CN113642175B - Shot peening deformation numerical simulation method considering coverage rate and path - Google Patents
Shot peening deformation numerical simulation method considering coverage rate and path Download PDFInfo
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Abstract
Description
技术领域Technical field
本发明涉及喷丸变形技术领域,特别是一种考虑覆盖率及路径的喷丸变形数值模拟方法。The invention relates to the technical field of shot peening deformation, in particular to a numerical simulation method of shot peening deformation that takes into account coverage and path.
背景技术Background technique
喷丸强化是一种表面强化技术,通过高速运动的弹丸流喷射工件表面,使工件表层发生不均匀的塑性变形,形成一定深度的残余压应力层,可以有效的提高零件的疲劳寿命,适用于各种形状与尺寸场合,广泛应用于汽车、航空等各个领域。而航空薄壁结构件作为飞机机身重要结构件,由于刚度较差,经喷丸处理后,构件容易发生变形,对零件精度影响较大。喷丸导致的零件变形大小与很多因素有关,包括受喷零件的材料特性、喷丸机的喷嘴与工件加工表面的距离和角度,还与弹丸大小、弹丸冲击速度、弹丸材料、入射角度以及覆盖率、喷丸路径等参数有关。Shot peening is a surface strengthening technology that sprays the surface of the workpiece with a high-speed moving shot stream, causing uneven plastic deformation on the surface of the workpiece and forming a residual compressive stress layer of a certain depth, which can effectively improve the fatigue life of the part and is suitable for Available in various shapes and sizes, they are widely used in various fields such as automobiles and aviation. As an important structural part of the aircraft fuselage, aviation thin-walled structural parts have poor stiffness. After shot peening, the components are prone to deformation, which has a greater impact on the accuracy of the parts. The deformation of parts caused by shot peening is related to many factors, including the material properties of the parts being sprayed, the distance and angle between the shot peening machine's nozzle and the workpiece surface, as well as the size of the projectile, the impact speed of the projectile, the material of the projectile, the angle of incidence and the coverage It is related to parameters such as rate and shot peening path.
在实际喷丸作业中,大量的喷丸参数需要调试,实验测量变形昂贵且费时。在实际作业前进行数值模拟仿真,利用数值仿真进行参数优化,可显著减少实验次数,从而提升参数优化效率,节约生产成本。目前采用最广泛的方法是通过依次计算各个弹丸的撞击作用而得到大量弹丸对其撞击作用产生的工件变形,然而在对实际零件进行喷丸强化数值模拟时,实际零件所需的弹丸数量巨大,模拟过程的计算量及成本难以接受。In actual shot peening operations, a large number of shot peening parameters need to be debugged, and experimental measurement of deformation is expensive and time-consuming. Conducting numerical simulations before actual operations and using numerical simulations for parameter optimization can significantly reduce the number of experiments, thereby improving the efficiency of parameter optimization and saving production costs. The most widely used method at present is to calculate the impact of each projectile in sequence to obtain the workpiece deformation caused by the impact of a large number of projectiles. However, when performing numerical simulations of shot peening on actual parts, the number of projectiles required for the actual part is huge. The computational complexity and cost of the simulation process are unacceptable.
发明内容Contents of the invention
本发明解决的技术问题是:提供了一种考虑覆盖率及路径的喷丸变形数值模拟方法,解决了大尺寸零件喷丸变形的数值模拟问题,并考虑了覆盖率及喷丸路径对变形的影响。The technical problem solved by the present invention is to provide a numerical simulation method for shot peening deformation that considers coverage rate and path, solves the numerical simulation problem of shot peening deformation of large-size parts, and considers the effects of coverage rate and shot peening path on deformation. Influence.
本发明的技术解决方案是:The technical solution of the present invention is:
为了解决上述技术问题,本发明提供了一种考虑覆盖率及路径的喷丸变形数值模拟方法,包括如下所述的步骤:In order to solve the above technical problems, the present invention provides a numerical simulation method for shot peening deformation considering coverage rate and path, which includes the following steps:
第一步,根据经验公式将喷丸工艺参数转换为弹丸的速度,经验公式如下式:The first step is to convert the shot peening process parameters into the velocity of the projectile according to the empirical formula. The empirical formula is as follows:
式中,Vs为弹丸速度,Ps为喷丸机喷射压力,Ds为弹丸直径,为弹丸流量;In the formula, V s is the projectile velocity, P s is the injection pressure of the shot peening machine, D s is the projectile diameter, is the projectile flow rate;
第二步,获取零件Johnson-Cook材料参数,在Abaqus中建立单弹丸撞击模型,弹丸的速度为第一步中由经验公式换算得出,所述的单弹丸撞击模型的靶材为边长为弹丸直径5倍的正方体块;In the second step, obtain the Johnson-Cook material parameters of the part and establish a single projectile impact model in Abaqus. The speed of the projectile is calculated from the empirical formula in the first step. The target material of the single projectile impact model has a side length of A cube block 5 times the diameter of the projectile;
第三步,提取单弹丸撞击模型中靶材撞击区域沿层深方向的位移,将沿层深方向位移为零的两点距离取为弹坑直径的大小;The third step is to extract the displacement of the target impact area along the layer depth direction in the single projectile impact model, and take the distance between two points where the displacement along the layer depth direction is zero as the diameter of the crater;
第四步,计算满足覆盖率要求所需的弹丸个数,在Matlab中将靶材表面分别沿垂直于深度方向的长度方向和宽方向等分,长度方向分为m份,即长度方向含m+1个节点,宽度方向分为n份,即宽度方向含n+1个节点,共生成N=(m+1)×(n+1)个节点之后,利用Matlab在靶材上方随机生成弹丸球心坐标,所述随机生成的弹丸球心空间坐标满足后生成的弹丸与已生成的弹丸空间位置上不重叠;The fourth step is to calculate the number of projectiles required to meet the coverage requirements. In Matlab, divide the target surface into equal parts along the length direction and width direction perpendicular to the depth direction. The length direction is divided into m parts, that is, the length direction contains m. +1 node, the width direction is divided into n parts, that is, the width direction contains n+1 nodes. After generating a total of N=(m+1)×(n+1) nodes, Matlab is used to randomly generate projectiles above the target. Sphere center coordinates, the generated projectile will not overlap with the generated projectile spatial position after the randomly generated projectile center space coordinates are satisfied;
第五步,根据弹丸的速度方向计算弹丸在靶材上的落点,计算每个节点到所有弹丸球心落点的距离,若某节点到所有弹丸球心落点的距离最小值小于弹坑的半径,则该节点处在喷丸区域,将所有处于喷丸区域的节点个数记为M,则覆盖率C=M/N×100%,若覆盖率C小于覆盖率要求,则增加弹丸的个数,直到C大于等于所需的覆盖率,记录此时弹丸个数及各个弹丸的空间坐标;The fifth step is to calculate the impact point of the projectile on the target according to the speed direction of the projectile, and calculate the distance from each node to the impact point of all projectile centers. If the minimum distance from a node to the impact point of all projectile centers is less than the crater radius, then the node is in the shot peening area. The number of all nodes in the shot peening area is recorded as M, then the coverage rate C=M/N×100%. If the coverage rate C is less than the coverage rate requirement, increase the number of projectiles. number until C is greater than or equal to the required coverage, record the number of projectiles and the spatial coordinates of each projectile at this time;
第六步,为了减小仿真结果的随机误差,利用MATLAB多次生成满足覆盖率要求的随机坐标,对每次的生成结果进行记录,并求出多次求解的所需弹丸个数的平均值,选择最接近平均值个数的一组弹丸坐标作为求解结果;The sixth step, in order to reduce the random error of the simulation results, use MATLAB to generate random coordinates that meet the coverage requirements multiple times, record each generation result, and find the average number of required projectiles for multiple solutions. , select the group of projectile coordinates closest to the average number as the solution result;
第七步,取第六步求解的弹丸坐标结果,在ABAQUS中建立多弹丸撞击靶材的模型;In the seventh step, take the projectile coordinate results solved in the sixth step and establish a model of multiple projectiles impacting the target in ABAQUS;
第八步,提取多弹丸撞击模型中靶材长度方向和宽度方向的深度-应力曲线,并记录应力、由正值过渡到负值,较趋近于零值的某一点的深度作为喷丸影响深度;The eighth step is to extract the depth-stress curve in the length direction and width direction of the target in the multi-projectile impact model, and record the stress, transition from positive value to negative value, and depth at a certain point closer to zero value as the impact of shot peening depth;
第九步,建立零件变形预测模型,不考虑喷丸路径,一次性将应力赋给零件,得到零件不考虑路径条件下的变形,特别是关注的零件某个特征点的变形值;The ninth step is to establish a part deformation prediction model, without considering the shot peening path, and assign stress to the part at one time to obtain the deformation of the part without considering the path, especially the deformation value of a certain feature point of the part of concern;
第十步,建立新的零件有限元模型,建立温度梯度场,所述温度梯度场的覆盖范围为喷丸区域,深度方向为零件受喷表面至喷丸影响深度,零件的其他部分温度设为25℃,所述温度梯度场的最大温度值的取值为任意的,但不大于材料的熔点,所述温度梯度场的最小温度值取25℃。The tenth step is to establish a new finite element model of the part and establish a temperature gradient field. The coverage range of the temperature gradient field is the shot peening area. The depth direction is from the surface of the part affected by shot peening to the depth affected by shot peening. The temperature of other parts of the part is set to 25°C. The maximum temperature value of the temperature gradient field is arbitrary, but not greater than the melting point of the material. The minimum temperature value of the temperature gradient field is 25°C.
第十一步,一段时间后再撤除温度场,这时候零件在温度场作用下就会有塑性变形,固定梯度温度场不变,改变材料的膨胀系数,使零件变形,当零件变形量,特别是关注的零件某个特征点的变形值与在赋应力条件下的变形值差值在可接受的范围内时,记录此时零件的膨胀系数,;The eleventh step is to remove the temperature field after a period of time. At this time, the part will undergo plastic deformation under the action of the temperature field. The fixed gradient temperature field remains unchanged, changing the expansion coefficient of the material, causing the part to deform. When the deformation amount of the part, especially When the difference between the deformation value of a certain characteristic point of the part concerned and the deformation value under stress conditions is within an acceptable range, record the expansion coefficient of the part at this time;
第十二步,建立新的零件有限元模型,将第十一步中得到的膨胀系数赋予零件材料,将等效温度场按喷丸的路径顺序依次赋予零件,一段时间后撤除,所述按路径赋予的温度梯度场的宽度与喷丸窄带宽度相等,得到零件在不同喷丸路径条件下的变形,特别是关注的零件某个特征点的变形值。In the twelfth step, establish a new finite element model of the part, assign the expansion coefficient obtained in the eleventh step to the part material, and assign the equivalent temperature field to the part in sequence according to the shot peening path. After a period of time, remove it. The width of the temperature gradient field given by the path is equal to the width of the shot peening narrow band, and the deformation of the part under different shot peening path conditions is obtained, especially the deformation value of a certain characteristic point of the part of concern.
本发明的有益效果在于:考虑了覆盖率及喷丸路径对零件变形的影响,可以对比不同覆盖率下或不同喷丸路径下零件的变形效果,从而制定更合适的喷丸工艺方案,且步骤第十一步中,材料膨胀率与零件变形值呈单调关系,通过改变膨胀率可以很容易实现零件变形量,特别是关注的零件某个特征点的变形值与在赋应力条件下的变形值差值在可接受的范围内时。The beneficial effect of the present invention is that: taking into account the influence of coverage rate and shot peening path on the deformation of parts, the deformation effects of parts under different coverage rates or different shot peening paths can be compared, thereby formulating a more appropriate shot peening process plan, and the steps In the eleventh step, the material expansion rate has a monotonic relationship with the deformation value of the part. By changing the expansion rate, the deformation amount of the part can be easily realized, especially the deformation value of a certain feature point of the part of concern and the deformation value under the stress condition. When the difference is within the acceptable range.
附图说明Description of drawings
图1为本发明实施例提供的一种考虑覆盖率及路径的喷丸变形数值模拟方法的流程图;Figure 1 is a flow chart of a numerical simulation method for shot peening deformation considering coverage and path provided by an embodiment of the present invention;
图2为满足覆盖率要求的计算流程图;Figure 2 is a calculation flow chart to meet coverage requirements;
图3为弹丸球心坐标随机生成流程图。Figure 3 is a flow chart for randomly generating projectile center coordinates.
具体实施方式Detailed ways
本发明说明书中未作详细描述的内容属本领域技术人员的公知技术。Contents not described in detail in the specification of the present invention are well-known technologies to those skilled in the art.
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the scope of protection of the present invention.
参照图1,示出了本发明实施例提供的一种考虑覆盖率及路径的喷丸变形数值模拟方法的流程图,如图1所示,该数值模拟方法,包括如下所述的步骤:Referring to Figure 1, there is shown a flow chart of a numerical simulation method for shot peening deformation considering coverage and path provided by an embodiment of the present invention. As shown in Figure 1, the numerical simulation method includes the following steps:
第一步,根据经验公式将喷丸工艺参数转换为弹丸的速度,经验公式如下式:The first step is to convert the shot peening process parameters into the velocity of the projectile according to the empirical formula. The empirical formula is as follows:
式中,Vs为弹丸速度,Ps为喷丸机喷射压力,Ds为弹丸直径,为弹丸流量;In the formula, V s is the projectile velocity, P s is the injection pressure of the shot peening machine, D s is the projectile diameter, is the projectile flow rate;
第二步,获取零件Johnson-Cook材料参数,在Abaqus中建立单弹丸撞击模型,弹丸的速度为第一步中由经验公式换算得出,所述的单弹丸撞击模型的靶材为边长为弹丸直径5倍的正方体块;In the second step, obtain the Johnson-Cook material parameters of the part and establish a single projectile impact model in Abaqus. The speed of the projectile is calculated from the empirical formula in the first step. The target material of the single projectile impact model has a side length of A cube block 5 times the diameter of the projectile;
第三步,提取单弹丸撞击模型中靶材撞击区域沿层深方向的位移,将沿层深方向位移为零的两点距离取为弹坑直径的大小;The third step is to extract the displacement of the target impact area along the layer depth direction in the single projectile impact model, and take the distance between two points where the displacement along the layer depth direction is zero as the diameter of the crater;
第四步,如图2所示的覆盖率计算流程图,计算满足覆盖率要求所需的弹丸个数,在Matlab中将靶材表面分别沿垂直于深度方向的长度方向和宽方向等分,长度方向分为m份,即长度方向含m+1个节点,宽度方向分为n份,即宽度方向含n+1个节点,共生成N=(m+1)×(n+1)个节点之后,利用Matlab在靶材上方随机生成弹丸球心坐标,如图3所示的弹丸球心坐标随机生成流程图,所述随机生成的弹丸球心空间坐标满足后生成的弹丸与已生成的弹丸空间位置上不重叠;The fourth step is as shown in the coverage calculation flow chart in Figure 2. Calculate the number of projectiles required to meet the coverage requirements. In Matlab, divide the target surface into equal parts along the length and width directions perpendicular to the depth direction. The length direction is divided into m parts, that is, the length direction contains m+1 nodes, and the width direction is divided into n parts, that is, the width direction contains n+1 nodes, generating a total of N=(m+1)×(n+1) After the node, Matlab is used to randomly generate the coordinates of the projectile center above the target. The flow chart of the random generation of the projectile center coordinates is shown in Figure 3. The randomly generated projectile center coordinates satisfy the generated projectile and the generated projectile. Projectiles do not overlap in space position;
第五步,根据弹丸的速度方向计算弹丸在靶材上的落点,计算每个节点到所有弹丸球心落点的距离,若某节点到所有弹丸球心落点的距离最小值小于弹坑的半径,则该节点处在喷丸区域,将所有处于喷丸区域的节点个数记为M,则覆盖率C=M/N×100%,若覆盖率C小于覆盖率要求,则增加弹丸的个数,直到C大于等于所需的覆盖率,记录此时弹丸个数及各个弹丸的空间坐标;The fifth step is to calculate the impact point of the projectile on the target according to the speed direction of the projectile, and calculate the distance from each node to the impact point of all projectile centers. If the minimum distance from a node to the impact point of all projectile centers is less than the crater radius, then the node is in the shot peening area. Record the number of nodes in the shot peening area as M, then the coverage rate C = M/N × 100%. If the coverage rate C is less than the coverage rate requirement, increase the number of projectiles. number until C is greater than or equal to the required coverage, record the number of projectiles and the spatial coordinates of each projectile at this time;
第六步,为了减小仿真结果的随机误差,利用MATLAB多次生成满足覆盖率要求的随机坐标,对每次的生成结果进行记录,并求出多次求解的所需弹丸个数的平均值,选择最接近平均值个数的一组弹丸坐标作为求解结果;The sixth step, in order to reduce the random error of the simulation results, use MATLAB to generate random coordinates that meet the coverage requirements multiple times, record each generation result, and find the average number of required projectiles for multiple solutions. , select the group of projectile coordinates closest to the average number as the solution result;
第七步,取第六步求解的弹丸坐标结果,在ABAQUS中建立多弹丸撞击靶材的模型;In the seventh step, take the projectile coordinate results solved in the sixth step and establish a model of multiple projectiles impacting the target in ABAQUS;
第八步,提取多弹丸撞击模型中靶材长度方向和宽度方向的深度-应力曲线,并记录应力、由正值过渡到负值,较趋近于零值的某一点的深度作为喷丸影响深度;The eighth step is to extract the depth-stress curve in the length direction and width direction of the target in the multi-projectile impact model, and record the stress, transition from positive value to negative value, and depth at a certain point closer to zero value as the impact of shot peening depth;
第九步,建立零件变形预测模型,不考虑喷丸路径,一次性将应力赋给零件,得到零件不考虑路径条件下的变形,特别是关注的零件某个特征点的变形值;The ninth step is to establish a part deformation prediction model, without considering the shot peening path, and assign stress to the part at one time to obtain the deformation of the part without considering the path, especially the deformation value of a certain feature point of the part of concern;
第十步,建立新的零件有限元模型,建立温度梯度场,所述温度梯度场的覆盖范围为喷丸区域,深度方向为零件受喷表面至喷丸影响深度,零件的其他部分温度设为25℃,所述温度梯度场的最大温度值的取值为任意的,但不大于材料的熔点,所述温度梯度场的最小温度值取25℃。In the tenth step, establish a new finite element model of the part and establish a temperature gradient field. The coverage range of the temperature gradient field is the shot peening area. The depth direction is from the surface of the part affected by shot peening to the depth affected by shot peening. The temperature of other parts of the part is set to 25°C. The maximum temperature value of the temperature gradient field is arbitrary, but not greater than the melting point of the material. The minimum temperature value of the temperature gradient field is 25°C.
第十一步,一段时间后再撤除温度场,这时候零件在温度场作用下就会有塑性变形,固定梯度温度场不变,改变材料的膨胀系数,使零件变形,当零件变形量,特别是关注的零件某个特征点的变形值与在赋应力条件下的变形值差值在可接受的范围内时,记录此时零件的膨胀系数,;The eleventh step is to remove the temperature field after a period of time. At this time, the part will undergo plastic deformation under the action of the temperature field. The fixed gradient temperature field remains unchanged, changing the expansion coefficient of the material, causing the part to deform. When the deformation amount of the part, especially When the difference between the deformation value of a certain characteristic point of the part concerned and the deformation value under stress conditions is within an acceptable range, record the expansion coefficient of the part at this time;
第十二步,建立新的零件有限元模型,将第十一步中得到的膨胀系数赋予零件材料,将等效温度场按喷丸的路径顺序依次赋予零件,一段时间后撤除,所述按路径赋予的温度梯度场的宽度与喷丸窄带宽度相等,得到零件在不同喷丸路径条件下的变形,特别是关注的零件某个特征点的变形值。In the twelfth step, establish a new finite element model of the part, assign the expansion coefficient obtained in the eleventh step to the part material, and assign the equivalent temperature field to the part in sequence according to the shot peening path. After a period of time, remove it. The width of the temperature gradient field given by the path is equal to the width of the shot peening narrow band, and the deformation of the part under different shot peening path conditions is obtained, especially the deformation value of a certain characteristic point of the part of concern.
尽管已经示出和描述了本发明的实施例,对于本领域的普通技术人员而言,可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型,本发明的范围由所附权利要求及其等同物限定。Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art will understand that various changes, modifications, and substitutions can be made to these embodiments without departing from the principles and spirit of the invention. and modifications, the scope of the invention is defined by the appended claims and their equivalents.
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