CN108920883B - Method for predicting service life of hot forming die based on fatigue and oxidation interaction - Google Patents

Method for predicting service life of hot forming die based on fatigue and oxidation interaction Download PDF

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CN108920883B
CN108920883B CN201810945661.XA CN201810945661A CN108920883B CN 108920883 B CN108920883 B CN 108920883B CN 201810945661 A CN201810945661 A CN 201810945661A CN 108920883 B CN108920883 B CN 108920883B
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陈明和
张鹏
谢兰生
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Nanjing University of Aeronautics and Astronautics
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Abstract

The invention provides a method for predicting the service life of a hot forming die based on fatigue and oxidation interaction, which comprises the following steps: step 1: performing a fatigue test on a hot forming die under the working condition of forming a titanium alloy part by the hot forming die, firstly judging whether the test is thermal mechanical fatigue or oxidation fatigue, and if so, performing the following steps; step 2: observing microstructure components of the oxide, and determining main components of the oxide; and step 3: establishing an oxide layer stress model; and 4, step 4: establishing a crack propagation rate model caused by oxide layer fracture; and 5: establishing a total damage rate model caused by fatigue oxidation interaction; step 6: by critical crack length acrCarrying out dimensionless transformation on the total damage rate model to obtain a service life prediction model of the hot forming die; and 7: and calculating the fatigue rotation cycle number and the total strain during the thermomechanical fatigue, and drawing a strain-fatigue curve. The invention can predict the failure condition of the hot forming die due to fatigue and oxidation in the actual service environment.

Description

Method for predicting service life of hot forming die based on fatigue and oxidation interaction
Technical Field
The invention relates to a problem of predicting the service life of a hot forming die under the interaction of fatigue and oxidation, in particular to a method for predicting the service life of the hot forming die under the interaction of fatigue and oxidation based on thermal mechanical fatigue. The method is particularly suitable for predicting the service life of the titanium alloy die which is loaded and formed at the temperature range of 600-800 ℃.
Background
With the rapid development of science and technology, the updating, application and service life of materials are the focus of attention of experts and scholars. At present, titanium alloys are widely used in the fields of aviation, aerospace, ships, automobiles and biomedical, and particularly in the fields of aerospace, the application specific gravity of titanium alloys tends to increase. Titanium alloy is a novel and light structural material which is applied to the aerospace field after steel and aluminum alloy, and the application level of the titanium alloy becomes an important mark for measuring the advanced degree of airplane material selection. The dosage of titanium alloy in the fields of commercial and military aircrafts is steadily increasing along with the upgrading and updating of products. The titanium alloys used in modern aircraft are widely used, mainly in aircraft fuselages, hydraulic lines, landing gear, cabin window frames, skins, fasteners, doors, wing structures, fan blades, compressor blades, and the like. The application of titanium alloy in aerospace craft is also very important, and the service environment is severe: ultrahigh temperature, ultralow temperature, high vacuum, high stress and strong corrosion. The method is typically applied to optimizing the structure of a spacecraft body, manufacturing a fuel tank, a rocket engine shell, a rocket nozzle guide pipe and a satellite shell.
The titanium alloy has high melting point, small density, high specific strength, strong corrosion resistance and half of the elastic modulus of steel. In the aspect of forming, the titanium alloy has the advantages of narrow deformation range, easiness in cracking, large resilience and difficulty in ensuring the dimensional precision. Therefore, titanium alloy parts are usually processed and manufactured by a hot forming method, and the forming temperature is generally between 600 ℃ and 800 ℃. This places certain demands on the dies for titanium alloy thermoforming.
The hot work die steel is mainly used for manufacturing dies for pressure processing in a high-temperature state, bears the action of periodic mechanical load during working, and stress concentration parts such as sharp corners, grooves and the like of a cavity are often cracked due to mechanical cycle plastic deformation. After the die cavity is contacted with the high-temperature metal, the local temperature can reach 500-800 ℃, sometimes even 1000 ℃, and the repeated heating and cooling are also carried out, so that the working surface of the die is easy to generate thermal mechanical fatigue cracks. Thermomechanical fatigue consists of a superposition of mechanical and temperature cycles.
The hot working die usually goes through thousands of or tens of thousands of cycles, the surface of the hot working die generates fatigue cracks, and finally the die is scrapped. In addition, when the high-temperature titanium alloy is forcibly formed, the high-temperature titanium alloy rubs against the surface of a cavity of a mold, so that the mold is easily worn and the hardness is reduced. According to the induction classification of failure mechanisms, the failure modes of the thermal forming die mainly comprise wear failure, plastic deformation failure and fracture failure, while the wear under the interaction of fatigue and oxidation is one of the main failure modes of the thermal working die in the service process, and the wear failure accounts for about 70% of the die failure. Under the action of high-temperature friction, an oxide film and oxide particles are formed on the grinding surface, and the oxide is Fe3O4Mainly contains a certain amount of Fe2O3The abrasive dust is Fe3O4、Fe2O3And a mixture of Fe. Taking 0Cr25Ni20 hot work die steel as an example, the high temperature wear mechanism is oxidation wear and fatigue spalling wear. The oxide film on the high-temperature wear surface has two stripping modes, namely the internal cracking of the oxide film or the cracking of the combination part of the oxide film and a steel matrix, belongs to slight oxidation wear, and the internal cracking of the matrix belongs to severe wear.
Oxidation and wear of steel at high temperatures are interactive. The stress and deformation of the steel in the abrasion process have obvious promotion effect on oxidation. Iron is oxidized in the air at a high temperature of more than 570 ℃ to form FeO and Fe3O4,Fe2O3The multilayer oxide layer of the layer, FeO, is adjacent to the metal side and FeO is absent below 570 ℃. The oxidative wear is in two states, slight oxidative wear and severe oxidative wear. The oxide abrasive dust generated by abrasion may be separated from the grinding surface to cause or form abrasive wear, and may also be densified between the sliding grinding surfaces to play a protective role, namely, oxidation-stripping-reoxidation mechanism. The abrasion process of the hot forming die is a gradual process, and the appearance of the die is changed relatively obviously only after the abrasion amount is accumulated to a certain degreeAnd (4) transforming.
Disclosure of Invention
The invention aims to provide a method for predicting the service life of a hot forming die based on fatigue and oxidation interaction, which can predict the failure condition of the hot forming die due to fatigue and oxidation in the actual service environment.
In order to achieve the purpose, the invention adopts the following technical scheme:
a method for predicting the service life of a hot forming die based on fatigue and oxidation interaction comprises the following steps:
step 1: carrying out fatigue test on a hot forming die under the working condition of forming a titanium alloy part by the hot working die, firstly judging whether the test is formed by superposing mechanical cycle and temperature cycle, and displaying whether fatigue cracks are grown through crystal and are expanded along the crystal by a microstructure;
step 2: microscopic analysis is carried out on the failure component, whether oxide cracks exist or not is judged, namely whether the oxide cracks cause failure or not is judged, and if not, the prediction method is not applicable;
and step 3: if the fatigue is thermal mechanical fatigue and oxidation fatigue, namely the failure is caused by fatigue and oxidation interaction, observing microstructure components of the oxide, determining main components of the oxide, and measuring relevant parameters of the oxide and a matrix material;
and 4, step 4: establishing an oxide layer stress model according to the parameters of the oxide and the parameters of the base material;
and 5: establishing a crack propagation rate model caused by oxide layer fracture;
step 6: establishing a total damage rate model caused by fatigue oxidation interaction;
and 7: by critical crack length acrCarrying out dimensionless transformation on the total damage rate model to obtain a service life prediction model of the hot forming die;
and 8: and (4) obtaining the fatigue rotation cycle number according to the service life prediction model of the hot forming die, calculating the total strain during the thermal mechanical fatigue period, and drawing a strain-fatigue curve.
Preferably, in step 4, the step of establishing a stress model of the oxide layer includes:
establishing a deformation compatibility equation:
Figure GDA0002429581320000031
establishing a force balance equation:
σOXf+(1-f)σS=σ (2)
wherein σOXStress of the oxide layer, EOXIs the elastic modulus of an oxide, αOXIs the coefficient of thermal expansion of the oxide, σSIs the matrix stress, ESIs the modulus of elasticity of the matrix material, αSIs the coefficient of thermal expansion of the matrix material, f is the volume percent of the oxide, T0The reference temperature of zero stress when the oxide is formed, T is the current temperature, and sigma is the ratio of the pressure of the punch to the contact area of the plate;
obtained by the formulae (1) and (2):
Figure GDA0002429581320000032
preferably, the growth of oxide cracks follows a parabolic relationship:
Figure GDA0002429581320000033
the crack propagation rate resulting from oxide layer fracture can be expressed as follows:
Figure GDA0002429581320000034
wherein h iscIs the critical layer thickness, tcIs the fracture time, a is the length of the crack, t is the crack growth time, and k is the parabolic rate coefficient.
Preferably, fatigue oxidation interaction results in a total damage rate:
Figure GDA0002429581320000041
wherein the content of the first and second substances,
Figure GDA0002429581320000042
in order to obtain the fatigue damage rate,
Figure GDA0002429581320000043
the oxidation damage rate and N are the number of cycles of fatigue cycle.
Preferably, the critical crack length acrWhen equation (6) is dimensionless, equation (6) is rewritten as:
Figure GDA0002429581320000044
wherein the content of the first and second substances,
Figure GDA0002429581320000045
according to the formula
Figure GDA0002429581320000046
To obtain:
Figure GDA0002429581320000047
KICis the fracture toughness of the material, Y is the shape factor of the test piece, σcThe average stress corresponding to the critical state, namely the breaking stress or the fracture strength of the crack body.
Has the advantages that: the invention combines a fatigue model and an oxidation model, establishes the constitutive relation of total damage rate of crack formation, growth and fatigue oxidation interaction, and can estimate the fatigue oxidation life of the titanium alloy material. The service life of the hot forming die under the interaction of fatigue and oxidation can be effectively predicted, the method is particularly suitable for mechanical fatigue at high temperature, and the stability and the accuracy of the prediction of the service life of the hot forming die under the interaction of fatigue and oxidation are improved.
Drawings
FIG. 1 is a flow chart of an embodiment of the present invention;
FIG. 2 is a graph of thermo-mechanical fatigue tests with different temperature and stress cycles;
FIG. 3 is a strain-fatigue curve obtained by a fatigue test using 0Cr25Ni20 as a base material;
wherein L CF is low Cycle Fatigue (L ow Cycle Fatigue), IP is in-phase Cycle, OP is reverse phase Cycle, DP diamond Cycle.
Detailed Description
The present invention will be further explained with reference to examples.
The technical scheme adopted by the invention for solving the technical problems is as follows: a method for predicting the service life of a hot forming die based on thermal mechanical fatigue under the interaction of fatigue and oxidation specifically comprises the following steps:
step 1: first, it is judged whether the test is a mechanical cycle and temperature cycle superimposed structure, that is, whether the test is thermal mechanical fatigue. The microstructure shows whether fatigue cracks are initiated by crystal crossing and spread along the crystal. If not, the prediction method is not applicable.
Step 2: and (4) carrying out microscopic analysis on the failed component to judge whether oxide cracks exist, namely judging whether the failed component is failed due to oxidation fatigue. If not, the prediction method is not applicable.
And step 3: modeling is performed if both thermo-mechanical and oxidative fatigue, i.e., failure is caused by fatigue, oxidative interactions.
When oxidation forms a continuous layer on the surface of the material, it will not only change the chemical composition of the near-surface region, but will also cause stress redistribution. This oxide layer will be forcibly compatible with matrix deformation until fracture, leading to premature crack nucleation. The stress on the substrate and oxide layer can be determined by deformation compatibility:
Figure GDA0002429581320000051
and the force balance is satisfied:
σOXf+(1-f)σS=σ (2)
wherein σOXOxidation by oxygenStress of the layer, EOXIs the modulus of elasticity of the oxide material,OXis the coefficient of thermal expansion of the oxide, σSIs the matrix stress, ESIs the modulus of elasticity of the matrix, αSIs the coefficient of thermal expansion of the matrix material, f is the volume percent of the oxide, T0Is the reference temperature of zero stress at the time of oxide formation, and T is the current temperature. Thereby, it is possible to deduce:
Figure GDA0002429581320000052
according to the formula (3), the oxide increases the surface stress by a magnification of
Figure GDA0002429581320000053
In addition, assume that a zero-stress state of the oxide is formed at the maximum temperature Tmax=T0As the loading temperature decreases, the oxidative stress increases. In particular, the destructive nature of oxidation is strongest when the temperature is lowered to the lowest and the stress is raised to the highest during a reverse phase thermomechanical fatigue cycle, which is susceptible to oxide spalling damage as predicted in (3).
Assuming that the oxide is at the critical stress σf,OXIs broken at the lower part
Figure GDA0002429581320000054
Wherein T isminIs the minimum value of the loading cycle temperature.
The oxide cracks are then either combined with fatigue-creep damage in the material or the above brittle fracture process is simply repeated, i.e. without significant fatigue or creep damage.
The growth of oxide cracks is assumed to follow a parabolic relationship:
Figure GDA0002429581320000061
where k is the parabolic rate coefficient, which can be looked up.
The crack propagation rate caused by the oxide layer breaking can be simply expressed as follows:
Figure GDA0002429581320000062
wherein h iscIs the critical layer thickness (known as the breaking stress, determined from (4)), tcIs the fracture time, a is the length of the crack, t is the crack growth time, and k is the parabolic rate coefficient. h iscThe solving steps are as follows: has the formula (4) to obtain sigmaf,OX,σf,OXIf F/A, then A is F/sigmaf,OX,hcF is the loading force, a is the area of the oxide layer and V is the volume of the oxide layer.
Then, fatigue oxidation interactions lead to a total damage rate:
Figure GDA0002429581320000063
wherein the content of the first and second substances,
Figure GDA0002429581320000064
in order to obtain the fatigue damage rate,
Figure GDA0002429581320000065
the oxidation damage rate and N are the number of cycles of fatigue cycle.
If the critical crack length a is usedcrBy making formula (7) non-dimensionalized, formula (7) is rewritten to
Figure GDA0002429581320000066
Wherein the content of the first and second substances,
Figure GDA0002429581320000067
in the experiment
Figure GDA0002429581320000068
The value is 0.7-2.2, and 1 can be taken for convenient calculation.
By
Figure GDA0002429581320000069
Obtaining:
Figure GDA00024295813200000610
KICis the fracture toughness of the material, Y is the shape factor of the test piece (Y can be 1 for convenient calculation), and sigmacThe average stress corresponding to the critical state, namely the breaking stress or the fracture strength of the crack body.
Calculating the total strain during thermomechanical fatigue: (tot) Is the sum of thermal and mechanical strain:
totth+mech=α(T-T0)+mech(10)
wherein the content of the first and second substances,this a strain of the heat, and is,mechis the mechanical strain, α is the coefficient of thermal expansion, T0Is the reference temperature and T is the current temperature. Mechanical strainmechGenerally considered as the sum of elastic and plastic strains.
Finally, an S-N (train Range-Number of Cycles to Failure) curve is obtained.
Taking the substrate material as 0Cr25Ni20 as an example, a simple mechanical fatigue test and a fatigue oxidation interaction fatigue test were performed, respectively, to obtain the strain-fatigue curve shown in fig. 3. From fig. 3, it can be seen that the actual test data point is closer to the prediction fitting curve, which indicates that the model can better predict the actual test result. It can be seen that under the condition of forming a titanium alloy part by taking the base material 0Cr25Ni20 as a hot die based on the thermal mechanical fatigue, the fatigue oxidation interaction is closer to the actual condition than the simple mechanical fatigue.

Claims (5)

1. A method for predicting the service life of a hot forming die based on fatigue and oxidation interaction is characterized by comprising the following steps:
step 1: performing a fatigue test on a hot forming die under the working condition of forming a titanium alloy part by the hot forming die, and firstly judging whether the test is formed by superposing mechanical cycle and temperature cycle, namely whether the test is thermal mechanical fatigue; the microstructure shows whether fatigue cracks are transcrystalline and are initiated and spread along the crystal; if not, the prediction method is not applicable;
step 2: microscopic analysis is carried out on the failure component, whether oxide cracks exist or not is judged, namely whether the oxide cracks cause failure or not is judged, and if not, the prediction method is not applicable;
and step 3: observing the microstructure components of the oxide generated on the surface of the hot forming die if the thermal mechanical fatigue and the oxidation fatigue are both thermal mechanical fatigue and oxidation fatigue, namely the failure is caused by fatigue and oxidation interaction, determining the main components of the oxide, and measuring the relevant parameters of the oxide and the base material of the hot forming die;
and 4, step 4: establishing an oxide layer stress model according to the parameters of the oxide and the parameters of the base material;
and 5: establishing a crack propagation rate model caused by oxide layer fracture;
step 6: establishing a total damage rate model caused by fatigue oxidation interaction;
and 7: carrying out dimensionless transformation on the total damage rate model by using the critical crack length to obtain a service life prediction model of the hot forming die;
and 8: and (4) obtaining the fatigue rotation cycle number according to the service life prediction model of the hot forming die, calculating the total strain during the thermal mechanical fatigue period, and drawing a strain-fatigue curve.
2. The method for predicting the service life of the hot forming die based on the fatigue and oxidation interaction as claimed in claim 1, wherein in the step 4, the step of establishing the oxide layer stress model comprises the following steps:
establishing a deformation compatibility equation:
Figure FDA0002444049780000011
establishing a force balance equation:
σOXf+(1-f)σS=σ (2)
obtained by the formulae (1) and (2):
Figure FDA0002444049780000012
wherein σOXStress of the oxide layer, EOXIs the elastic modulus of an oxide, αOXIs the coefficient of thermal expansion of the oxide, σSIs the matrix stress, ESIs the modulus of elasticity of the matrix material, αSIs the coefficient of thermal expansion of the matrix material, f is the volume percent of the oxide, T0Is the reference temperature of zero stress when the oxide is formed, T is the current temperature, and sigma is the ratio of the punch pressure to the sheet contact area.
3. The method for predicting the service life of the hot forming die based on the fatigue and oxidation interaction as claimed in claim 1, wherein in the step 5, the step of establishing the crack propagation rate model comprises the following steps:
the growth of oxide cracks follows a parabolic relationship:
Figure FDA0002444049780000021
the crack propagation rate resulting from oxide layer fracture can be expressed as follows:
Figure FDA0002444049780000022
wherein h iscIs the critical layer thickness, tcIs the fracture time, a is the length of the crack, t is the crack growth time, and k is the parabolic rate coefficient.
4. The method for predicting the service life of the hot forming die based on the fatigue and oxidation interaction as claimed in claim 3, wherein in the step 6, the model of the total damage rate caused by the fatigue and oxidation interaction is as follows:
Figure FDA0002444049780000023
wherein the content of the first and second substances,
Figure FDA0002444049780000024
in order to obtain the fatigue damage rate,
Figure FDA0002444049780000025
the oxidation damage rate and N are the number of cycles of fatigue cycle.
5. The method for predicting the service life of the hot forming die based on the fatigue and oxidation interaction as claimed in claim 4, wherein in step 7, the critical crack length a is usedcrWhen equation (6) is dimensionless, equation (6) is rewritten as:
Figure FDA0002444049780000026
wherein the content of the first and second substances,
Figure FDA0002444049780000027
acris defined as:
Figure FDA0002444049780000028
KICis the fracture toughness of the material, Y is the shape factor of the test piece, σcThe average stress corresponding to the critical state, namely the breaking stress or the fracture strength of the crack body.
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