CN113255069B - Method for predicting surface topography of ultrasonic shot blasting material - Google Patents

Method for predicting surface topography of ultrasonic shot blasting material Download PDF

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CN113255069B
CN113255069B CN202110249007.7A CN202110249007A CN113255069B CN 113255069 B CN113255069 B CN 113255069B CN 202110249007 A CN202110249007 A CN 202110249007A CN 113255069 B CN113255069 B CN 113255069B
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尹飞
蔡旭阳
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Abstract

The invention relates to a rapid and accurate ultrasonic shot blasting material surface morphology prediction method, which comprises the steps of firstly adopting a finite element to simulate single impact to determine the internal relation between plastic deformation and material properties and process conditions, then utilizing a simulation result to develop an iterative algorithm for simulating multiple impacts so as to calculate the displacement and equivalent plastic strain distribution of a machining surface node, and finally utilizing Origin software to draw a contour map on the machining surface. The method not only ensures the rationality and accuracy of the simulation method, but also effectively avoids huge calculation amount and calculation time, and the finally constructed core algorithm can quickly and accurately simulate the appearance and strain distribution of the surface of the processed material.

Description

Method for predicting surface topography of ultrasonic shot blasting material
Technical Field
The invention relates to the technical field of surface quality prediction of ultrasonic shot blasting materials, in particular to a set of numerical algorithm for ultrasonic shot blasting surface quality evaluation.
Background
Nowadays, nanostructured materials are receiving wide attention due to their ultra-high performance characteristics, and ultrasonic peening has been used to generate nanostructured layers on the surface of materials as an efficient method for producing nanostructured materials. However, one potential problem with ultrasonic peening techniques is that repeated impacts during machining can produce rough surfaces that defeat the benefits of nanocrystalline microstructures and also produce stress concentrations at certain points on the machined surface that promote crack formation. Therefore, it is important to predict and control the surface quality of the ultrasonic shot-peening material.
Although there are many methods for evaluating the quality of the surface processed by ultrasonic shot blasting at present, these methods have common defects, such as simulation of single impact, failure to perform calculation analysis on accumulated displacement and accumulated plastic strain of the processed surface after multiple impacts, and waste of a lot of time and resources due to high frequency of processing if a finite element method is used for simulating multiple impacts.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method for predicting the surface appearance of the ultrasonic shot blasting material aiming at the defects of time and labor consumption of manual experiments and long calculation time of a finite element simulation method in the prior art.
The technical scheme adopted by the invention for solving the technical problems is as follows:
a method for predicting the surface topography of an ultrasonic shot blasting material comprises the following steps:
s1, simulating single impact by adopting a finite element, analyzing and determining a functional relation F between the displacement distribution D and the material strain epsilon and the distance delta x between the node and the impact central point, and a functional relation G between the equivalent plastic strain PEEQ and the material strain epsilon and the distance delta x between the node and the impact central point;
s2, carrying out iterative computation on the multiple impacts, wherein the iterative algorithm specifically comprises the following steps:
s2.1, generating a matrix of the coordinate and displacement distribution of the machining surface node;
s2.2, setting impact time and other processing parameters;
s2.3, generating a random impact center on the machining surface, and recording coordinate information of the random impact center;
s2.4, optimizing a machined surface node displacement matrix and an equivalent plastic strain matrix by utilizing a single impact simulation result: and coding the functional relations F and G, calling the functional relations F and G in multiple impact iterations, and calculating the displacement and equivalent plastic strain of each node when the accumulated strain is different after each impact by using the F and the G so as to achieve the purpose of predicting the surface morphology after multiple impacts.
In the above scheme, step S1 is performed in the Abaqus platform; step S2 is performed in Matlab platform.
In the scheme, the method further comprises the step of S3, drawing the contour map of the surface topography of the material after shot blasting impact by using the Origin platform.
In the above scheme, in the iterative algorithm in step S2.4, the iterative relationship of the accumulated displacement and the iterative relationship of the accumulated plastic strain between the nth impact and the n-1 st impact at a certain node on the material surface are as follows:
Δdn＝F(εn-1,Δxn)
Δεn＝G(εn-1,Δxn)
Dn＝Dn-1+Δdn
εn＝εn-1+Δεn
in the formula,. DELTA.dnAnd Δ εnDisplacement and equivalent plastic strain, respectively, induced after the nth impact, n being 1,2,3 … …; Δ xnCalculating the distance between the node and the impact center point of the nth impact; dn-1And εn-1Respectively accumulating the node displacement and the accumulated plastic strain after the n-1 impact; dnAnd εnThe cumulative displacement and the cumulative plastic strain of the node after the nth impact, respectively.
In the above scheme, step S2 further includes S2.5, and recording the processed surface peak-valley value.
In the above scheme, step S2 further includes S2.6, performing cyclic judgment to determine whether the machining time has reached a set time, and if not, returning to S2.3 to generate a random impact center, and continuing to update the displacement of the machined surface node and the equivalent plastic strain matrix; otherwise, the calculation flow is ended.
In the above scheme, in step S2.1, the surface to be processed is decomposed into a series of nodes, the nodes are used as the study objects, the (x, y) coordinates of each node are used to determine the position of the node on the surface of the processed material, and simultaneously, a displacement distribution z perpendicular to the processed surface is generated to record the displacement distribution at the node after the subsequent processing; the coordinate information of a series of nodes is formed into a matrix.
In the above scheme, in step S2.2, the impact time is the total time of shot peening; the processing parameters include the Young's modulus and Poisson's ratio of the processed material.
The invention has the beneficial effects that:
1. the invention develops a set of numerical algorithm for evaluating the surface quality of ultrasonic shot blasting, firstly adopts a finite element to simulate single impact to determine the internal relation between plastic deformation and material properties and process conditions, and then utilizes a simulation result to develop an iterative algorithm for simulating multiple impacts. Therefore, the rationality of the simulation method is guaranteed, huge calculation amount and calculation time are effectively avoided, and the finally constructed core algorithm can quickly and accurately simulate the appearance and the strain distribution of the surface of the machined material.
2. It is found that in the process of multiple impacts, the processing conditions are kept unchanged, the material properties are changed due to the continuously accumulated plastic strain after each impact, and the continuously accumulated plastic strain leads to the work hardening of the material and the improvement of the yield stress. Therefore, in an iterative algorithm for simulating multiple impacts, repeated plastic strain caused by impact of the steel ball is taken as an accumulated plastic problem, and an isotropic hardening model is adopted. Therefore, the accuracy of the algorithm can be ensured.
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The invention will be further described with reference to the accompanying drawings and examples, in which:
FIG. 1 is a flow chart of the method for predicting the surface topography of ultrasonic shot blasting material according to the invention.
FIG. 2 is a schematic illustration of a finite element simulation single shot in an embodiment of the present invention, wherein (a) a finite element simulation model of a single shot; (b) a simulation result of the displacement; (c) simulation results of equivalent plastic strain; (d) and (4) optically observing the dents generated by a single impact experiment in the ultrasonic shot blasting process.
FIG. 3 is a displacement and equivalent plastic strain curve plot drawn by polynomial fitting of single impact finite element model data derived in an embodiment of the present invention, wherein (a) the processed material surface node displacement is plotted against strain value and position variation curve; (b) and (3) processing the equivalent plastic strain PEEQ of the surface node of the material according to the same strain value and position change curve.
FIG. 4 is contour map of surface topography of shot blasting samples under different impact times drawn by Origin software in the embodiment of the invention.
Fig. 5 is a schematic structural diagram of an experimental facility for experimental verification of an algorithm in an embodiment of the present invention.
FIG. 6 is a comparison of simulated and experimental images at multiple impacts in an example of the invention.
Detailed Description
For a more clear understanding of the technical features, objects and effects of the present invention, embodiments of the present invention will now be described in detail with reference to the accompanying drawings.
As shown in fig. 1, a method for predicting a surface topography of an ultrasonic shot-blasting material according to an embodiment of the present invention includes the following steps:
and S1, simulating single impact by adopting a finite element in an Abaqus platform, analyzing and determining a functional relation F between the displacement distribution D and the material strain epsilon and the distance delta x between the node and the impact central point, and a functional relation G between the equivalent plastic strain PEEQ and the material strain epsilon and the distance delta x between the node and the impact central point.
S2, carrying out iterative computation on multiple impacts in a Matlab platform, wherein the iterative algorithm specifically comprises the following steps:
s2.1, generating a matrix of coordinates and displacement distribution of nodes on the machined surface
Decomposing the surface to be processed into a series of nodes, taking the nodes as a research object, determining the positions of the nodes on the surface of the processed material by using (x, y) coordinates of each node, and generating a displacement distribution z (the unprocessed initial value is 0) vertical to the processed surface to record the displacement distribution at the nodes after subsequent processing; the coordinate information of a series of nodes is formed into a matrix.
S2.2, setting the impact time T and other processing parameters
The impact time is the total time of shot blasting, iteration is continued in the total time, and the calculation is stopped after the total time is exceeded; the processing parameters comprise Young modulus, Poisson ratio and the like of the processing material.
S2.3, generating random impact centers on the processed surface
And generating a random impact center on the processing surface, and recording the coordinate information of the random impact center.
S2.4, optimizing a machined surface node displacement matrix and a plastic strain matrix by utilizing a single impact simulation result
And coding the functional relations F and G, calling the functional relations F and G in multiple impact iterations, and calculating the displacement and equivalent plastic strain of each node when the accumulated strain is different after each impact by using the F and the G so as to achieve the purpose of predicting the surface morphology after multiple impacts. In the iterative algorithm, an iterative relation of accumulated displacement and accumulated plastic strain between nth impact and n-1 impact at a certain node of the surface of the material is as follows:
Δdn＝F(εn-1,Δxn)
Δεn＝G(εn-1,Δxn)
Dn＝Dn-1+Δdn
εn＝εn-1+Δεn
in the formula,. DELTA.dnAnd Δ εnDisplacement and equivalent plastic strain, respectively, induced after the nth impact, n being 1,2,3 … …; Δ xnCalculating the distance between the node and the impact center point of the nth impact; dn-1And εn-1Respectively accumulating the node displacement and the accumulated plastic strain after the n-1 impact; dnAnd epsilonnThe cumulative displacement and the cumulative plastic strain of the node after the nth impact, respectively.
And integrating the displacements of all the nodes on the machined surface to form a surface appearance moire pattern after n times of impacts on the machined surface, and integrating the PEEQ of all the nodes on the machined surface to form a PEEQ moire pattern after n times of impacts on the machined surface.
S2.5, recording the peak valley value of the processed surface;
s2.6, circularly judging, namely judging whether the machining time reaches the set time, if not, returning to S2.3 to generate a random impact center, and continuously updating the displacement and equivalent plastic strain matrix of the machined surface node; otherwise, the calculation flow is ended.
S3, drawing a surface topography contour map by using Origin platform
And after the circulation is finished, obtaining the coordinate changes of the displacement and the equivalent plastic strain of all nodes on the surface of the processed material, importing the data into Origin software, and drawing a contour map of the surface topography of the material after shot blasting impact.
The method for predicting the surface topography of the ultrasonic shot blasting material provided by the invention is specifically described by an embodiment.
Simulation for single impact in S1 and Abaqus platform
The three-dimensional finite element model shown in FIG. 2(a) is used for calculating the node displacement and strain distribution of the material surface in the single impact process, and the specific purpose is to obtain a fitting matrix [ a ] of the functional relation F of the impact surface displacement distribution, the strain value and the impact position through polynomial fitting]And a fitting matrix [ b ] of PEEQ on the machined surface as a function of strain value and impact position G]. The finite element model simulates that a shot of 6.4mm diameter impacts 25X 3mm in size at a velocity of 3.6m/s3The center of the AISI-1018 steel sheet of (1). Wherein the processed material AISI-1018 steel plate Abaqus model has Young modulus, density and Poisson ratio of 210GPa and 7800kg/m3And 0.3. By performing a tensile test on the AISI-1018 bar material, a stress-strain curve of the material is obtained, which is assigned to the plastic characteristic curve of the Abaqus model of the AISI-1018 steel plate. Taking friction between the shot blasting and the processed material into account, locally refining the mesh in the processing impact area, wherein the size of the refined mesh is 0.1 multiplied by 0.1mm3And the calculation efficiency is improved. Fig. 2(b) and (c) show displacement and equivalent plastic strain distribution moire patterns of the surface of the impact specimen, respectively. Fig. 2(d) shows an optical micrograph of the dimple after the single impact experiment, and it can be seen from fig. 2(d) that the diameter of the dimple is 1.233mm, and the diameter of the simulated dimple in fig. 2(b) is 1.2mm, which is in good agreement with the experimental results, and verifies the accuracy of the single impact finite element model. The single impact finite element model data is derived, and a displacement and equivalent plastic strain curve chart is drawn by utilizing polynomial fitting and is shown in figure 3.
And (3) after the data and the curve of the single impact are obtained in an abaqus platform, sorting to obtain fitting matrixes [ a ] and [ b ] in functions F and G, and finally calculating to obtain matrix equations of the functional relations F and G as the following formula (1) and formula (2).
Figure GDA0003520577560000061
Figure GDA0003520577560000062
In the formulas (1) and (2), epsilon is a strain value, and deltax is the distance (position for short) between a node and an impact center.
S2 iterative algorithm for multiple impacts in Matlab platform
S2.1, generating a matrix of the coordinate and displacement distribution of the machining surface node;
s2.2, setting impact time T and other processing parameters;
s2.3, generating a random impact center on the machining surface;
s2.4, optimizing displacement and equivalent plastic strain matrixes by using single impact simulation results (F and G)
The F and G relation obtained on the Abaqus platform is introduced into Matlab, the F and G functional relation is coded in a script, the F and G functional relation is called in the following multiple impact iterations, and the F and G are used for calculating the displacement and equivalent plastic strain of each node when the accumulated strain is different after each impact so as to achieve the purpose of predicting the surface morphology after multiple impacts.
The following describes a process of performing multiple iterative simulation of multiple impacts using F and G, taking a certain node of the machined surface as an example.
For the first impact:
initial strain value epsilon of input surface node during first impact0And position Δ x1And calculating the displacement deltad induced by the first impact1And equivalent plastic strain delta epsilon1；
Δd1＝F(ε0,Δx1)；Δε1＝G(ε0,Δx1)
Calculating the cumulative displacement D of the node after the first impact1And accumulated plastic strain epsilon1Accumulated plastic strain epsilon1Will be used for the second impact calculation;
D1＝D0+Δd1；ε1＝ε0+Δε1
for the second impact:
strain value after first impact of input surface node epsilon1And position Δ x2And calculating the displacement deltad caused by the second impact2And equivalent plastic strain delta epsilon2；
Δd2＝F(ε1,Δx2)；Δε2＝G(ε1,Δx2)
Calculating the accumulated displacement D of the node after the second impact2And accumulated plastic strain epsilon2Accumulated plastic strain epsilon2Will be used for the next impact calculation;
D2＝D1+Δd2；ε2＝ε1+Δε2
for the nth impact:
strain value epsilon after (n-1) th impact of input surface noden-1And position Δ xnAnd calculating the displacement deltad caused by the n-th impactnAnd equivalent plastic strain delta epsilonn；
Δdn＝F(εn-1,Δxn)；Δεn＝G(εn-1,Δxn)
Calculating the cumulative displacement D of the node after the nth impactnAnd accumulated plastic strain epsilonn；
Dn＝Dn-1+Δdn；εn＝εn-1+Δεn
In the above iterative process,. epsilon0The initial strain value of the impact specimen was set to 0, and D was the same0As the initial displacement value of the node, 0 is also set; Δ dnAnd Δ εnRespectively displacement and equivalent plastic strain induced after the nth impact; Δ xnCalculating the distance between the node and the impact center point of the nth impact; dnAnd εnThe accumulated displacement and accumulated plastic strain of the node after the nth impact are respectively measured; f is Δ dnSame epsilonn-1，ΔxnG is Δ εnSame epsilonn-1，ΔxnF and G are obtained by analyzing finite element single impact simulation results.
The displacement of the node and the equivalent plastic strain change after each impact were imported into Origin software.
S2.5, recording the peak and valley values of the processed surface (peak and valley value)
S2.6, judging circularly
Judging whether the machining time reaches the set time or not, if not, returning to S2.3 to generate a random impact center, and continuously updating the displacement and equivalent plastic strain matrix of the machining surface node; otherwise, the calculation flow is ended.
S3, generating contour map
And obtaining the coordinate change of the node displacement and the plastic strain of the surface of the processed material in Matlab, importing the data into Origin software, and drawing a contour map of the surface topography of the material after shot blasting impact, as shown in FIG. 4. The contour map can evaluate the roughness of the surface of the material after shot blasting, equivalent plastic strain PEEQ, concentrated stress distribution and other information, and provides predictive and instructive analysis for shot blasting manufacturing.
In order to verify the effectiveness of the method, the ultrasonic shot blasting experimental equipment shown in fig. 5 is designed to verify the accuracy of the algorithm developed by the invention.
The verification experiment used a 3mm thick AISI-1018 steel plate, and sample 1 was fixed on top of a cylindrical mold 2 having an inner diameter of 20mm, and the upper portion of sample 1 was fixed by a fixing block 5. The distance between the specimen and the ultrasonic probe 3 was 10 mm. A commercial steel ball 4 of S550 stainless steel having a diameter of 6.4mm was charged into the cylindrical mold for giving the required impact to the sample. The shot peening was powered by a 20KHz ultrasonic generator and impacted on the test specimens at an average velocity of 3.6m/s and an impact frequency of 70 shots per second.
Fig. 6 shows the evolution of surface morphology and strain distribution with the number of impacts (time) during ultrasonic peening with a shot diameter of 6.4 mm. Fig. 6(a) - (c) experimental measurement results of the machined specimen surface with shot blasting times of 10 minutes, 20 minutes and 30 minutes, respectively. According to the experimental data, the peak-to-valley values (P-V values) of the surface topography of the test piece in the shot blasting for 10 minutes, 20 minutes and 30 minutes were 107.64 μm, 139.11 μm and 155.82 μm, respectively. Accordingly, the peak-to-valley values (P-V values) of the surface topography of the processed sample obtained by the simulation calculation using the algorithm constructed in the present invention were 119.8 μm, 153.7 μm, and 177.5 μm for impact times of 10 minutes, 20 minutes, and 30 minutes, respectively. Fig. 6(d) - (f) show the results of simulation of the surface topography and cumulative strain distribution of the samples after 10, 20 and 30 minutes of shot blasting, respectively.
Compared with the experimental measurement result and the simulation calculation result, the calculation result and the experimental result of the method have smaller errors, and the calculation model provided by the invention can provide a simple and economic method for predicting the surface morphology and the equivalent plastic strain of the AISI-1018 low-carbon steel in the ultrasonic shot blasting process within the error allowable range.
The invention provides an algorithm for predicting the surface quality of ultrasonic shot blasting, which comprises three functional modules: the first part is a finite element simulation model, and provides functional relations F and G; based on a finite element simulation result, the invention encodes the F and G functional relation in a main body calculation module established on a Matlab platform, thereby calculating the displacement and strain distribution of the nodes on the processing surface; the last part is to draw a contour map of the machined surface using Origin software.
Finally, a set of AISI-1018 steel plate ultrasonic shot blasting experiments are designed for verifying the algorithm precision developed by the invention. Through qualitative analysis of an experimental image and quantitative information (P-V value) obtained by using a non-contact 3D contourgraph, an algorithm simulation result developed by the method is consistent with an experimental result, and the accuracy and the efficiency of the algorithm are fully proved.
While the present invention has been described with reference to the embodiments shown in the drawings, the present invention is not limited to the embodiments, which are illustrative and not restrictive, and it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the invention as defined in the appended claims.

Claims (8)

1. The method for predicting the surface topography of the ultrasonic shot blasting material is characterized by comprising the following steps of:
s1, simulating single impact by adopting a finite element, analyzing and determining a functional relation F between the displacement distribution D and the material strain epsilon and the distance delta x between the node and the impact central point, and a functional relation G between the equivalent plastic strain PEEQ and the material strain epsilon and the distance delta x between the node and the impact central point; aiming at the calculation data of single impact, obtaining a fitting matrix [ a ] of the functional relation F of impact surface displacement distribution and strain value and impact position and a fitting matrix [ b ] of the functional relation G of the PEEQ of the processing surface and strain value and impact position through polynomial fitting, wherein the matrix equations of the functional relations F and G are as the following formulas (1) and (2):
Figure FDA0003520577550000011
Figure FDA0003520577550000012
s2, carrying out iterative computation on the multiple impacts, wherein the iterative algorithm specifically comprises the following steps:
s2.1, generating a matrix of the coordinate and displacement distribution of the machining surface node;
s2.2, setting impact time and other processing parameters;
s2.3, generating a random impact center on the machining surface, and recording coordinate information of the random impact center;
s2.4, optimizing a machined surface node displacement matrix and an equivalent plastic strain matrix by utilizing a single impact simulation result: and coding the functional relations F and G, calling the functional relations F and G in multiple impact iterations, and calculating the displacement and equivalent plastic strain of each node when the accumulated strain is different after each impact by using the F and the G so as to achieve the purpose of predicting the surface morphology after multiple impacts.
2. The method for predicting the surface morphology of an ultrasonic shot-peening material according to claim 1, wherein the step S1 is performed in an Abaqus stage; step S2 is performed in Matlab platform.
3. The method for predicting the surface topography of an ultrasonic shot-peening material according to claim 1 or 2, further comprising a step S3 of drawing a contour map of the surface topography of the material after shot peening impact using an Origin platform.
4. The method for predicting the surface morphology of an ultrasonic shot-peening material according to claim 1, wherein in the iterative algorithm in step S2.4, the iterative relationship of the cumulative displacement and the iterative relationship of the cumulative plastic strain between the nth impact and the (n-1) th impact at a certain node on the material surface are as follows:
Δdn＝F(εn-1,Δxn)
Δεn＝G(εn-1,Δxn)
Dn＝Dn-1+Δdn
εn＝εn-1+Δεn
in the formula,. DELTA.dnAnd Δ εnDisplacement and equivalent plastic strain, respectively, induced after the nth impact, n being 1,2,3 … …; Δ xnCalculating the distance between the node and the impact center point of the nth impact; dn-1And εn-1Respectively accumulating the node displacement and the accumulated plastic strain after the n-1 impact; dnAnd εnThe cumulative displacement and the cumulative plastic strain of the node after the nth impact, respectively.
5. The method for predicting the surface morphology of the ultrasonic shot-peening material as claimed in claim 1, wherein the step S2 further includes S2.5 recording the peak-to-valley values of the machined surface.
6. The method for predicting the surface morphology of the ultrasonic shot-blasting material according to claim 5, wherein the step S2 further comprises the steps of S2.6, circularly judging whether the processing time reaches the set value, if not, returning to S2.3 to generate a random impact center, and continuously updating the displacement of the processing surface node and the equivalent plastic strain matrix; otherwise, the calculation flow is ended.
7. The method for predicting the surface morphology of the ultrasonic shot-peening material according to claim 1, wherein in step S2.1, the surface to be machined is decomposed into a series of nodes, the nodes are taken as a research object, the (x, y) coordinates of each node are used for determining the positions of the nodes on the surface of the machined material, and meanwhile, a displacement distribution z vertical to the machined surface is generated so as to record the displacement distribution at the nodes after subsequent machining; the coordinate information of a series of nodes is formed into a matrix.
8. The method for predicting the surface morphology of an ultrasonic shot-peening material according to claim 1, wherein in step S2.2, the impact time is the total time of shot peening; the processing parameters include the Young's modulus and Poisson's ratio of the processed material.
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