CN116956684A - Ultrasonic shot peening strengthening residual stress and deformation analysis method - Google Patents
Ultrasonic shot peening strengthening residual stress and deformation analysis method Download PDFInfo
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- CN116956684A CN116956684A CN202310930319.3A CN202310930319A CN116956684A CN 116956684 A CN116956684 A CN 116956684A CN 202310930319 A CN202310930319 A CN 202310930319A CN 116956684 A CN116956684 A CN 116956684A
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- 238000005728 strengthening Methods 0.000 title claims abstract description 23
- 238000005480 shot peening Methods 0.000 title claims abstract description 19
- 238000004458 analytical method Methods 0.000 title claims description 17
- 238000000034 method Methods 0.000 claims abstract description 49
- 238000005422 blasting Methods 0.000 claims abstract description 36
- 238000004088 simulation Methods 0.000 claims abstract description 17
- 230000008878 coupling Effects 0.000 claims abstract description 16
- 238000010168 coupling process Methods 0.000 claims abstract description 16
- 238000005859 coupling reaction Methods 0.000 claims abstract description 16
- 230000003068 static effect Effects 0.000 claims abstract description 12
- 238000004364 calculation method Methods 0.000 claims abstract description 11
- 238000010276 construction Methods 0.000 claims abstract description 4
- 230000006870 function Effects 0.000 claims description 25
- 239000002245 particle Substances 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 10
- 239000008188 pellet Substances 0.000 claims description 7
- 238000009826 distribution Methods 0.000 claims description 6
- 238000011160 research Methods 0.000 claims description 6
- 238000005452 bending Methods 0.000 claims description 5
- 238000010586 diagram Methods 0.000 claims description 5
- 238000006073 displacement reaction Methods 0.000 claims description 4
- 239000006187 pill Substances 0.000 claims description 3
- 230000035945 sensitivity Effects 0.000 claims description 3
- 238000012935 Averaging Methods 0.000 claims description 2
- 238000005482 strain hardening Methods 0.000 claims description 2
- 230000002787 reinforcement Effects 0.000 abstract description 3
- 238000011156 evaluation Methods 0.000 abstract description 2
- 238000012360 testing method Methods 0.000 description 13
- 230000000452 restraining effect Effects 0.000 description 3
- 229910000639 Spring steel Inorganic materials 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 238000012512 characterization method Methods 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 230000000977 initiatory effect Effects 0.000 description 1
- 230000000670 limiting effect Effects 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000012821 model calculation Methods 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 230000011218 segmentation Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
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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]
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F2119/00—Details relating to the type or aim of the analysis or the optimisation
- G06F2119/14—Force analysis or force optimisation, e.g. static or dynamic forces
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Abstract
The invention discloses a method for analyzing ultrasonic shot peening strengthening residual stress and deformation, which adopts a mode of combining finite element FEM and discrete element DEM to establish an ultrasonic shot peening coupling model; based on the established ultrasonic shot blasting coupling model, obtaining residual stress curves in the depth direction under different process parameters through simulation calculation, and returning out correlation coefficients according to a corresponding equation of the residual stress curves to complete the construction of the initial stress function; and (3) introducing the constructed initial stress function into the component in a Fortran program mode through a user subprogram SIGINI of finite element software ABAQUS, and analyzing and solving the component by using an ABAQUS static solver to obtain deformation conditions under different ultrasonic shot blasting process parameters. The method can save calculation time, realize quick evaluation of residual stress in the workpiece, complete initial stress deformation prediction and obtain reasonable deformation under the premise of ensuring reinforcement.
Description
Technical Field
The invention relates to the technical field of ultrasonic shot blasting processes, in particular to a method for analyzing residual stress and deformation of ultrasonic shot blasting reinforcement.
Background
Ultrasonic shot blasting is a metal surface treatment process, and is mainly used for improving the fatigue strength of parts, inhibiting the initiation of fatigue cracks and improving the fatigue life of the parts. At present, numerical simulation of ultrasonic shot peening is mostly modeled by adopting a finite element method, the modeling process is complex, the mutual collision relation among shot particles is not fully considered in the analysis process, and the simulated residual stress field is different from the stress field under the real working condition. The ultrasonic shot peening deformation numerical simulation is mainly completed by an equivalent load method, and the equivalent load method mainly comprises an in-plane extrusion method, an equivalent thermal load method and a direct stress method.
The in-plane extrusion method and the equivalent thermal load method have certain limitations and complexity when aiming at large-size workpieces, and the calculation amount is large; the direct stress method is to apply the shot-peening induced stress obtained by finite element simulation directly on the integral point of the finite element unit in the form of initial stress by adopting statics, obtain the shot-peening deformation result after stress balance calculation, and perform function characterization on the obtained residual stress curve by the direct stress method, wherein the residual stress curve after ultrasonic peening comprises a shot-peening stress layer and a bending deformation layer, and the residual stress field cannot be accurately characterized by only a single function.
Disclosure of Invention
The invention aims to provide a method for strengthening residual stress and deformation analysis by ultrasonic shot blasting, which is characterized in that a discrete element DEM-finite element FEM (Discrete Element Method-Finite Element Method) ultrasonic shot blasting coupling model is established based on display dynamics, and a discrete element particle model is introduced to consider the influences of the size, the contact attribute and the number of shot particles.
The invention aims at realizing the following technical scheme:
a method of ultrasonic peening strengthening residual stress and deformation analysis, the method comprising:
step 1, establishing an ultrasonic shot blasting coupling model by adopting a mode of combining finite element FEM and discrete element DEM;
step 2, based on the established ultrasonic shot blasting coupling model, obtaining residual stress curves in the depth direction under different process parameters through simulation calculation, and returning out a correlation coefficient according to a corresponding equation of the residual stress curves to complete the construction of an initial stress function;
step 3, importing the constructed initial stress function into the component in a Fortran program mode through a user subprogram SIGINI of finite element software ABAQUS, and analyzing and solving the component by using an ABAQUS static solver to obtain deformation conditions under different ultrasonic shot blasting process parameters;
wherein, the ultrasonic shot blasting process parameters comprise: amplitude, frequency, pellet diameter.
According to the technical scheme provided by the invention, the method can save calculation time, realize quick evaluation of residual stress in the workpiece, complete initial stress deformation prediction, further coordinate the relation between ultrasonic shot blasting process parameters and stress and deformation, and obtain reasonable deformation on the premise of ensuring reinforcement.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed in the description of the embodiments will be briefly described below, it being obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic flow chart of a method for ultrasonic peening strengthening residual stress and deformation analysis according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of an ultrasonic shot peening DEM-FEM coupling model in an example of the present invention;
FIG. 3 is a graph showing the fit of residual stress versus simulation curves for parameters with amplitudes of 40-100 μm in an example of the present invention;
FIG. 4 is a finite element model of an Almen test strip of the present invention;
FIG. 5 is a cloud image of results of ultrasonic peening strengthening deformation simulation of an A-type Almen test piece in an example of the present invention;
Detailed Description
The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments of the present invention, and this is not limiting to the present invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to fall within the scope of the invention.
Fig. 1 is a schematic flow chart of a method for analyzing residual stress and deformation of ultrasonic shot peening according to an embodiment of the present invention, the method includes:
step 1, establishing an ultrasonic shot blasting coupling model by adopting a mode of combining finite element FEM and discrete element DEM;
in this step, as shown in fig. 2, a schematic diagram of an ultrasonic peening DEM-FEM coupling model in the embodiment of the invention is shown, specifically, a workpiece in an ultrasonic peening strengthening process is regarded as a continuous medium, a pellet is regarded as a discrete system, the whole strengthening process is regarded as a combination of the continuous system and the discrete system, a particle system is generated by adopting a static method, a pellet generating component is additionally established in pretreatment, grid generating unit nodes are divided, inp keywords are modified, the pellet generating component unit nodes are converted into PD3D particle units, each particle represents one pellet, the size of each particle unit is the same, deformation of the particle unit is not considered, and the particle unit is set as a rigid body;
the Johnson-Cook model is used for describing dynamic mechanical behavior of the workpiece in the ultrasonic shot peening process, and the expression is as follows:
wherein sigma is material stress; a is the static yield stress of the material; b is a material strain exponentiation coefficient; epsilon is the equivalent plastic strain of the material; n is a strain hardening exponent; c is a strain rate sensitivity coefficient;is a strain influencing factor; t (T) * Is a temperature influencing factor; m is a temperature sensitivity coefficient;
the workpiece adopts a local grid refinement principle, the center of the workpiece is selected as a research area, and the grid of the research area is set to be not more than one tenth of the diameter of the pill so as to obtain good stress gradient, and the grid size of other areas except the research area is increased; the parts except the workpiece are provided with rigid body constraint, deformation is not considered, the workpiece is a three-dimensional variable entity unit, an eight-node reduction integral unit (C3D 8R) is adopted, the unit has an hourglass control mode, the unit does not generate serious distortion after simulation, and the simulation analysis method is suitable for simulation analysis of large strain and high strain rate;
the amplitude is loaded by adopting a Fourier function, and as the waveform diagram of ultrasonic vibration is a sine wave, sinusoidal displacement load is applied, and the contact in the ultrasonic shot blasting coupling model is divided into two parts:
the particles are in Hertz contact model, hard contact is adopted between the particles and other parts, the friction coefficient is 0.3, and an ultrasonic shot blasting coupling simulation analysis is carried out by using a display power solver.
Step 2, based on the established ultrasonic shot blasting coupling model, obtaining stress cloud pictures under different process parameters through simulation calculation, extracting residual stress curves along the depth direction, performing curve fitting, and returning out correlation coefficients according to a corresponding equation of the residual stress curves to complete the construction of an initial stress function;
in the step, based on the established ultrasonic shot blasting coupling model, extracting residual stress data of a plurality of paths of a workpiece along the depth direction by using a Python script program, carrying out averaging treatment on the residual stress data of the same depth, and constructing an S-shaped residual stress curve by using the average value, wherein the figure 3 is a comparison graph of the residual stress fitting and the simulation curve under the parameter of the amplitude of 40-100 mu m in the example of the invention;
dividing a residual stress curve into a shot blasting stress layer and a bending deformation layer according to the distribution rule of the residual stress in the workpiece after ultrasonic shot blasting strengthening; the stress distribution rule of the shot blasting stress layer along the thickness direction of the workpiece is similar to a cosine function, so that the shot blasting stress layer is approximately expressed by the cosine function; the stress distribution rule of the bending deformation layer is approximately expressed by a polynomial function, and the optimal correlation coefficient is obtained after a plurality of iterations through piecewise fitting, wherein the fitting formula is as follows:
wherein A is i 、ω i 、a. b, c, d, e, f is a control parameter; z represents the depth of a certain layer of the workpiece; e, e i Representing the depth of the shot peening stress layer; h represents the thickness of the workpiece;
control parameter omega i Andthe expression of (2) is:
wherein the control parameter omega i Anddepth of stress layer e i And maximum compressive stress layer depth m i And (3) representing.
Step 3, importing the constructed initial stress function into the component in a Fortran program mode through a user subprogram SIGINI of finite element software ABAQUS, and analyzing and solving the component by using an ABAQUS static solver to obtain deformation conditions under different ultrasonic shot blasting process parameters; wherein, the ultrasonic shot blasting process parameters comprise: amplitude, frequency, pellet diameter.
In the step, based on the initial stress function constructed in the step 2, the initial stress function is imported into a finite element model in a Fortran program mode by modifying the keywords of the user subprogram SIGINI of finite element software ABAQUS;
defining the distance of the finite element model along the thickness direction by a user subroutine SIGINI so as to distinguish the initial stress functions corresponding to the areas with different thicknesses, and completing editing of the initial stress functions by taking node coordinates or integral points as variables;
because the directly-introduced ultrasonic shot blasting residual stress cannot completely meet the initial condition of the finite element model, the stress balance static analysis is required to be carried out on the ultrasonic shot blasting residual stress, and then the strengthening deformation of the workpiece is represented by the maximum displacement of the simulation result.
For example, taking an a-type alcan test piece as an example, the deformation condition after ultrasonic shot peening is simulated, a three-dimensional entity unit is used to create an a-type alcan test piece model, as shown in fig. 4, which is a finite element model schematic diagram of the a-type alcan test piece in the embodiment of the present invention, the workpiece is the a-type alcan test piece, and the material is spring steel. The segmentation function is imported into the deformed part in a Fortran program mode through editing a user subprogram SIGINI to finish giving initial stress, and a static solver is adopted to analyze and calculate the initial stress so as to obtain the deformation condition of the test piece under a specific stress state.
(1) Pretreatment: an A-type Almen test piece model is created, the size is 76 x 32 x 1.32mm, the material property is set, the density of spring steel is 7.8e-9g/mm < 3 >, the Poisson ratio is 0.29, the elastic modulus is 205GPa, the related parameters A in the Johnson-Cook equation are 1408MPa, B is 600.8MPa, C is 0.0134, n is 0.234, an eight-node reduction unit C3D8R is adopted, the mesh size is required to be not more than one tenth of the size of a pill, and good convergence of model calculation is ensured. Setting two analysis steps, wherein the first analysis step is to set the complete fixed constraint of the bottom surface of the test piece and perform stress balance calculation; the second analysis step is used for releasing stress, restraining the degrees of freedom of the bottom surface of the test piece in the x direction, the y direction and the z direction, restraining the degrees of freedom of the bottom surface of the test piece in the y direction and the z direction and restraining the degrees of freedom of the bottom surface of the test piece in the third point in the z direction;
(2) Solving: a static solver is selected for solving, an operation is created, and a SIGINI subroutine is called for solving calculation;
(3) And (3) post-processing, namely finishing calculation and checking the deformation quantity of the ultrasonic shot peening strengthening of the workpiece, and further coordinating the relationship between strengthening and deformation according to the deformation quantity, wherein a cloud chart of simulation results of the ultrasonic shot peening strengthening deformation of the A-shaped Almen test piece in the embodiment of the invention is shown in FIG. 5.
It is noted that what is not described in detail in the embodiments of the present invention belongs to the prior art known to those skilled in the art.
In addition, it will be understood by those skilled in the art that all or part of the steps in implementing the methods of the above embodiments may be implemented by a program to instruct related hardware, and the corresponding program may be stored in a computer readable storage medium, where the storage medium may be a read only memory, a magnetic disk or an optical disk, etc.
The foregoing is only a preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions easily contemplated by those skilled in the art within the scope of the present invention should be included in the scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope of the claims. The information disclosed in the background section herein is only for enhancement of understanding of the general background of the invention and is not to be taken as an admission or any form of suggestion that this information forms the prior art already known to those of ordinary skill in the art.
Claims (4)
1. A method for ultrasonic peening strengthening residual stress and deformation analysis, the method comprising:
step 1, establishing an ultrasonic shot blasting coupling model by adopting a mode of combining finite element FEM and discrete element DEM;
step 2, based on the established ultrasonic shot blasting coupling model, obtaining residual stress curves in the depth direction under different process parameters through simulation calculation, and returning out a correlation coefficient according to a corresponding equation of the residual stress curves to complete the construction of an initial stress function;
step 3, importing the constructed initial stress function into the component in a Fortran program mode through a user subprogram SIGINI of finite element software ABAQUS, and analyzing and solving the component by using an ABAQUS static solver to obtain deformation conditions under different ultrasonic shot blasting process parameters;
wherein, the ultrasonic shot blasting process parameters comprise: amplitude, frequency, pellet diameter.
2. The method for ultrasonic peening strengthening residual stress and deformation analysis according to claim 1, wherein the process of step 1 is specifically:
the method comprises the following steps of regarding a workpiece in an ultrasonic shot peening strengthening process as a continuous medium, regarding a shot as a discrete system, regarding the whole strengthening process as a combination of the continuous system and the discrete system, describing the dynamic mechanical behavior of the workpiece in the ultrasonic shot peening strengthening process by adopting a Johnson-Cook model, wherein the expression is as follows:
wherein sigma is material stress; a is the static yield stress of the material; b is a material strain exponentiation coefficient; epsilon is the equivalent plastic strain of the material; n is a strain hardening exponent; c is a strain rate sensitivity coefficient;is a strain influencing factor; t (T) * Is a temperature influencing factor; m is temperature sensitivityCoefficients;
the workpiece adopts a local grid refinement principle, the center of the workpiece is selected as a research area, and the grid of the research area is set to be not more than one tenth of the diameter of the pill so as to obtain good stress gradient, and the grid size of other areas except the research area is increased;
the amplitude is loaded by adopting a Fourier function, and as the waveform diagram of ultrasonic vibration is a sine wave, sinusoidal displacement load is applied, and the contact in the ultrasonic shot blasting coupling model is divided into two parts:
the particles are in Hertz contact with other components, and the friction coefficient is 0.3.
3. The method for analyzing the ultrasonic peening strengthening residual stress and deformation according to claim 1, wherein in the step 2, residual stress data of a plurality of paths of a workpiece along the depth direction is extracted by using a Python script program based on the established ultrasonic peening coupling model, the residual stress data of the same depth is subjected to averaging treatment, and an S-shaped residual stress curve is constructed by using an average value;
dividing a residual stress curve into a shot blasting stress layer and a bending deformation layer according to the distribution rule of the residual stress in the workpiece after ultrasonic shot blasting strengthening; the stress distribution rule of the shot blasting stress layer along the thickness direction of the workpiece is similar to a cosine function, so that the shot blasting stress layer is approximately expressed by the cosine function; the stress distribution rule of the bending deformation layer is approximately expressed by a polynomial function;
the optimal correlation coefficient is obtained through piecewise fitting after multiple iterations, and the fitting formula is as follows:
wherein A is i 、ω i 、a. b, c, d, e, f is a control parameter; z represents the depth of a certain layer of the workpieceA degree; e, e i Representing the depth of the shot peening stress layer; h represents the thickness of the workpiece;
control parameter omega i Andthe expression of (2) is:
wherein the control parameter omega i Anddepth of stress layer e i And maximum compressive stress layer depth m i And (3) representing.
4. The method for ultrasonic peening strengthening residual stress and deformation analysis according to claim 1, wherein in step 3, based on the initial stress function constructed in step 2, the initial stress function is imported into the finite element model in the form of a Fortran program by modifying the keywords of the user subroutine SIGINI of the finite element software ABAQUS;
defining the distance of the finite element model along the thickness direction by a user subroutine SIGINI so as to distinguish the initial stress functions corresponding to the areas with different thicknesses, and completing editing of the initial stress functions by taking node coordinates or integral points as variables;
because the directly-introduced ultrasonic shot blasting residual stress cannot completely meet the initial condition of the finite element model, the stress balance static analysis is required to be carried out on the ultrasonic shot blasting residual stress, and then the strengthening deformation of the workpiece is represented by the maximum displacement of the simulation result.
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| CN117951967A (en) * | 2024-03-26 | 2024-04-30 | 成都飞机工业（集团）有限责任公司 | Shot-blasting forming simulation method, device, equipment and medium |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117951967A (en) * | 2024-03-26 | 2024-04-30 | 成都飞机工业（集团）有限责任公司 | Shot-blasting forming simulation method, device, equipment and medium |
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