CN109115383B - Fatigue life prediction method for cold extrusion reinforced hole - Google Patents
Fatigue life prediction method for cold extrusion reinforced hole Download PDFInfo
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- CN109115383B CN109115383B CN201710492275.5A CN201710492275A CN109115383B CN 109115383 B CN109115383 B CN 109115383B CN 201710492275 A CN201710492275 A CN 201710492275A CN 109115383 B CN109115383 B CN 109115383B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
- G01L5/0047—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes measuring forces due to residual stresses
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/17—Systems in which incident light is modified in accordance with the properties of the material investigated
- G01N21/41—Refractivity; Phase-affecting properties, e.g. optical path length
- G01N21/45—Refractivity; Phase-affecting properties, e.g. optical path length using interferometric methods; using Schlieren methods
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F30/00—Computer-aided design [CAD]
- G06F30/20—Design optimisation, verification or simulation
- G06F30/23—Design optimisation, verification or simulation using finite element methods [FEM] or finite difference methods [FDM]
Abstract
The invention discloses a fatigue life prediction method for a cold extrusion reinforced hole. The fatigue life prediction method of the cold extrusion reinforced hole comprises the following steps: determining the cold extrusion working condition; establishing a finite element analysis model by adopting finite element analysis software according to the determined cold extrusion working condition; setting cold extrusion process parameters and carrying out finite element simulation analysis to obtain simulation results of residual stress distribution and interference; manufacturing a cold extrusion test piece based on a cold extrusion working condition and cold extrusion process parameters; measuring the residual stress distribution and the interference quantity of the cold extrusion test piece; correcting the finite element analysis model according to the comparison; and performing prediction analysis on the fatigue life based on the corrected finite element analysis model. The method can accurately and efficiently predict the fatigue life of the cold extrusion hole under different cold extrusion process methods, and provides reliable basis for the selection and optimization of the cold extrusion process methods.
Description
Technical Field
The invention relates to the technical field of fatigue life prediction methods, in particular to a fatigue life prediction method for a cold extrusion reinforced hole.
Background
According to statistics, investigation and statistical analysis of fatigue failure of an airplane structural member in service period show that more than 70% of structural fatigue problems occur at joints, and the structural fatigue problems become one of the most main sources of structural failure of the aircraft. The cold extrusion process can achieve the purpose of improving the fatigue life in a mode of improving the residual stress, but different process methods have different influences on the fatigue life, and an optimal process method needs to be obtained through experimental analysis.
The fatigue life under the specific cold extrusion process can be obtained by a test method, but the method needs to spend a great deal of manpower, financial resources and time in the actual production process. Therefore, a method for analyzing and predicting fatigue life is needed to reduce the test amount, the traditional fatigue life prediction method and the simulation analysis performed by software can analyze the fatigue life under different structural forms, but the influence of different processes on the fatigue life cannot be analyzed usually, and the accuracy still has a defect.
Therefore, a new simulation analysis method is needed, which can establish the relationship between the cold extrusion process and the fatigue life by using fewer tests, so as to efficiently and accurately and reliably predict the fatigue life of different cold extrusion process methods.
Disclosure of Invention
The invention aims to solve the technical problem that the fatigue life prediction method in the prior art is difficult to consider the influence caused by different cold extrusion processes, and the fatigue life test method has the defects of overhigh cost and overlong period of fatigue life test.
The invention solves the technical problems through the following technical scheme:
the invention provides a fatigue life prediction method for a cold extrusion reinforced hole, which is characterized by comprising the following steps of:
step one, determining a cold extrusion working condition;
secondly, establishing a finite element analysis model by adopting finite element analysis software according to the determined cold extrusion working condition;
setting cold extrusion process parameters and carrying out finite element simulation analysis on the basis of the finite element analysis model to obtain simulation results of residual stress distribution and interference amount corresponding to the cold extrusion process parameters;
fourthly, manufacturing a cold extrusion test piece based on the cold extrusion working condition and the cold extrusion process parameter;
measuring the residual stress distribution and the interference quantity of the cold extrusion test piece by adopting a residual stress measuring instrument and an interference quantity measuring instrument;
step six, comparing the simulation result of the residual stress distribution and the interference amount obtained in the step three with the measurement result of the residual stress distribution and the interference amount obtained in the step five, and correcting the finite element analysis model according to the comparison result so that the simulation result approaches to the measurement result;
and seventhly, based on the corrected finite element analysis model, adopting fatigue life analysis software, and performing prediction analysis on the fatigue life of the cold extrusion reinforced hole by taking the residual stress distribution as an input quantity.
Preferably, the cold extrusion working condition comprises the pore diameter and/or the material property of the cold extrusion reinforced pore.
Preferably, the finite element analysis model established in step two includes a test piece portion and a squeeze bar portion.
Preferably, the cold extrusion process parameters include extrusion rate and/or extrusion rate.
Preferably, the measurement of the residual stress distribution and the interference amount of the cold-extruded test piece in the fifth step includes measurement of at least 8 reference points.
Preferably, the third, fourth and fifth steps are respectively executed based on a plurality of groups of cold extrusion process parameters to obtain simulation results and measurement results of residual stress distribution and interference amount respectively corresponding to the plurality of groups of cold extrusion process parameters, and the finite element analysis model is corrected according to comparison results of the simulation results and the measurement results of the residual stress distribution and the interference amount respectively corresponding to the plurality of groups of cold extrusion process parameters in the sixth step.
Preferably, the fatigue life analysis software used in step seven is msc.
Preferably, in the seventh step, the fatigue life of the cold extrusion strengthened hole is predicted and analyzed by adopting a fatigue life S-N analysis method.
Preferably, in the step seven, in the prediction analysis of the fatigue life of the cold extrusion strengthened hole, the goodman equation is also used for correcting the average stress.
On the basis of the common knowledge in the field, the above preferred conditions can be combined randomly to obtain the preferred embodiments of the invention.
The positive progress effects of the invention are as follows:
the fatigue life prediction method of the cold extrusion reinforced hole can overcome the defects of the existing method, help to improve the simulation effectiveness and accuracy of the established finite element simulation model by using limited tests, accurately and efficiently predict the fatigue life of the cold extrusion hole under different cold extrusion process methods, and provide reliable basis for the selection and optimization of the cold extrusion process methods. Compared with the existing method, the method can effectively reduce the test time and the test cost, and achieve the purpose of rapid comparative analysis.
Drawings
FIG. 1 is a flowchart illustrating a method for predicting fatigue life of a cold extrusion strengthened hole according to a preferred embodiment of the present invention.
Detailed Description
The following detailed description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings, is intended to be illustrative, and not restrictive, and it is intended that all such modifications and equivalents be included within the scope of the present invention.
In the following detailed description, directional terms, such as "left", "right", "upper", "lower", "front", "rear", and the like, are used with reference to the orientation as illustrated in the drawings. Components of embodiments of the present invention can be positioned in a number of different orientations and the directional terminology is used for purposes of illustration and is in no way limiting.
Referring to fig. 1, a method for predicting fatigue life of a cold extrusion strengthened hole according to a preferred embodiment of the present invention includes the following steps:
determining a cold extrusion working condition, preferably, the cold extrusion working condition comprises the aperture and the material property of a cold extrusion reinforced hole;
secondly, establishing a finite element analysis model by adopting finite element analysis software according to the determined cold extrusion working condition, wherein the finite element analysis model preferably comprises a test piece part and an extrusion rod part;
setting cold extrusion process parameters and carrying out finite element simulation analysis on the basis of the finite element analysis model to obtain a simulation result of residual stress distribution and interference amount corresponding to the cold extrusion process parameters, wherein the cold extrusion process parameters preferably comprise extrusion rate and extrusion speed;
fourthly, manufacturing a cold extrusion test piece based on the cold extrusion working condition and the cold extrusion process parameter;
measuring the residual stress distribution and the interference quantity of the cold extrusion test piece by adopting a residual stress measuring instrument and an interference quantity measuring instrument;
step six, comparing the simulation result of the residual stress distribution and the interference amount obtained in the step three with the measurement result of the residual stress distribution and the interference amount obtained in the step five, and correcting the finite element analysis model according to the comparison result so that the simulation result approaches to the measurement result;
and seventhly, based on the corrected finite element analysis model, adopting fatigue life analysis software, and performing prediction analysis on the fatigue life of the cold extrusion reinforced hole by taking the residual stress distribution as an input quantity.
According to some preferred embodiments of the present invention, in the above method, the third, fourth and fifth steps may be performed based on a plurality of sets of cold extrusion process parameters to obtain simulation results and measurement results of residual stress distribution and interference amount corresponding to the plurality of sets of cold extrusion process parameters, respectively, and the finite element analysis model is modified according to comparison results of the simulation results and the measurement results of residual stress distribution and interference amount corresponding to the plurality of sets of cold extrusion process parameters, respectively, in the sixth step.
According to some preferred embodiments of the present invention, the measuring of the residual stress distribution and the interference amount of the cold-pressed test piece in the fifth step includes measuring at least 8 reference points.
According to a further preferred embodiment of the present invention, msc.fatigue fatigue life analysis software may be used in the above method, wherein specifically, a fatigue life S-N analysis method may be used, and a goodman equation is used to correct the average stress.
The fatigue life prediction method of the cold extrusion strengthened hole of the present invention is described below with reference to an application example.
In the working condition of cold extrusion in the application example, 1 4mm 2060T8E30 aluminum lithium alloy plate is subjected to cold extrusion by adopting a slotted bush of Cr15Ni7Mo2Al, and the final nominal diameter of a cold-extruded hole is 4.420 mm.
Firstly, modeling is carried out by using finite element simulation software ABAQUS, the adopted process parameters comprise the aperture of an initial hole of 4.530mm and the extrusion time of 0.2s, and finite element simulation analysis is carried out on the cold extrusion process by the process parameters to obtain the residual stress distribution.
Secondly, manufacturing a cold extrusion test piece under the simulation working condition, drilling a 4mm 2060T8E30 aluminum lithium alloy plate, enabling the hole to reach a 4.420mm nominal value by adopting a cold extrusion process, and testing residual stress by adopting a residual stress measuring instrument. To ensure the sufficiency of the data, it is recommended to measure not less than 10 holes, each hole taking not less than 8 measurement points. And after the measurement is finished, comparing the measurement result with the simulation result, and correcting the simulation model to a certain extent. Thus, a modified finite element analysis model is obtained. Based on the analysis model, the fatigue life of the cold extrusion hole under different process parameters can be predicted and analyzed.
Different residual stress distributions can be obtained by using the corrected finite element analysis model by inputting different process parameters. And then, guiding the residual stress distribution into a fatigue life analysis software MSC.fatigue, establishing the same fatigue prediction working condition, selecting a fatigue life S-N analysis method, correcting the average stress by adopting a Goodman equation, selecting a maximum principal stress mode to analyze the multiaxis of the stress, and predicting the fatigue life of the cold extrusion hole under different process parameters by using the reliability of the fatigue life of 50% for example.
While specific embodiments of the invention have been described above, it will be appreciated by those skilled in the art that these are by way of example only, and that the scope of the invention is defined by the appended claims. Various changes and modifications to these embodiments may be made by those skilled in the art without departing from the spirit and scope of the invention, and these changes and modifications are within the scope of the invention.
Claims (8)
1. A fatigue life prediction method for a cold extrusion reinforced hole is characterized by comprising the following steps:
step one, determining a cold extrusion working condition;
secondly, establishing a finite element analysis model by adopting finite element analysis software according to the determined cold extrusion working condition;
setting cold extrusion process parameters and carrying out finite element simulation analysis on the basis of the finite element analysis model to obtain simulation results of residual stress distribution and interference amount corresponding to the cold extrusion process parameters;
fourthly, manufacturing a cold extrusion test piece based on the cold extrusion working condition and the cold extrusion process parameter;
measuring the residual stress distribution and the interference quantity of the cold extrusion test piece by adopting a residual stress measuring instrument and an interference quantity measuring instrument;
step six, comparing the simulation result of the residual stress distribution and the interference amount obtained in the step three with the measurement result of the residual stress distribution and the interference amount obtained in the step five, respectively executing the step three, the step four and the step five based on a plurality of groups of cold extrusion process parameters to obtain the simulation result and the measurement result of the residual stress distribution and the interference amount respectively corresponding to the plurality of groups of cold extrusion process parameters, and correcting the finite element analysis model according to the comparison result of the simulation result and the measurement result of the residual stress distribution and the interference amount respectively corresponding to the plurality of groups of cold extrusion process parameters in the step six so as to enable the simulation result to approach the measurement result;
and seventhly, based on the corrected finite element analysis model, adopting fatigue life analysis software, and performing prediction analysis on the fatigue life of the cold extrusion reinforced hole by taking the residual stress distribution as an input quantity.
2. A fatigue life prediction method according to claim 1, wherein the cold extrusion regime comprises cold extrusion strengthened pore size and/or material properties.
3. A method for predicting fatigue life as set forth in claim 1, wherein the finite element analysis model established in the second step includes a test piece portion and a squeeze bar portion.
4. A method of fatigue life prediction according to claim 1, wherein the cold extrusion process parameters comprise extrusion rate and/or extrusion rate.
5. A method of predicting fatigue life according to claim 1, wherein the measuring of the residual stress distribution and the interference amount of the cold-extruded test piece in the fifth step includes measuring at least 8 reference points.
6. The fatigue life prediction method of claim 1, wherein the fatigue life analysis software used in step seven is msc.
7. A fatigue life prediction method according to claim 6, wherein in the seventh step, a fatigue life S-N analysis method is used for the prediction analysis of the fatigue life of the cold extrusion strengthened hole.
8. A fatigue life prediction method according to claim 7, wherein in the prediction analysis of the fatigue life of the cold extrusion strengthened hole in the seventh step, the average stress is further corrected by using a goodman equation.
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| CN110765549B (en) * | 2019-10-16 | 2020-11-03 | 昆山六丰机械工业有限公司 | Method and system for analyzing structural stress of automobile casting |
| CN111209702A (en) * | 2020-01-02 | 2020-05-29 | 中车青岛四方机车车辆股份有限公司 | Method and device for simulating and testing alignment of rail train body strength |
| CN111241741B (en) * | 2020-03-25 | 2023-04-28 | 南京市特种设备安全监督检验研究院 | Crane wheel rail abrasion monitoring method based on residual stress influence interval correction |
| CN111737812A (en) * | 2020-05-13 | 2020-10-02 | 南京航空航天大学 | Fatigue life prediction method for secondary extrusion reinforced hole |
| CN112100766A (en) * | 2020-08-28 | 2020-12-18 | 北京航空航天大学 | Fatigue life prediction method for cold extrusion reinforced hole structure |
| CN112214846A (en) * | 2020-09-09 | 2021-01-12 | 浙江意动科技股份有限公司 | Method for reducing stress concentration |
| CN112906269B (en) * | 2021-02-08 | 2023-09-26 | 南通中远海运船务工程有限公司 | Method for prolonging fatigue life of complex structure of crude oil-to-barge |
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