical derivation, the accuracy is relatively low, the calculation complexity is extremely high, and the acquisition conditions of some special parameters are harsh, so that the method is not suitable for industrial popularization. Therefore, a relatively simple and accurate fatigue life prediction method is urgently needed for the problem of thermomechanical fatigue failure.
Disclosure of Invention
In order to solve the problems of the existing thermomechanical fatigue life prediction method, the invention provides a thermomechanical fatigue life prediction method of a metal material based on low cycle fatigue. The method combines the advantage of high accuracy of a fitting method based on a large amount of experimental data, simultaneously greatly reduces the requirement of experimental amount, and does not have complex formula derivation calculation.
In order to achieve the purpose, the invention adopts the technical scheme that:
a method for predicting the thermomechanical fatigue life of a metal material based on low cycle fatigue specifically comprises the following steps:
(1) analyzing the service working condition of the service component, and determining the temperature and the mechanical strain range of the metal material in thermal mechanical fatigue, wherein the thermal mechanical fatigue load is characterized in that: the mechanical load varies periodically with time and the temperature varies periodically with time. In the step, the temperature range and the mechanical strain range of the thermal mechanical fatigue test need to be selected according to the actual working condition, and the mechanical load change period is the same as the temperature load change period. If the mechanical load is the same as the temperature change period, if the temperature peak value corresponds to the mechanical load peak value, the mechanical load is called as the same phase; conversely, if the temperature load valley corresponds to the mechanical load peak, it is called the anti-phase. The method is suitable for the same-phase and reverse-phase thermo-mechanical fatigue.
(2) And determining a target strain amplitude, namely determining a thermal strain and mechanical strain amplitude value for performing thermomechanical fatigue life prediction.
(3) Selecting metal materials to carry out constant-temperature low-cycle fatigue performance test to obtain low-cycle fatigue median hysteresis energy Wa,LCF(hysteresis loop area) and establishing the median hysteresis energy W of low cycle fatiguea,LCFAmplitude of mechanical strain epsilonmechA quantitative relationship between them. The temperature of the low-cycle fatigue test needs to be the highest temperature corresponding to the thermo-mechanical fatigue working condition, at least two different mechanical strain amplitudes need to be selected for the low-cycle fatigue test, at least one effective data test is carried out on each strain amplitude, and the low-cycle fatigue test under the condition of a target strain amplitude is not needed.
(4) Selecting metal materials to carry out thermo-mechanical fatigue performance test to obtain thermo-mechanical median hysteresis energy Wa,TMF(ii) a The thermomechanical fatigue test requires the selection of at least two different mechanical strain amplitudes, which should be the same as those selected in step (3). At least one valid data test is carried out on each strain amplitude; if the reliability analysis of the material or the component is needed, the system research is carried out according to the relevant requirements.
(5) The thermomechanical median hysteresis energy W in the step (4) isa,TMFFitting by substituting energy method formula to obtain metal material parameters beta and W0(ii) a The formula of the energy method refers to thermomechanical median hysteresis energy Wa,TMFAnd thermo-mechanical fatigue life NfThe relation of (a) is specifically shown as formula (1);
in the formula (1), NfFor thermomechanical fatigue life, Wa,TMFFor thermomechanical median hysteresis energy (median life-corresponding hysteresis loop)Area), beta and W0Are fitting parameters. In formula (1), the value of β is the ability to convert the degree of external action into energy that damages the material. Microscopically, the beta value is related to the evolution of the microstructure of the material (such as dislocation, twin crystal, hole and crack), when the beta value is reduced, under the same external plastic work, the inside of the material is easy to generate defects and the original defects (such as hole, crack and the like) are easily expanded, so that the damage degree is improved. W0The plastic work done to cause the material to fail, which can be considered a single deformation. WaThe hysteresis loop area corresponding to the median lifetime can be calculated by Origin and other software. The formula model has definite physical significance and better fitting precision. After fitting, the beta, W under the condition of the thermomechanical load can be obtained0The specific value of (a) is an exponential relationship between the thermomechanical fatigue life and the hysteresis energy. Since the corresponding hysteresis energy cannot be obtained without performing the thermomechanical fatigue test under the condition of the target strain amplitude, the corresponding hysteresis energy cannot be obtained directly according to beta, W0The specific value of (a) is used for predicting the thermomechanical fatigue life.
(6) According to the test results of the step (3) and the step (4), establishing thermomechanical fatigue, low cycle fatigue hysteresis energy and mechanical strain amplitude epsilonmethAnd obtaining the relevant material parameters; in this step, the hysteresis energy and the mechanical strain amplitude epsilon of thermal mechanical fatigue, low cycle fatiguemethThe quantitative relation of (A) is the difference between the hysteresis energies of thermo-mechanical fatigue and low cycle fatigue for cast iron or cast aluminumaAmplitude of mechanical strain epsilonmethThe linear relationship of (a), as in equation (3); the material parameters in the linear relationship are A and K;
ΔWa＝Wa,TMF-Wa,LCF＝A+K·εmech
(3)；
equation (3) may be converted into equation (4);
Wa,TMF＝A+Kεmech+Wa,LCF
(4)。
wherein A and K are fitting parameters, Wa,TMFIs the area of the thermo-mechanical fatigue hysteresis loop, Wa,LCFThe area of the hysteresis loop of the low-cycle fatigue,ΔWathe difference value of the thermomechanical fatigue hysteresis loop area and the low cycle fatigue hysteresis loop area is shown. A is a toughness sensitivity coefficient and is controlled by the static toughness of the material, the larger the static toughness is, the smaller A is, and the better the thermal mechanical fatigue property of the material is. K is a strain sensitivity coefficient, and for different materials and different temperatures, the increase amplitude of the hysteresis loop difference value is different along with the increase of strain; k is affected by the plastic deformability of the material. The better the plasticity, the smaller the K, the better the TMF performance. And taking the mechanical strain amplitude as an independent variable, and taking the difference value of the thermomechanical fatigue hysteresis loop area and the low-cycle fatigue hysteresis loop area as a dependent variable to perform linear fitting. The specific values of A and K under the temperature condition can be obtained.
(7) Calculating the thermomechanical fatigue median hysteretic energy under the target strain amplitude determined in the step (2) through the quantitative relation established in the step (6) and the low-cycle fatigue median hysteretic energy under the mechanical strain amplitude in the step (3); if the low cycle fatigue at the target strain amplitude is not tested, according to the median hysteresis energy W of the low cycle fatigue in the step (3)a,TMFAnd (3) calculating the low-cycle fatigue hysteresis loop area under the target strain amplitude determined in the step (2) according to the quantitative relation between the target strain amplitude and the mechanical strain amplitude.
(8) And (3) substituting the thermomechanical fatigue hysteresis energy area under the target strain amplitude obtained by calculation in the step (7) into the formula (1), and obtaining the thermomechanical fatigue life by calculation, namely the final target life. Substituting into the formula process, beta, W0The specific numerical value of (3) is the same as that calculated in the step (4).
The invention has the following advantages and beneficial effects:
1. an energy model is adopted, thermomechanical fatigue life prediction is carried out based on low cycle fatigue, and the physical significance is clear.
2. The model has good universality and good applicability to different-phase thermo-mechanical fatigue experiments of metal materials.
3. The calculation is simple and has higher precision, the required minimum experimental amount is 4 fatigue experimental data (2 low cycle fatigue experimental data and 2 thermal mechanical fatigue experimental data), and the time, manpower and money cost are greatly saved.
Drawings
FIG. 1 is a flow chart of a method for predicting the thermomechanical fatigue life of a metal material based on low cycle fatigue.
FIG. 2 is a linear relationship between the thermo-mechanical fatigue of cast iron and the difference between low cycle fatigue hysteresis energies; wherein: (a)400 ℃; (b) at 500 ℃.
FIG. 3 is the low cycle fatigue median hysteresis energy W of cast irona,LCFLinear relationship to mechanical strain amplitude.
FIG. 4 shows the results of thermo-mechanical fatigue life prediction of cast iron materials at 125-400 ℃ and 125-500 ℃ in reverse direction.
FIG. 5 shows the prediction result of thermomechanical fatigue life of cast aluminum material at 120-350 ℃ in the same direction.
The specific implementation mode is as follows:
the invention is further illustrated below with reference to examples and figures.
Example 1:
in this embodiment, the life of the cast iron material is predicted according to the reverse thermomechanical fatigue condition, and the prediction process is shown in fig. 1, and the specific process is as follows:
firstly, the cast iron material is taken from a cylinder cover of a diesel engine, the thermal mechanical fatigue temperature load to be predicted is determined to be 125-400 ℃ and 125-500 ℃ according to working conditions, and the mechanical strain condition is +/-0.1% -0.4%.
Secondly, in the embodiment, for the working condition of 125-400 ℃ of temperature, the target strain amplitude is +/-0.15%, +/-0.2%, +/-0.3%; under the working condition that the temperature is 125-500 ℃, the target strain amplitude is +/-0.15%, +/-0.2%, +/-0.3%. A plurality of strain amplitudes is selected here as target strain amplitude for comparison with experimental results.
Thirdly, testing the low-cycle fatigue, wherein the testing conditions are as follows: three tests are carried out at 400 ℃, and the mechanical strain is +/-0.15%, +/-0.2%, +/-0.3% respectively; three tests were carried out at 500 ℃ and the mechanical strains were. + -. 0.15%,. + -. 0.2%,. + -. 0.3%, respectively. And calculating the median life hysteresis loop area of each test datum.
Fourthly, testing thermo-mechanical fatigue, wherein the testing conditions are as follows: three tests are carried out at the temperature of 125-400 ℃, and the mechanical strain is +/-0.15%, +/-0.2%, +/-0.3% respectively; three tests are carried out at 125-500 ℃, and the mechanical strain is +/-0.15%, +/-0.2%, +/-0.3% respectively. And calculating the median life hysteresis loop area of each test datum. For the above tests, fitting was performed according to the following formulas, respectively, and an exponential relationship was established.
In the relation of thermal mechanical fatigue at 125-400 ℃: beta is 1.59, W0＝7994.7；
In the relation of thermal mechanical fatigue at 125-500 ℃: beta-1.75, W0＝1570.0。
Fifthly, according to the thermal mechanical fatigue and low cycle fatigue performance tests, fitting according to the following formula respectively, and establishing a linear relation. Fig. 2 shows the fitting results.
Wa,TMF＝A+Kεmech+Wa,LCF
In the relation of 125-400 ℃ thermo-mechanical fatigue (400 ℃ low cycle fatigue): a-42.7, K-441.3;
in the relation of 125-500 ℃ thermal mechanical fatigue (500 ℃ low cycle fatigue): a is-12.3 and K is 155.8.
Sixth, median hysteretic energy W through low cycle fatiguea,LCFAnd calculating the low cycle fatigue hysteresis loop area under the target strain amplitude according to the quantitative relation between the target strain amplitude and the mechanical strain amplitude. FIG. 3 shows the median hysteresis energy W of low cycle fatiguea,LCFLinear relationship with the mechanical strain amplitude.
Wa,LCF＝B+a·εmech
For the 400 ℃ low cycle fatigue relationship: b-37.58, a-300.06;
for the 500 ℃ low cycle fatigue relationship: b-53.12, a-353.37;
and seventhly, calculating the area of the thermomechanical fatigue hysteresis loop under different mechanical strain amplitudes according to the linear relation in the fifth step.
And eighthly, respectively calculating the thermal mechanical fatigue conditions of 125-400 ℃ and 125-500 ℃ according to the exponential relation in the fourth step, and finally prolonging the service life under the target mechanical strain amplitude. Fig. 4 shows that the predicted value is within 1.5 times of the life interval, and LPF in fig. 4 indicates the life prediction coefficient, i.e. the larger of the ratio of the calculated value to the experimental value or the ratio of the experimental value to the calculated value.
Example 2:
the service life of the cast aluminum material is predicted according to the same-position thermo-mechanical fatigue working condition.
Firstly, the cast aluminum material is taken from a piston of a diesel engine, the thermal mechanical fatigue temperature load to be predicted is determined to be 125-350 ℃ according to working conditions, and the mechanical strain condition is +/-0.1% - +/-0.4%.
Secondly, in the embodiment, for the working condition that the temperature load is 125-350 ℃, the target strain amplitude is +/-0.25%, +/-0.35%, +/-0.3%, +/-0.45%; a plurality of strain amplitudes is selected here as target strain amplitude for comparison with experimental results.
Thirdly, testing the low-cycle fatigue, wherein the testing conditions are as follows: four tests are carried out at 350 ℃, and the mechanical strain is +/-0.25%, +/-0.35%, +/-0.3%, +/-0.45% respectively; and calculating the median life hysteresis loop area of each test datum.
Fourthly, testing thermo-mechanical fatigue, wherein the testing conditions are as follows: three tests are carried out at 120-350 ℃, and the mechanical strain is +/-0.2% and +/-0.4% respectively; and calculating the median life hysteresis loop area of each test datum. For the above tests, fitting was performed according to the following formulas, respectively, and an exponential relationship was established.
In the thermal mechanical fatigue relationship of 120-350 ℃: β ═ 1.92, W0＝1638.8。
Fifthly, according to the thermal mechanical fatigue and low cycle fatigue performance tests, fitting according to the following formula respectively, and establishing a linear relation.
Wa,TMF＝A+Kεmech+Wa,LCF
In the relation of 120-350 ℃ thermal mechanical fatigue (350 ℃ low cycle fatigue): a ═ 4.9, K ═ 27.0;
sixth, passing median low cycle fatigueRetardation energy Wa,LCFAnd calculating the low cycle fatigue hysteresis loop area under the target strain amplitude according to the quantitative relation between the target strain amplitude and the mechanical strain amplitude.
And seventhly, calculating the area of the thermomechanical fatigue hysteresis loop under different mechanical strain amplitudes according to the linear relation in the fifth step.
And eighthly, calculating the final service life under the target mechanical strain range under the thermal mechanical fatigue condition of 120-350 ℃ according to the exponential relation in the fourth step. Fig. 5 shows the results and error bands of the predicted values and the actual values.
The foregoing embodiments and comparative examples are merely illustrative of the principles and capabilities of the present invention, and not all that is required is that one obtain additional embodiments in accordance with the present embodiments without the use of inventive faculty, and such additional embodiments are within the scope of the present invention.
Claims (6)
1. A method for predicting the thermomechanical fatigue life of a metal material based on low cycle fatigue is characterized by comprising the following steps: the prediction method specifically comprises the following steps:
(1) analyzing the service working condition of the service component, and determining the temperature and the mechanical strain range of the metal material in thermal mechanical fatigue, wherein the thermal mechanical fatigue load is characterized in that: the mechanical load changes periodically with time, and the temperature changes periodically with time; the temperature range and the mechanical strain range of the thermal mechanical fatigue test need to be selected according to actual working conditions, and the mechanical load change period is the same as the temperature load change period;
(2) determining a target strain amplitude, namely determining a thermal strain and a mechanical strain amplitude range for predicting the thermomechanical fatigue life, wherein the thermal strain range is obtained through temperature change;
(3) selecting metal materials to carry out constant-temperature low-cycle fatigue performance test to obtain low-cycle fatigue median hysteresis energy Wa,LCFAnd establishing the median hysteresis energy W of low cycle fatiguea,LCFAmplitude of mechanical strain epsilonmechA quantitative relationship between;
(4) selecting metal materials to carry out thermo-mechanical fatigue performance test to obtain thermo-mechanical median hysteresis energy Wa,TMF；
(5) Thermo-mechanical treatment in step (4)Retardation value of energy Wa,TMFFitting by substituting energy method formula to obtain metal material parameters beta and W0(ii) a The formula of the energy method refers to thermomechanical median hysteresis energy Wa,TMFAnd thermo-mechanical fatigue life NfThe relation of (a) is specifically shown as formula (1);
in equation (1), the value of beta is the ability to convert the degree of external action into energy to damage the material, W0Plastic work for single deformation causing material failure;
(6) according to the test results of the step (3) and the step (4), establishing thermomechanical fatigue, low cycle fatigue hysteresis energy and mechanical strain amplitude epsilonmethAnd obtaining the relevant material parameters;
(7) calculating the thermomechanical fatigue median hysteretic energy under the target strain amplitude determined in the step (2) through the quantitative relation established in the step (6) and the low-cycle fatigue median hysteretic energy under the mechanical strain amplitude in the step (3); if the low cycle fatigue under the target strain amplitude is not tested, calculating through the quantitative relation between the median hysteresis energy of the low cycle fatigue and the mechanical strain amplitude in the step (3);
(8) and (3) substituting the thermomechanical fatigue median hysteresis energy under the target strain amplitude obtained by calculation in the step (7) into the formula (1), and obtaining the thermomechanical fatigue life by calculation, namely the final target life.
2. The method for predicting the thermomechanical fatigue life of a metallic material based on low cycle fatigue of claim 1, characterized in that: in the step (3), the highest temperature corresponding to the thermo-mechanical fatigue working condition is selected as the experimental temperature for the low cycle fatigue performance test.
3. The method for predicting the thermomechanical fatigue life of a metallic material based on low cycle fatigue of claim 1, characterized in that: in the step (3), at least two different mechanical strain amplitudes are selected for the low-cycle fatigue test, and each strain amplitude is tested by at least one effective data.
4. The method for predicting the thermomechanical fatigue life of a metallic material based on low cycle fatigue of claim 1, characterized in that: in the step (3), the median hysteresis energy W of low cycle fatiguea,LCFThe quantitative relation between the mechanical strain amplitude and the mechanical strain amplitude is expressed as a linear relation for cast iron or cast aluminum materials, the linear relation is shown as a formula (2), wherein B and a are material parameters, and the quantitative relation is expressed as a linear relation for low-cycle fatigue at 125-400 ℃: b-37.58, a-300.06; in the relation of 125-500 ℃ low cycle fatigue: b-53.12, a-353.37;
Wa,LCF＝B+a·εmech (2)。
5. the method for predicting the thermomechanical fatigue life of a metallic material based on low cycle fatigue of claim 1, characterized in that: in the step (4), at least two different mechanical strain amplitudes are selected for the thermomechanical fatigue test, and the selected strain amplitudes are the same as those selected in the step (3); at least one valid data test is carried out on each strain amplitude; if the reliability analysis of the material or the component is needed, the system research is carried out according to the relevant requirements.
6. The method for predicting the thermomechanical fatigue life of a metallic material based on low cycle fatigue of claim 1, characterized in that: in the step (6), the hysteresis energy and the mechanical strain amplitude epsilon of the thermal mechanical fatigue and the low cycle fatiguemethThe quantitative relationship between the thermal mechanical fatigue and the low cycle fatigue hysteresis energy difference Delta W for cast iron or cast aluminum materialsaAmplitude of mechanical strainmethThe linear relationship of (a), as in equation (3); in the linear relation, the material parameters are A and K, wherein A is a toughness sensitivity coefficient, and K is a strain sensitivity coefficient;
ΔWa＝Wa,TMF-Wa,LCF＝A+K·εmech (3)；
equation (3) may be converted into equation (4);
Wa,TMF＝A+Kεmech+Wa,LCF (4)。
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