WO2018201521A1 - 一种激光冲击和超声振动挤压协同强化装置及方法 - Google Patents

一种激光冲击和超声振动挤压协同强化装置及方法 Download PDF

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Publication number
WO2018201521A1
WO2018201521A1 PCT/CN2017/084796 CN2017084796W WO2018201521A1 WO 2018201521 A1 WO2018201521 A1 WO 2018201521A1 CN 2017084796 W CN2017084796 W CN 2017084796W WO 2018201521 A1 WO2018201521 A1 WO 2018201521A1
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Prior art keywords
hole
laser
transducer
laser shock
mandrel
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PCT/CN2017/084796
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English (en)
French (fr)
Inventor
姜银方
李鑫
姜文帆
黄建云
甘学东
李旭
戚洪飞
虞文军
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江苏大学
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Application filed by 江苏大学 filed Critical 江苏大学
Priority to US16/322,488 priority Critical patent/US11542571B2/en
Publication of WO2018201521A1 publication Critical patent/WO2018201521A1/zh

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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D10/00—Modifying the physical properties by methods other than heat treatment or deformation
    • C21D10/005—Modifying the physical properties by methods other than heat treatment or deformation by laser shock processing
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/06—Surface hardening
    • C21D1/09—Surface hardening by direct application of electrical or wave energy; by particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/352—Working by laser beam, e.g. welding, cutting or boring for surface treatment
    • B23K26/356—Working by laser beam, e.g. welding, cutting or boring for surface treatment by shock processing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P9/00—Treating or finishing surfaces mechanically, with or without calibrating, primarily to resist wear or impact, e.g. smoothing or roughening turbine blades or bearings; Features of such surfaces not otherwise provided for, their treatment being unspecified
    • B23P9/04—Treating or finishing by hammering or applying repeated pressure
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D10/00—Modifying the physical properties by methods other than heat treatment or deformation
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2221/00—Treating localised areas of an article

Definitions

  • the invention belongs to the field of surface strengthening of parts, and provides a laser shock and ultrasonic vibration extrusion synergistic strengthening device and method, which are mainly applied to hole strengthening with severe stress concentration in industries such as aviation, aerospace, train and ship.
  • the hole structure In the field of aerospace and other fields, due to design, manufacturing and assembly, the hole structure will be difficult to avoid. If the hole is not strengthened, the unreinforced hole will become one of the danger sources of fatigue damage of the entire part. , resulting in reduced safety performance and service life.
  • the strengthening methods currently widely used are cold extrusion strengthening and laser shock strengthening.
  • the direct cold extrusion technology of the mandrel is to force the mandrel to pass through the pore diameter slightly smaller than the diameter of the mandrel, so that the wall of the hole is elastically plastically deformed, thereby introducing residual stress on the surface of the hole wall, thereby improving the fatigue life of the hole.
  • the mandrel in direct contact with the wall of the hole, and the friction between the two is large, and the plastic flow of the surface layer of the hole wall is severe, causing scratches on the surface of the hole wall and breakage of the mandrel. Therefore, the ordinary mandrel cold extrusion technology can not achieve the extrusion strengthening effect of effectively improving the high-strength metal pores.
  • Patent CN102205488A describes a method of cold extrusion of a slitted bushing. By adding a slotted bushing between the hole wall and the mandrel, the bushing is pressed by the mandrel, and the bushing is then pressed against the hole wall to cause residual compressive stress around the inner hole to achieve a strengthening effect.
  • the mandrel is easily broken, the process is complicated, and one bushing is consumed each time, resulting in a substantial increase in processing cost. And a large number of diameters less than 3.5mm can not be used for cold extrusion strengthening, and the size of the aperture of the small hole is greatly limited.
  • Laser shock strengthening is to strengthen the stress distribution of the inner wall of the small hole by strengthening the surface of the material to achieve the effect of strengthening the small hole, but this regulation is limited by many factors, especially the material thickness and the like.
  • Laser shock-strengthened holes have both single-sided impact and double-sided impact. After single-sided laser shock peening, there is tensile stress in the middle of the small hole wall, and the fatigue life is negative.
  • the stress distribution of the hole wall if the double-sided punching parameters are appropriate, the effect is better than the single-sided punching, and the “stress peak” distribution of the double-sided punching is more inclined to the middle of the thickness direction of the sheet, but the single-sided punching is close. Tensile stress is generated at the surface of the sheet.
  • Patent CN101942546A describes a laser shock-strengthening aperture technique in which an energy absorption rod is placed at an appropriate position inside a small hole, and a laser pulse acts on the slope of the head of the energy absorption rod to induce a plasma explosion to generate an impact.
  • the wave acts on the inner wall of the small hole to strengthen the small hole.
  • this method cannot ensure that the small holes having a diameter of less than 3 mm are effectively strengthened.
  • Ultrasonic wire drawing is to couple the energy of the ultrasonic wave to the wire drawing die through solid or liquid, and transmit it to the wire through the contact of the wire drawing die and the wire.
  • the ultrasonic vibration has a great influence on the plastic deformation of the wire.
  • Ultrasonic wire drawing can reduce drawing force, increase drawing speed, reduce friction, reduce mold wear, prolong die life, prevent biting mold wall, reduce wire breakage rate, improve steel surface quality and improve material mechanical properties. Good role.
  • Ultrasonic vibration extrusion strengthening technology is to make the surface of the part be impacted by the tool head with pressure (tension) and high-frequency longitudinal impact force, so that the micro-peaks and valleys on the surface of the workpiece are flattened, and the surface metal is plastically deformed and strengthened to form compressive stress. In turn, the surface fatigue strength of the part is enhanced.
  • the ultrasonic vibration is used to strengthen the small hole, the hole angle of the small hole cannot be effectively strengthened and is easily deformed.
  • Patent CN103710494A describes an ultrasonic-based small hole strengthening method and device for placing a piezoelectric ceramic column at a suitable position inside a small hole, wherein the piezoelectric ceramic column is a vibrating member, and is polarized and connected to the ultrasonic generator. .
  • the inner wall of the small hole is impacted to produce a certain plastic deformation to introduce residual stress, and the inner wall of the small hole is honed and strengthened.
  • the piezoelectric ceramic column needs to be subjected to relatively strict polarization treatment before use, the process is extremely complicated and there is a problem of uneven distribution of residual stress.
  • Patent CN105734233A provides an ultrasonic strengthening method and application thereof for improving the fatigue life of a metal workpiece.
  • the surface of the metal workpiece is ultrasonically processed by an ultrasonic machining tool, and the ultrasonic machining tool is adjusted for processing.
  • the different pressures of the surface are used to achieve the preset compressive stress on the metal surface, and finally the purpose of eliminating the residual stress and improving the fatigue life is achieved.
  • the ultrasonic strengthening can refine the surface of the metal workpiece, improve the surface microhardness, and improve the wear resistance and corrosion resistance.
  • the strengthening method can only reduce the residual stress of the workpiece surface, can not achieve significant reinforcement, and is not suitable for the inner wall reinforcement.
  • Patent CN10162828 discloses a tangentially telescopic ultrasonic torsion transducer, in which two symmetrically distributed drive assemblies generate a pair of stretching vibrations of the same frequency, amplitude and vibration direction in the tangential direction of the transducer.
  • the two connecting arms on the cover body generate a pair of tangential vibrations with the same frequency amplitude and the same vibration direction, so that the front cover body generates pure torsional vibration in the tangential direction, and the large amplitude torsional vibration is output after being amplified by the horn to cut Ultrasonic pure torsional vibration is obtained in a simple manner of direct drive.
  • This transducer is pure torsional vibration, cannot change the vibration mode, and cannot meet the requirements of hole reinforcement.
  • the object of the present invention is to provide a laser shock and ultrasonic vibration extrusion synergistic strengthening device and method for the defects of the above-mentioned strengthening technology. It overcomes the shortcomings of the traditional strengthening process and solves the shortage of single laser shock and single ultrasonic vibration extrusion strengthening hole.
  • the small hole can be comprehensively strengthened.
  • the problem of ultrasonic vibration extrusion strengthening for hole angle strengthening is solved, and the problem of tensile stress in the middle of the hole wall during laser shock strengthening and the limitation of the aperture size are solved, which solves the problem that the material strengthening effect of the laser shock strengthening thickening is not obvious. .
  • the method can improve the surface quality of the hole wall, and the process is simple.
  • the technical solution of the present invention is: in order to achieve the above object, the method of the present invention simultaneously performs laser shock strengthening and ultrasonic vibration extrusion strengthening on the opened holes in the sheet, and finally applies a core of axial tensile force and radial ultrasonic vibration.
  • the rods pass through the holes continuously and uniformly, giving the holes a higher fatigue resistance and a smoother inner surface.
  • a laser shock and ultrasonic vibration extrusion synergistic strengthening device comprising a laser component, a vibration component, a hydraulic component and a connecting component;
  • the laser assembly comprises an absorbing layer, a constraining layer, a laser beam and a laser; the absorbing layer is placed on the upper surface of the metal sheet, the constraining layer is placed above the absorbing layer, and the laser is located above the metal sheet to emit a laser beam to the metal sheet
  • the upper surface of the hole is laser shock reinforced;
  • the vibration assembly includes a core rod, a transducer and an ultrasonic generator;
  • the core rod includes a connecting section, a guiding section, a fitting section, a front cone section, a working ring and a rear cone section which are sequentially connected;
  • the hydraulic assembly includes a cylinder, a piston rod, a piston, a cylinder and a hydraulic pump station; the piston rod is mounted inside the cylinder, one end of the piston rod is connected to the piston, and the other end of the piston rod and the transducer rear cover Connected by a connecting sleeve and installed in the bracket body, the cylinder body is connected by a oil pipe and a hydraulic pump station;
  • the connecting component comprises a clamp, a worktable, a front end cover, a sleeve, a transducer guiding sleeve, a connecting sleeve, a bracket body and a rear end cover;
  • the clamp is mounted on the worktable, the front end cover and one end of the sleeve Connected, the other end of the sleeve is screwed to one end of the transducer guiding sleeve, and the transducer guiding sleeve is mounted on the working table, and one end of the bracket body is connected with the other end of the transducer guiding sleeve, the bracket body
  • the other end is connected to the lower end of the cylinder, and the rear end cover is mounted on the upper end of the cylinder;
  • the connecting portion of the mandrel is connected to the transducer and is mounted in the transducer guiding sleeve, the transducer guiding sleeve Installed on top of the workbench
  • the axial length of the front cone section and the rear cone section of the mandrel bar is not more than 15 mm, the surface roughness Ra of the front cone section and the rear cone section is ⁇ 0.2 ⁇ m, and the front cone angle and the rear cone angle are 2.5-4 °; the working ring has a surface roughness Ra ⁇ 0.1 ⁇ m.
  • the transducer includes a transducer front cover, a pre-tightening screw, a piezoelectric ceramic, an electrode piece, and a change End cap, insulating tube and insulating sheet;
  • the connecting portion of the mandrel is screwed to the front cover of the transducer, and the insulating sheet, the electrode sheet and the piezoelectric ceramic are sequentially arranged above the front cover of the transducer, and the electrode piece is installed between each pair of piezoelectric ceramics, the uppermost portion
  • the piezoelectric ceramics are sequentially connected with the electrode sheets, the insulating sheets and the rear end cover of the transducer, and the various parts of the transducer are connected by a pre-tightening screw, and the outer surface of the pre-tightening screw is covered with an insulating tube.
  • a method according to the laser shock and ultrasonic vibration extrusion synergistic strengthening device which uses laser impact strengthening and ultrasonic vibration extrusion strengthening to simultaneously strengthen the opened holes in the metal sheet, and the core rod and the hole are gapped
  • the state of the fit is to constrain the hole to prevent the distortion of the hole and the hole angle when the laser strikes the outer surface of the workpiece, and to increase the reinforcing effect of the hole wall;
  • the core rod in the hole applies ultrasonic vibration, Power ultrasound with a certain frequency, amplitude and mode interacts with the laser shock wave to form a three-dimensional compressive stress distribution at a certain depth near the hole wall, including the following steps:
  • the ultrasonic generator is electrically connected with the transducer, the vibration mode and parameters of the ultrasonic generator are set, and the ultrasonic generator is turned on to generate the modal ultrasonic vibration of the mandrel;
  • the absorbing layer in the step S1 is an aluminum foil, and the constraining layer is water.
  • the fitting tolerance of the matching section and the hole in the step S2 is H6/h5, H7/h6, H8/h7 or H9/h9.
  • the ultrasonic generator adopts a breathing vibration in the step S4; the ultrasonic vibration frequency is 15 to 60 kHz, the alternating radial amplitude is 2 to 40 ⁇ m; and the velocity of the mandrel through the hole is 10 to 50 mm/min.
  • the laser impact position of the laser in the step S5 is performed around the hole of the hole, and the circumferential spot overlap ratio and the radial spot overlap ratio are both greater than 50%.
  • the laser incident angle of the laser in the step S5 is greater than 60°.
  • the ultrasonic extrusion between the mandrel and the hole in the step S6 is strengthened by the working ring and the hole of the mandrel. After the extrusion is completed, the ultrasonic extrusion allowance is maintained at 1% to 6%.
  • the laser module of the present invention mainly functions to perform laser shock peening.
  • the primary function of the vibrating assembly is to provide radial ultrasonic vibration.
  • the main function of the hydraulic assembly is to subject the vibrating assembly to axial tension so that the mandrel can be strengthened through the bore.
  • the main function of the clamp is to position the hole and clamp the metal sheet.
  • the invention simultaneously performs laser shock strengthening and ultrasonic vibration extrusion strengthening on the opened holes of the metal sheet, and finally the core rod which applies the axial pulling force and the radial ultrasonic vibration continuously and uniformly passes through the hole, so that the hole is obtained higher.
  • the anti-fatigue property and the smoother inner surface overcome the limitation of the aperture size of the small hole and can also strengthen the hole of any size.
  • the invention overcomes the defects of single laser shock strengthening and single ultrasonic vibration extrusion strengthening, so that the metal component forms residual compressive stress from the surface of the hole to the inner wall, the stress distribution is more reasonable, and the middle of the hole wall and the hole angle can be effectively effective. strengthen.
  • the invention solves the deficiencies of the traditional cold extrusion strengthening, reduces the pressing force of the mandrel bar, improves the extrusion amount, and is less prone to breakage of the mandrel bar during the strengthening process, and the surface of the hole wall is strengthened after the strengthening, and the fatigue life is greatly increased. improve.
  • the invention also solves the problem that the engineering structural member can not be double-sided laser impact strengthening, and the single-sided laser impact enhancement has no gain, so that the stress concentration hole structure of the engineering structural member is effectively strengthened.
  • the invention has the characteristics of simple structure, simple process and convenient operation.
  • FIG. 1 is a schematic view showing the structure of a laser shock and ultrasonic vibration extrusion synergistic strengthening device according to an embodiment of the present invention.
  • FIG. 2 is a schematic structural view of a core rod according to an embodiment of the present invention.
  • FIG. 3 is a schematic view showing a strengthening process according to an embodiment of the present invention.
  • FIG. 4 is a schematic view showing a laser shock-enhanced spot and a hole position distribution according to an embodiment of the present invention
  • Figure 5 is a side cross-sectional view showing a metal sheet and a hole according to an embodiment of the present invention.
  • Figure 6 is a plan view showing a metal sheet and a hole according to an embodiment of the present invention.
  • FIG. 7 is a schematic structural view of a transducer according to an embodiment of the present invention.
  • Figure 8 is an enlarged schematic view of Figure 7I;
  • Figure 9 is a comparison diagram of stress distribution of a hole wall according to an embodiment of the present invention.
  • Figure 10 is a comparison diagram of stress distribution in the middle of a hole wall according to an embodiment of the present invention.
  • Fig. 11 is a comparison diagram of surface stress distribution according to an embodiment of the present invention.
  • curve 701 is laser shock reinforced hole wall stress
  • curve 702 is laser shock and ultrasonic vibration extrusion synergistically strengthens hole wall stress
  • curve 703 is ultrasonic vibration extrusion to strengthen hole wall stress
  • a curve 704 is a laser shock reinforced hole wall middle section stress
  • a curve 705 is an ultrasonic vibration squeeze to strengthen a middle wall stress
  • a curve 706 is a laser shock and ultrasonic vibration extrusion synergistically strengthening a middle wall stress
  • curve 707 is laser shock reinforced surface stress
  • curve 708 is ultrasonic vibration squeezing to strengthen surface stress
  • curve 709 is laser shock and ultrasonic vibration squeezing synergistically strengthen surface stress.
  • the invention adopts laser impact strengthening and ultrasonic vibration extrusion strengthening to simultaneously strengthen the opened hole 7 on the metal sheet 5, and the core rod 1 and the hole 7 are in a clearance fit state to restrain the hole 7 to prevent laser shock. Distortion of the hole and the hole angle on the outer surface of the workpiece, and increasing the reinforcing effect of the hole wall; when the laser impacts the outer surface of the metal sheet 5, the core rod 1 in the hole 7 applies ultrasonic vibration, using a certain frequency, amplitude and mode The power ultrasound interacts with the laser shock wave to form a three-dimensional compressive stress distribution at a certain depth near the wall of the hole.
  • FIG. 1 shows an embodiment of a laser shock and ultrasonic vibration extrusion synergistic strengthening device according to the present invention, the laser shock and ultrasonic vibration extrusion synergistic strengthening device comprising a laser component, a vibration component, a hydraulic component and a connection component.
  • the mandrel 1 used in the present invention is as shown in FIG. 2.
  • the mandrel 1 comprises, in order, a connecting section 101, a guiding section 102, a fitting section 103, a front cone section 104, a working ring 105 and a rear cone section 106.
  • the axial length of the front cone section 104 and the rear cone section 106 is not more than 15 mm, and the surface roughness Ra of the front cone section 104 and the rear cone section 106 is ⁇ 0.2 ⁇ m, the front cone angle and the rear cone angle are 2.5-4°, and the angle is too large.
  • the guiding property of the mandrel 1 is poor. If it is too small, the surface quality of the hole 7 is easily affected.
  • the diameter of the working ring 105 is determined according to the size of the hole to be strengthened. The diameter tolerance is less than 0.005 mm, and the surface roughness Ra of the working ring 105 is ⁇ 0.1 ⁇ m. .
  • the principle of the laser shock and ultrasonic vibration extrusion synergistic strengthening method of the present invention is as shown in FIG. 3, and the hole 7 is opened on the metal sheet 5, so that the axis of the core rod 1 is aligned with the axis of the hole 7, and the core rod 1 is self-aligned. Bottom up slowly through the hole 7, which cooperates The segment 103 forms a clearance fit with the hole 7, and the tolerances can be H6/h5, H7/h6, H8/h7 and H9/h9, so that the mandrel 1 generates ultrasonic vibration of a certain mode, and the hole circumference is strengthened by laser shock.
  • the mandrel 1 having a certain mode ultrasonic vibration is uniformly passed through the upper hole 7 of the metal sheet 5.
  • the respiratory vibration frequency of the mandrel 1 is preferably 15 to 60 kHz
  • the alternate radial amplitude is preferably 2 to 40 ⁇ m
  • the speed of the mandrel 1 through the hole 7 is preferably 10 to 50 mm/min, according to engineering Choose the appropriate parameters for the actual needs.
  • the laser shock-enhanced spot and the hole position distribution are shown in FIG. 4, and FIG. 5 and FIG. 6 are respectively a side cross-sectional view and a plan view of the metal plate and the hole.
  • a residual compressive stress is formed near the inner wall of the hole 7, and the radial residual compressive stress layer is deepened, and the part can be offset under the service condition.
  • the tensile stress improves the stress environment around the hole 7, and solves the problem of tensile stress generated in the middle of the inner wall of the hole after laser shock strengthening; on the other hand, the hole angle of the hole 7 can be effectively strengthened by laser shock strengthening.
  • the combination of the above two aspects enhances the ability of the material around the hole 7 to resist crack initiation and expansion, so that the small hole can be fully strengthened.
  • the mandrel 1 is in a state of ultrasonic vibration of a certain mode, can reduce frictional force during extrusion, etc., effectively solves the problem of breakage of the mandrel 1 during extrusion, and can also improve the surface quality of the hole 7 so that The surface is more smooth.
  • the vibration assembly of the laser shock and ultrasonic vibration extrusion synergistic strengthening device of the present invention includes a mandrel 1, a transducer 13, and an ultrasonic generator 18. 7 and 8 are schematic structural views of the transducer 13, the mandrel 1 is screwed to the transducer front cover 27, and the insulating sheet 33, the electrode sheet 30, and the piezoelectric layer are sequentially disposed above the transducer front cover 27.
  • the ceramic 29 is provided with an electrode sheet 30 between each pair of piezoelectric ceramics 29, and the uppermost piezoelectric ceramic 29 is sequentially connected to the electrode 30, the insulating sheet 33, and the transducer rear end cover 31, between the respective portions of the transducer 13
  • the pre-tightening screws 28 are connected, and the outer surface thereof is covered with an insulating tube 32.
  • the laser assembly includes an absorbing layer 2, a constraining layer 3, a laser beam 4, and a laser 14.
  • the absorbing layer 2 is placed on the upper surface of the metal sheet 5, and the constraining layer 3 is placed above the absorbing layer 2, and is subjected to laser shock peening by the laser beam 4 emitted from the laser 14, wherein the absorbing layer 2 is preferably an aluminum foil, and the constraining layer 3 is preferably water.
  • the hydraulic assembly includes a cylinder barrel 16, a piston rod 20, a piston 21, a nut 22, a cylinder block 23, and a hydraulic pump station 26.
  • the piston rod 20 is mounted inside the cylinder tube 16.
  • One end of the piston rod 20 and the piston 21 are connected by a nut 22, and the cylinder block 23 is connected to the hydraulic pump station 26 through a fuel pipe.
  • the vibration assembly includes a core rod 1, a transducer 13, and an ultrasonic generator 18.
  • the mandrel 1 is screwed to the transducer 13 and the sonotrode 18 is connected to the transducer 13 by wires.
  • the connection assembly includes a clamp 8, a table 9, a front end cover 10, a sleeve 11, a transducer guide sleeve 12, a connection sleeve 15, a bracket body 19, and a rear end cover 25.
  • the clamp 8 is mounted on the table 9, the front end cover 10 is screwed to the sleeve 11, the sleeve 11 is screwed to the transducer guide sleeve 12, and the transducer guide sleeve 12 is mounted on On the table 9, the holder body 19 and the transducer guide sleeve 12 are connected by a screw 17, and the rear end cover 25 is mounted above the cylinder 23.
  • the connecting section 101 of the mandrel 1 is screwed to the transducer front cover 27 and mounted in the transducer guiding sleeve 12, and the transducer guiding sleeve 12 is mounted above the table 9.
  • One end of the piston rod 20 of the hydraulic assembly is connected to the transducer rear cover 31 via a connecting sleeve 15 and is mounted in the bracket body 19.
  • the bracket body 19 and the transducer guide sleeve 12 are connected by a screw 17.
  • the main function of the hydraulic assembly is to subject the vibrating assembly to axial tension so that the mandrel 1 can be strengthened through the bore 7.
  • the jig 8 is mounted on the bottom plate of the table 9, and its main function is to position the hole 7 and clamp the metal sheet 5.
  • the invention provides a method for synergistic strengthening of laser shock and ultrasonic vibration extrusion.
  • the specific implementation process is as follows:
  • the size of the mandrel fitting section 103 is determined according to the size of the reinforcing hole and the hole shaft matching principle, and the matching section 103 forms a clearance fit with the hole 7, and the tolerance can be H6/h5, H7/ H6, H8/h7 and H9/h9 ensure the confinement effect of the mandrel 1 in the hole 7.
  • the front cone section 104 and the rear cone section 106 have an axial length of not more than 15 mm, and the front cone section 104 and the rear cone section 106 have a surface roughness Ra ⁇ 0.2 ⁇ m, and the front cone angle and the rear cone angle are preferably 2.5-4 degrees, and the angle is too large.
  • the guiding property of the mandrel 1 is poor. If it is too small, the surface quality of the hole 7 is easily affected.
  • the diameter of the working ring 105 is determined according to the size of the hole to be strengthened. The diameter tolerance should be less than 0.005 mm, and the surface roughness Ra of the working ring 105 is ⁇ 0.1. Mm.
  • the axis of the mandrel 1 is aligned with the axis of the hole 7, and the threaded end of the mandrel 1 is slowly passed through the hole 7 from bottom to top, ensuring that the connecting section 101 of the mandrel 1 and the transducer 13 are connected by threads.
  • the ultrasonic generator 18 is turned on to cause the core rod 1 to generate ultrasonic vibration of a certain mode.
  • the ultrasonic vibration adopts a breathing vibration, and the vibration mode can also be changed as needed.
  • the ultrasonic vibration frequency is preferably 15 to 60 kHz, and the alternating radial amplitude is preferably 2 to 40 ⁇ m.
  • the vibration component and the connection component are mounted on the metal sheet 5, the laser beam 4 cannot be vertically irradiated, so the laser incident angle 401 should be greater than 60°, and the laser shock enhancement effect is better.
  • the running route is controlled, and the outer surface around the hole 7 is subjected to laser shock strengthening.
  • the laser power density is selected according to the material properties of the workpiece and the thickness of the workpiece at the hole position.
  • the laser impact position is performed around the hole circumference, and the circumferential spot overlap ratio and the radial spot overlap ratio are both greater than 50%, and the circumferential direction and the diameter are completed.
  • the impact is repeated once and can be repeated 2 to 3 times; it can also be impacted by a ring laser beam of large energy, at which time the mandrel 1 passes through the center of the ring laser beam, and the spot is entirely irradiated around the hole 7 without moving the spot.
  • the pressing device After the laser impact is completed, the pressing device is started, and the mandrel 1 is slowly passed through the hole 7 at a constant speed.
  • the ultrasonic extrusion strengthening between the mandrel 1 and the hole 7 is squeezed through the working ring 105 and the hole 7, and the ultrasonic wave is turned off.
  • the device 18 performs laser shock and ultrasonic vibration extrusion synergistic strengthening.
  • the invention should set process parameters such as extrusion speed and extrusion amount according to the process requirements.
  • the mandrel is required to pass through the hole continuously and uniformly, so that the hole wall is fully deformed, and no pause, intermittent or impact load is allowed in the extrusion process until the mandrel passes through the hole completely.
  • the speed should not be too slow, and it is prone to sticking and breaking.
  • the extrusion speed can be selected within 10 to 50 mm/min according to actual engineering needs.
  • the amount of extrusion is one of the most important process parameters in the strengthening process, which directly affects the fatigue life gain brought by this process. If the amount of extrusion is too small, the elastoplastic deformation area is small, and the resulting reinforcing effect is limited; if the amount of extrusion is too large, cracks and microscopic defects are easily generated around the hole, thereby reducing the fatigue life. Therefore, the determination of the range of process parameters of the extrusion amount is an important step in the implementation of the process of the present invention.
  • the amount of extrusion depends mainly on the material of the hole to be strengthened, the state of heat treatment, the applied load level, the initial hole diameter, the hole depth, and the hole margin. In the method of the invention, the suitable extrusion amount can be selected according to the actual engineering needs, and the preferred value of the ultrasonic extrusion allowance is 1% to 6%, so that the pores are sufficiently strengthened.
  • holes with a pore size of 2.6 mm are reinforced.
  • the outer surface of the metal sheet is pretreated, and an aluminum foil is attached as an absorbing layer 2 around the hole, and water is used as the constraining layer 3 to allow water to flow through the surface of the aluminum foil at a uniform rate.
  • the model size of the mandrel 1 is selected, the diameter of the mandrel fitting section 103 is 2.6 mm, and the mating section 103 forms a clearance fit with the hole 7, with a tolerance of H7/h6, which ensures the restraining effect of the mandrel 1 in the hole 7.
  • the mandrel front cone section 104 and the rear cone section 105 have an axial length of 6 mm, and the front cone section 104 and the rear cone section 105 have a surface roughness Ra of 0.2 ⁇ m, a front taper angle and a rear taper angle of 3°, and a working ring diameter.
  • the amount of extrusion in this embodiment is 3%, so the diameter of the working ring 105 is 2.678 mm, the diameter tolerance is less than 0.005 mm, and the surface roughness Ra of the working ring is 0.1 ⁇ m.
  • the ultrasonic generator 18 is adjusted to set the vibration mode and parameters.
  • the ultrasonic vibration adopts a breathing vibration
  • the ultrasonic vibration frequency is 40 kHz
  • the alternating radial amplitude is 20 ⁇ m.
  • the ultrasonic generator 18 is turned on to cause the core rod 1 to generate ultrasonic vibration.
  • the laser running path and the laser incident angle are controlled to be 70°, and the outer surface around the hole is subjected to laser shock strengthening.
  • the circumferential spot overlap ratio and the radial spot overlap ratio were both 60%, and the circumferential and radial impacts were completed once, and the impact was repeated twice.
  • the hydraulic pump station (26) is opened, the hydraulic component is started, the mandrel 1 is slowly passed through the hole 7 at a constant speed, and the extrusion speed is 20 mm/min, and the ultrasonic extrusion is strengthened between the mandrel 1 and the hole 7 through the work.
  • the ring 105 and the hole 7 are pressed against each other.
  • the ultrasonic generator 18 is turned off, and the laser shock and the ultrasonic vibration extrusion are synergistically strengthened.
  • the hole 7 is fully strengthened.
  • the stress distribution of the hole wall is compared.
  • the abscissa is the thickness distance from the A side to the B side, and the ordinate is the stress.
  • the metal sheet A surface 501 and the metal sheet B surface are shown. 502
  • curve 701 is laser shock reinforced hole wall stress
  • curve 702 is laser shock and ultrasonic vibration extrusion synergistically strengthen hole wall stress
  • curve 703 is ultrasonic vibration extrusion to strengthen hole wall stress.
  • a single laser shock-strengthening hole will produce a tensile stress of about 50 MPa in the middle of the inner wall of the hole.
  • the residual vibration stress of the single ultrasonic vibration extrusion-enhanced hole angle is not obvious, and the residual angle of the hole is compared with the synergistic strengthening by laser shock and ultrasonic vibration.
  • the compressive stress is reduced by about 150 MPa. After the laser shock and ultrasonic vibration extrusion are synergistically strengthened, the hole is comprehensively strengthened, and the residual compressive stress distribution is uniform and reasonable.
  • the stress distribution in the middle of the hole wall is compared.
  • the abscissa is the distance in the Y direction from the middle of the hole wall.
  • the Y direction is the middle position of the hole wall, and the ordinate is the stress.
  • Curve 704 is a laser shock to strengthen the middle section stress of the hole wall, and there is only a tensile stress of about 50 MPa in the middle position of the hole wall.
  • Curve 705 is the ultrasonic vibration extrusion to strengthen the middle section stress of the hole wall.
  • Curve 706 is the laser impact and ultrasonic vibration extrusion to strengthen the middle section stress of the hole wall.
  • the residual pressure stress will be generated in the middle part of the hole wall.
  • the residual compressive stress is about 1.3 times that of a single ultrasonic vibration extrusion, and the strengthening effect is more obvious.
  • the surface stress distribution is compared, and the abscissa is the distance from the edge Y direction of the hole, as shown in Fig. 11 is the Y direction from the edge of the hole, and the ordinate is the stress.
  • Curve 707 is the laser shock to strengthen the surface stress
  • curve 708 is the ultrasonic vibration extrusion to strengthen the surface stress
  • curve 709 is the laser shock and ultrasonic vibration extrusion synergistically strengthen the surface stress.
  • the single ultrasonic vibration extrusion strengthens the residual compressive stress layer shallowly, and the residual compressive stress layer of the hole after laser shock and ultrasonic vibration extrusion is deeper than the single laser impact enhancement by about 0.5 mm, and the peak of the tensile stress. Small about 50MPa.
  • the hole is fully strengthened from the surface to the inner wall, overcoming the defects of single laser shock strengthening and single ultrasonic vibration extrusion strengthening.

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Abstract

一种激光冲击和超声振动挤压协同强化装置及方法，所述装置包括激光组件、振动组件、液压组件和连接组件。所述方法采用激光冲击强化和超声振动挤压强化同时对金属板料（5）上已开的孔（7）进行强化，所述芯棒（1）与孔成间隙配合状态以对孔进行约束，以防止激光冲击工件外表面时孔和孔角的畸变，并增加孔壁的强化效果；在激光冲击金属板料外表面时，孔中的芯棒施加超声振动，利用一定频率、振幅和模态的功率超声与激光冲击波产生相互作用，在孔壁附近一定深度形成三维的压应力分布，使孔获得较高的抗疲劳性能和较光整的内表面。克服了传统强化工艺的缺陷，解决了单一激光冲击和单一超声振动挤压强化孔的不足。

Description

一种激光冲击和超声振动挤压协同强化装置及方法 技术领域
本发明属于零件表面强化领域，提供一种激光冲击和超声振动挤压协同强化装置及方法，主要应用于航空、航天、列车及船舶等工业中应力集中严重的孔强化。
背景技术
在航空航天等领域，由于设计、制造和装配等原因，零件会难以避免的出现孔结构，如果不对孔进行强化处理，则未强化孔就会成为整个零件受力部位疲劳破坏的危险源之一，从而导致安全性能和使用寿命降低。目前广泛使用的强化方法是冷挤压强化和激光冲击强化等。
芯棒直接冷挤压技术，是使芯棒强行通过比芯棒直径略小的孔径，使孔壁发生弹塑性变形，从而在孔壁表面引入残余应力，进而提高孔的疲劳寿命。但该技术在挤压过程中，芯棒与孔壁直接接触，两者间摩擦力大，孔壁表层金属塑性流动严重，导致孔壁表面出现划痕，芯棒断裂等问题。因此普通芯棒冷挤压技术无法达到有效提高高强度金属小孔的挤压强化效果。
专利CN102205488A叙述了一种开缝衬套冷挤压加工孔的方法。通过在孔壁和芯棒之间要增加一个开缝的衬套，用芯棒挤压衬套，衬套再对孔壁进行挤压，使内孔周围产生残余压应力，达到强化效果。但挤压过程中芯棒极易断裂，工艺较为复杂且每次消耗一个衬套，导致加工成本大幅提高。并且大量直径小于3.5mm的无法采用冷挤压强化，对小孔孔径尺寸限制较大。
激光冲击强化是通过对材料表面的强化来调控小孔内壁的应力分布，达到对小孔的强化效果，但这种调控受很多因素的限制，特别是材料厚度等因素。激光冲击强化小孔有单面冲击和双面冲击两种。单面激光冲击强化后小孔孔壁中部存在拉应力，疲劳寿命呈负增益。对于孔壁的应力分布来说，如果双面冲参数适当，效果优于单面冲，双面冲的“应力波峰”分布更倾向于板料厚度方向的中部，但是单双面冲均在靠近板料表面的地方产生拉应力。因此对于厚度大的板料上的小孔，激光冲击强化存在缺陷，孔壁中部无法得到强化。并且在实际生产过程中，工件形状复杂多变，双面冲往往不容易实现，故应用受到一定的限制。
专利CN101942546A叙述了一种激光冲击强化小孔技术，该技术是在小孔内部适当位置放置能量吸收杆，激光脉冲作用在能量吸收杆头部斜面，诱导等离子体爆炸产生冲击 波作用于小孔内壁，从而对小孔进行强化。但该方法无法保证直径小于3mm的小孔得到有效的强化。
超声波拉丝是将超声波的能量通过固体或液体耦合到拉丝模具上，通过拉丝模具和金属丝的接触传递到金属丝上，超声振动对金属丝的塑性形变产生很大的影响。超声波拉丝在降低拉拔力，提高拉丝速度，降低摩擦力从而减少模具磨损，延长模具寿命，防止咬粘模壁，降低断线率，提高钢表面质量和改善材料力学性能等方面都能起到良好的作用。
超声振动挤压强化技术是使零件表面被有压力(拉力)和高频纵向冲击力的工具头撞击，使工件表面的微观峰谷被压平，同时表层金属发生塑性变形强化，形成压应力，进而增强零件表面耐疲劳强度。但使用超声振动挤压强化小孔时，小孔的孔角无法得到有效的强化且极易发生变形。
专利CN103710494A叙述了一种基于超声波的小孔强化方法及装置，该方法是在小孔内部适当位置放置压电陶瓷柱，其中压电陶瓷柱为振动部件，进行极化后与超声波发生器相连接。通过压电陶瓷柱的旋转和径向运动撞击小孔内壁产生一定的塑性变形从而引入残余应力，对小孔内壁进行珩磨与强化。但是由于压电陶瓷柱在使用之前需要进行较为严格的极化处理，因此工艺极为复杂，且存在残余应力分布不均匀问题。
专利CN105734233A提供一种提高金属工件疲劳寿命的超声强化方法及其应用，通过将金属工件装夹在超声波加工机床上，利用超声波加工刀具对金属工件表面进行超声加工，通过调整超声波加工刀具对于加工工作面的不同压力来实现对金属表面预置压应力，最终达到消除残余应力，提高疲劳寿命的目的。同时该超声强化能使金属工件表面晶粒细化，表面显微硬度提高，耐磨性和耐腐蚀性提高。该强化方法只能使工件表面加工残余应力降低，不能实现明显的强化，且不适用于孔内壁强化。
专利CN10162828公开了一种切向伸缩式超声波扭转换能器，对称分布的两个驱动组件在换能器切向方向上产生的一对频率、振幅、振动方向相同的伸缩振动，此振动使前盖体上的两个连接臂产生一对频率振幅相同，振动方向相同的切向振动，使前盖体在切向方向产生纯扭转振动，经过变幅杆放大后输出大振幅扭转振动，以切向直接驱动的简单方式获得了超声波纯扭转振动。此换能器为纯扭转振动，无法改变振动模态，不能适应孔的强化的要求。
发明内容
本发明的目的是针对上述强化技术的缺陷，提出了一种激光冲击和超声振动挤压协同强化装置及方法。克服了传统强化工艺的缺陷，解决了单一激光冲击和单一超声振动挤压强化孔的不足，通过激光冲击和超声振动挤压协同强化，可以使小孔得到全面的强化。解决了超声振动挤压强化对于孔角强化的不足，解决了激光冲击强化时孔壁中部存在拉应力的问题和对孔径尺寸的限制，解决了激光冲击强化厚度大的材料强化效果不明显的问题。且该方法可提高孔壁表面质量，工艺过程简单。
本发明的技术方案是：为了实现上述目的，本发明的方法即对板料上已开好的孔同时进行激光冲击强化和超声振动挤压强化，最后施加轴向拉力和径向超声振动的芯棒连续均匀地通过孔，使孔获得较高的抗疲劳性能和较光整的内表面。
一种激光冲击和超声振动挤压协同强化装置，包括激光组件、振动组件、液压组件和连接组件；
所述激光组件包括吸收层、约束层、激光束和激光器；所述吸收层置于金属板料上表面，约束层置于吸收层上方，激光器位于金属板料上方发出的激光束对金属板料上表面的孔进行激光冲击强化；
所述振动组件包括芯棒、换能器和超声波发生器；所述芯棒包括依次连接的连接段、导向段、配合段、前锥段、工作环和后锥段；超声波发生器与换能器电连接；
所述液压组件包括缸筒、活塞杆、活塞、缸体和液压泵站；活塞杆安装在缸筒内部，活塞杆的一端和活塞连接，所述活塞杆的另一端与换能器后盖板通过连接套筒相连接，并安装在支架体内，所述缸体通过油管和液压泵站连接；
所述连接组件包括夹具、工作台、前端盖、套筒、换能器导向套筒、连接套筒、支架体和后端盖；所述夹具安装在工作台上，前端盖与套筒的一端连接，套筒的另一端与换能器导向套筒的一端螺纹连接，且换能器导向套筒安装在工作台上，支架体的一端与换能器导向套筒的另一端连接，支架体的另一端与缸体的下端连接，后端盖安装在缸体的上端；所述芯棒的连接段与换能器连接，并安装在换能器导向套筒内，换能器导向套筒安装在工作台的上方。
上述方案中，所述芯棒的前锥段和后锥段轴向长度不超15mm，前锥段和后锥段的表面粗糙度Ra≤0.2μm，前锥角和后锥角为2.5～4°；所述工作环的表面粗糙度Ra≤0.1μm。
上述方案中，所述换能器包括换能器前盖板、预紧力螺钉、压电陶瓷、电极片、换 能器后端盖、绝缘管和绝缘片；
所述芯棒的连接段与换能器前盖板螺纹连接，换能器前盖板上方依次安装绝缘片、电极片、压电陶瓷，每对压电陶瓷间都安装有电极片，最上方的压电陶瓷依次与电极片、绝缘片、换能器后端盖相连，换能器各个部分之间由预紧力螺钉相连接，预紧力螺钉外表面套有绝缘管。
一种根据所述的激光冲击和超声振动挤压协同强化装置的方法，采用激光冲击强化和超声振动挤压强化同时对金属板料上已开的孔进行强化，所述芯棒与孔成间隙配合状态以对孔进行约束，以防止激光冲击工件外表面时孔和孔角的畸变，并增加孔壁的强化效果；在激光冲击金属板料外表面时，孔中的芯棒施加超声振动，利用一定频率、振幅和模态的功率超声与激光冲击波产生相互作用，在孔壁附近一定深度形成三维的压应力分布，具体包括以下步骤：
S1.对已开孔的金属板料外表面进行预处理，在所述金属板料外表面先设置吸收层，再在吸收层上设置约束层；
S2.根据孔的尺寸选择芯棒型号尺寸，芯棒配合段与孔间隙配合；
S3.将所述芯棒的轴线与孔轴线对准后使芯棒穿过孔，芯棒的连接段与换能器连接，换能器后盖板与液压组件的活塞杆连接；
S4.超声波发生器与换能器电连接，设置超声波发生器的振动模态和参数，打开超声波发生器，使芯棒产生模态的超声振动；
S5.调节激光器的光斑形状、光斑大小及激光功率密度，在芯棒产生模态的超声振动的同时对孔四周的外表面进行激光冲击强化；
S6.完成激光冲击后，打开液压泵站，启动液压组件，将芯棒匀速缓慢挤压的通过孔，关闭超声波发生器，完成激光冲击和超声振动挤压协同强化。
上述方案中，所述步骤S1中的吸收层为铝箔，约束层为水。
上述方案中，所述步骤S2中配合段与孔的配合公差为H6/h5、H7/h6、H8/h7或H9/h9。
上述方案中，所述步骤S4中超声波发生器采用呼吸式振动；超声振动频率为15～60kHz，交替式径向振幅为2～40μm；芯棒通过孔的速度为10～50mm/min。
上述方案中，所述步骤S5中激光器的激光冲击位置为绕孔的孔周进行，周向光斑搭接率和径向光斑搭接率均大于50％。
上述方案中，所述步骤S5中激光器的激光入射角大于60°。
上述方案中，所述步骤S6中芯棒与孔之间超声挤压强化通过芯棒的工作环与孔相互 挤压完成，超声挤压余量保持在1％～6％。
本发明所述激光组件主要作用是进行激光冲击强化。所述振动组件的主要作用是提供径向超声振动。所述液压组件的主要作用是使振动组件受到轴向拉力，使芯棒能够通过孔完成强化。所述夹具主要作用是定位孔和夹紧金属板料。
与现有技术相比，本发明的有益效果是：
1.本发明对金属板料上已开好的孔同时进行激光冲击强化和超声振动挤压强化，最后施加轴向拉力和径向超声振动的芯棒连续均匀地通过孔，使孔获得较高的抗疲劳性能和较光整的内表面，克服了小孔孔径尺寸的限制，也可以强化任意尺寸的孔。
2.本发明克服了单一激光冲击强化和单一超声振动挤压强化的缺陷，使金属构件从孔表面到内壁深处形成残余压应力，应力分布更合理，孔壁中部及孔角都能得到有效强化。
3.本发明解决了传统冷挤压强化的不足，减少了芯棒的挤压力，提高了挤压量，强化过程中不易出现芯棒断裂的现象，强化后孔壁表面光整，疲劳寿命大幅提高。
4.本发明还解决了工程结构件无法进行双面激光冲击强化，而单面激光冲击强化无增益的问题，使工程结构件应力集中孔结构得到了有效的强化。
5.本发明具有结构简单，且工艺过程简单，操作方便等特点。
附图说明
图1是本发明一实施方式的激光冲击和超声振动挤压协同强化装置结构示意图。
图2是本发明一实施方式的芯棒结构示意图；
图3是本发明一实施方式的强化过程示意图；
图4是本发明一实施方式的激光冲击强化光斑及孔位置分布示意图；
图5是本发明一实施方式的金属板料及孔的侧面剖视图；
图6是本发明一实施方式的金属板料及孔的俯视图；
图7是本发明一实施方式的换能器结构示意图；
图8是图7I处的放大示意图；
图9是本发明一实施方式的孔壁应力分布对比图；
图10是本发明一实施方式的孔壁中段应力分布对比图；
图11是本发明一实施方式的表面应力分布对比图。
图中，1、芯棒，101、连接段，102、导向段，103、配合段，104、前锥段，105、工作环，106、后锥段，2、吸收层，3、约束层，4、激光束，401、激光入射角，5、金 属板料，501、金属板料A面，502、金属板料B面，6、光斑，7、孔，8、夹具，9、工作台，10、前端盖，11、套筒，12、换能器导向套筒，13、换能器，14、激光器，15、连接套筒，16、缸筒，17、螺钉，18、超声波发生器，19、支架体，20、活塞杆，21、活塞，22、螺母，23、缸体，24、后端盖密封圈，25、后端盖，26、液压泵站，27、换能器前盖板，28、预紧力螺钉，29、压电陶瓷，30、电极片，31、换能器后盖板，32、绝缘管，33、绝缘；
图9中，曲线701为激光冲击强化孔壁应力；曲线702为激光冲击和超声振动挤压协同强化孔壁应力；曲线703为超声振动挤压强化孔壁应力；
图10中，曲线704为激光冲击强化孔壁中段应力；曲线705为超声振动挤压强化孔壁中段应力；曲线706为激光冲击和超声振动挤压协同强化孔壁中段应力；
图11中，曲线707为激光冲击强化表面应力；曲线708为超声振动挤压强化表面应力；曲线709为激光冲击和超声振动挤压协同强化表面应力。
具体实施方式
下面结合附图和具体实施方式对本发明作进一步详细说明，但本发明的保护范围并不限于此。
本发明采用激光冲击强化和超声振动挤压强化同时对金属板料5上已开的孔7进行强化，所述芯棒1与孔7成间隙配合状态以对孔7进行约束，以防止激光冲击工件外表面时孔和孔角的畸变，并增加孔壁的强化效果；在激光冲击金属板料5外表面时，孔7中的芯棒1施加超声振动，利用一定频率、振幅和模态的功率超声与激光冲击波产生相互作用，在孔壁附近一定深度形成三维的压应力分布。
图1所示为本发明所述激光冲击和超声振动挤压协同强化装置的一种实施方式，所述激光冲击和超声振动挤压协同强化装置包括激光组件、振动组件、液压组件和连接组件。
本发明中采用的芯棒1如图2所示，所述芯棒1依次包括连接段101、导向段102、配合段103、前锥段104、工作环105和后锥段106。前锥段104和后锥段106轴向长度不超过15mm，前锥段104和后锥段106的表面粗糙度Ra≤0.2μm，前锥角和后锥角为2.5-4°，角度过大则芯棒1的导向性差，过小则易影响孔7的表面质量，工作环105直径大小根据需强化孔的大小来确定，直径公差小于0.005mm，工作环105的表面粗糙度Ra≤0.1μm。
本发明的激光冲击和超声振动挤压协同强化方法原理如图3所示，金属板料5上已开好孔7，使芯棒1的轴线与孔7的轴线对准，将芯棒1自下而上缓慢穿过孔7，其配合 段103与孔7形成间隙配合，配合公差可为H6/h5、H7/h6、H8/h7和H9/h9，使芯棒1产生一定模态的超声振动，同时用激光冲击强化孔周。强化完成后使具有一定模态超声振动的芯棒1匀速通过金属板料5上孔7。其中：芯棒1的呼吸式超声振动频率优选值为15～60kHz，交替式径向振幅优选值为2～40μm，芯棒1通过孔7的速度优选值为10～50mm/min，可根据工程实际需求选取合适参数。激光冲击强化光斑及孔位置分布如图4所示，图5和图6分别为金属板料及孔的侧剖视图和俯视图。
经过上述强化处理后，一方面，在具有一定模态超声振动芯棒1的挤压作用下，孔7内壁附近形成残余压应力，加深了径向残余压应力层，在服役条件下可以抵消部分拉应力，改善孔7周围的应力环境，解决了激光冲击强化后孔内壁中部产生拉应力的问题；另一方面，通过激光冲击强化，使孔7孔角也能得到有效强化。以上两方面共同作用增强了孔7周边材料抗裂纹萌生与扩展的能力，使小孔能够得到全面的强化。此外，芯棒1处于一定模态的超声振动状态，能够降低挤压过程中的摩擦力等，有效解决挤压过程中的芯棒1的断裂问题，还能够提高孔7的表面质量，使其表面更加光整。
本发明的激光冲击和超声振动挤压协同强化装置的振动组件包括芯棒1、换能器13和超声波发生器18。如图7和8所示为换能器13的结构示意图，芯棒1与换能器前盖板27螺纹连接，换能器前盖板27上方依次安装绝缘片33、电极片30、压电陶瓷29，每对压电陶瓷29间都安装有电极片30，最上方的压电陶瓷29依次与电极30、绝缘片33、换能器后端盖31相连，换能器13各个部分之间由预紧力螺钉28相连接，其外表面套有绝缘管32。
所述激光组件包括吸收层2、约束层3、激光束4和激光器14。吸收层2置于金属板料5上表面，约束层3置于吸收层2上方，通过激光器14发出的激光束4进行激光冲击强化，其中吸收层2优选选铝箔，约束层3优选水。
所述液压组件包括缸筒16、活塞杆20、活塞21、螺母22、缸体23和液压泵站26。活塞杆20安装在缸筒16内部，活塞杆20的一端和活塞21通过螺母22连接，缸体23通过油管和液压泵站26连接。
所述振动组件包括芯棒1、换能器13和超声波发生器18。芯棒1与换能器13通过螺纹连接，超声波发生器18通过导线与换能器13连接。
所述连接组件包括夹具8、工作台9、前端盖10、套筒11、换能器导向套筒12、连接套筒15、支架体19和后端盖25。夹具8安装在工作台9上，前端盖10与套筒11通过螺纹连接，套筒11与换能器导向套筒12通过螺纹连接，且换能器导向套筒12安装在 工作台9上，支架体19与换能器导向套筒12通过螺钉17连接，后端盖25安装在缸体23上方。
芯棒1的连接段101与换能器前盖板27通过螺纹连接，并安装在换能器导向套筒12内，换能器导向套筒12安装在工作台9的上方。所述液压组件的活塞杆20的一端与换能器后盖板31通过连接套筒15相连接，并安装在支架体19内。支架体19和换能器导向套筒12通过螺钉17相连接。液压组件的主要作用是使振动组件受到轴向拉力，使芯棒1能够通过孔7完成强化。夹具8安装在工作台9底板上，其主要作用是定位孔7和夹紧金属板料5。
本发明提供一种激光冲击和超声振动挤压协同强化的方法具体实施过程如下：
S1、对已开孔7的金属板料5外表面进行预处理，设置吸收层2和约束层3。在孔7周围贴上铝箔或黑漆等作为吸收层2，其主要作用是保护零件不被激光灼伤并增强对激光能量的吸收。使用水作为约束层3，使水约束层3匀速流过吸收层2表面。
S2、选择芯棒1型号尺寸，芯棒配合段103的尺寸根据需要强化孔的尺寸和孔轴配合原则来确定，配合段103与孔7形成间隙配合，配合公差可为H6/h5、H7/h6、H8/h7和H9/h9，保证芯棒1在孔7内的约束效应。前锥段104和后锥段106轴向长度不超过15mm，前锥段104和后锥段106的表面粗糙度Ra≤0.2μm，前锥角和后锥角优选2.5-4°，角度过大则芯棒1的导向性差，过小则易影响孔7的表面质量，工作环105直径大小根据需强化孔的大小来确定，直径公差应小于0.005mm，工作环105的表面粗糙度Ra≤0.1μm。
S3、使芯棒1的轴线与孔7的轴线对准，将芯棒1有螺纹一端自下而上缓慢穿过孔7，保证芯棒1的连接段101与换能器13通过螺纹相连接，安装前端盖10。
S4、设置振动模态和参数，在超声波发生器18上可调整振动频率和振幅等参数。打开超声波发生器18，使芯棒1产生一定模态的超声振动。超声振动采用呼吸式振动，也可以根据需要改变振动模态，超声振动频率优选值为15～60kHz，交替式径向振幅优选值为2～40μm。
S5、调节激光器14的参数光斑形状和大小及激光功率密度等。由于金属板料5上方安装有振动组件和连接组件，使得激光束4无法垂直照射，因此激光入射角401应大于60°，保证激光冲击强化的效果较好。控制其运行路线，对孔7四周的外表面进行激光冲击强化。激光功率密度根据工件的材料性能和工件在孔位置的厚度进行选择，激光冲击位置为绕孔周进行，周向光斑搭接率和径向光斑搭接率均大于50％，完成周向和径向 冲击为一遍，可重复2～3遍；也可以采用大能量的环形激光束进行冲击，这时芯棒1穿过环形激光束中心，光斑整体辐照在孔7的周围，无需移动光斑。
S6、完成激光冲击后，启动挤压装置，将芯棒1匀速缓慢的通过孔7，芯棒1与孔7之间超声挤压强化通过工作环105与孔7相互挤压完成，关闭超声波发生器18，完成激光冲击和超声振动挤压协同强化。
本发明在实际工作过程中，应根据工艺要求，设定工艺参数，如挤压速度、挤压量等。
在超声振动挤压强化过程中，要求芯棒连续、均匀地通过孔，使孔壁得到充分变形，不允许在挤压过程中有停顿、间歇和冲击载荷，直至芯棒完全通过孔。速度不能过慢，容易出现卡棒、断棒现象。挤压速度过快时，会造成塑变不充分、晶格组织不稳定。因此，挤压速度可根据实际工程需要，在10～50mm/min内选取。
挤压量是本强化工艺中最重要的工艺参数之一，其直接影响此工艺带来的疲劳寿命增益。若挤压量过小，弹塑性变形区域小，由此产生的强化效果有限；若挤压量过大，容易在孔的周围产生裂纹及微观缺陷，从而降低疲劳寿命。因此，挤压量工艺参数范围的确定是本发明工艺实施的重要环节。挤压量的大小主要取决于被强化的孔的材料、热处理状态、所受外加载荷水平、初始孔直径、孔深以及孔边距等因素。在本发明方法中，可以根据实际工程需要，选取适合的挤压量，超声挤压余量的优选值为1％～6％，保证孔得到充分强化。
实施例：
对6mm厚金属板料，孔径大小为2.6mm的孔进行强化。对金属板料外表面进行预处理，在孔周围贴上铝箔作为吸收层2，使用水作为约束层3，使水匀速流过铝箔表面。选择芯棒1的型号尺寸，芯棒配合段103的直径为2.6mm，配合段103与孔7形成间隙配合，配合公差为H7/h6，保证芯棒1在孔7内的约束效应。芯棒前锥段104和后锥段105轴向长度为6mm，前锥段104和后锥段105的表面粗糙度Ra为0.2μm，前锥角和后锥角为3°，工作环直径大小根据需强化孔7的大小来确定，本实施例中挤压量为3％,因此工作环105直径为2.678mm，直径公差小于0.005mm，工作环的表面粗糙度Ra为0.1μm。使芯棒1的轴线与孔7的轴线对准，将芯棒1有螺纹一端自下而上缓慢穿过孔，保证芯棒1的连接段101与换能器13通过螺纹相连接，安装前端盖10。调节超声波发生器18，设置振动模态和参数，本实施例中超声振动采用呼吸式振动，超声振动频率为40kHz，交替式径向振幅为20μm。打开超声波发生器18，使芯棒1产生超声振动。调节激光器的 参数，具体参数如下：光斑直径1mm，能量为2G，脉冲宽度20.1ns，波长1.054μm。控制激光器运行路线和激光入射角度为70°，对孔四周的外表面进行激光冲击强化。周向光斑搭接率和径向光斑搭接率均为60％，完成周向和径向冲击为一遍，重复冲击2遍。完成激光冲击后，打开液压泵站(26)，启动液压组件，将芯棒1匀速缓慢的通过孔7，挤压速度为20mm/min，芯棒1与孔7之间超声挤压强化通过工作环105与孔7相互挤压完成。挤压强化结束后关闭超声波发生器18，完成激光冲击和超声振动挤压协同强化。
激光冲击和超声振动挤压协同强化后，孔7得到全面强化。如图9所示为孔壁应力分布对比图，横坐标为从A面到B面的厚向距离，纵坐标为应力大小，如图5所示金属板料A面501和金属板料B面502，曲线701为激光冲击强化孔壁应力，曲线702为激光冲击和超声振动挤压协同强化孔壁应力，曲线703为超声振动挤压强化孔壁应力。单一激光冲击强化孔内壁中部会产生约50MPa的拉应力，单一超声振动挤压强化孔角残余压应力较小强化效果不明显，与采用激光冲击和超声振动挤压协同强化相比，孔角残余压应力减小约150MPa，激光冲击和超声振动挤压协同强化后孔得到全面强化，且残余压应力分布均匀合理。
如图10所示为孔壁中段应力分布对比图，横坐标为离开孔壁中段位置Y方向上的距离，如图10所示为离开孔壁中段位置Y方向，纵坐标为应力大小。曲线704为激光冲击强化孔壁中段应力，孔壁中段位置仅存在约50MPa的拉应力。曲线705为超声振动挤压强化孔壁中段应力，曲线706为激光冲击和超声振动挤压协同强化孔壁中段应力，激光冲击和超声振动挤压协同强化后孔壁中段位置会产生残余压应力，残余压应力的大小约为单一超声振动挤压强化的1.3倍，强化效果更明显。
如图11所示为表面应力分布对比图，横坐标为离开孔边缘Y方向上的距离，如图11所示为离开孔边缘Y方向，纵坐标为应力大小。曲线707为激光冲击强化表面应力，曲线708为超声振动挤压强化表面应力，曲线709为激光冲击和超声振动挤压协同强化表面应力。由应力对比图可知，单一超声振动挤压强化残余压应力层较浅，激光冲击和超声振动挤压协同强化后孔的残余压应力层比单一激光冲击强化深约0.5mm，且拉应力的波峰小约50MPa。孔从表面到内壁深处得到了全面强化，克服了单一激光冲击强化和单一超声振动挤压强化的缺陷。
应当理解，虽然本说明书是按照各个实施例描述的，但并非每个实施例仅包含一个独立的技术方案，说明书的这种叙述方式仅仅是为清楚起见，本领域技术人员应当将说明书作为一个整体，各实施例中的技术方案也可以经适当组合，形成本领域技术人员可 以理解的其他实施方式。
上文所列出的一系列的详细说明仅仅是针对本发明的可行性实施例的具体说明，它们并非用以限制本发明的保护范围，凡未脱离本发明技艺精神所作的等效实施例或变更均应包含在本发明的保护范围之内。

Claims (10)

  1. 一种激光冲击和超声振动挤压协同强化装置，其特征在于，包括激光组件、振动组件、液压组件和连接组件；
    所述激光组件包括吸收层(2)、约束层(3)、激光束(4)和激光器(14)；所述吸收层(2)置于金属板料(5)上表面，约束层(3)置于吸收层(2)上方，激光器(14)位于金属板料(5)上方发出的激光束(4)对金属板料(5)上表面的孔(7)进行激光冲击强化；
    所述振动组件包括芯棒(1)、换能器(13)和超声波发生器(18)；所述芯棒(1)包括依次连接的连接段(101)、导向段(102)、配合段(103)、前锥段(104)、工作环(105)和后锥段(106)；超声波发生器(18)与换能器(13)电连接；
    所述液压组件包括缸筒(16)、活塞杆(20)、活塞(21)、缸体(23)和液压泵站(26)；活塞杆(20)安装在缸筒(16)内部，活塞杆(20)的一端和活塞(21)连接，所述活塞杆(20)的另一端与换能器后盖板(31)通过连接套筒(15)相连接，并安装在支架体(19)内，所述缸体(23)通过油管和液压泵站(26)连接；
    所述连接组件包括夹具(8)、工作台(9)、前端盖(10)、套筒(11)、换能器导向套筒(12)、连接套筒(15)、支架体(19)和后端盖(25)；所述夹具(8)安装在工作台(9)上，前端盖(10)与套筒(11)的一端连接，套筒(11)的另一端与换能器导向套筒(12)的一端螺纹连接，且换能器导向套筒(12)安装在工作台(9)上，支架体(19)的一端与换能器导向套筒(12)的另一端连接，支架体(19)的另一端与缸体(23)的下端连接，后端盖(25)安装在缸体(23)的上端；所述芯棒(1)的连接段(101)与换能器(13)连接，并安装在换能器导向套筒(12)内，换能器导向套筒(12)安装在工作台(9)的上方。
  2. 根据权利要求1所述所述激光冲击和超声振动挤压协同强化装置，其特征在于，所述芯棒(1)的前锥段(104)和后锥段(106)轴向长度不超15mm，前锥段(104)和后锥段(106)的表面粗糙度Ra≤0.2μm，前锥角和后锥角为2.5～4°；所述工作环(105)的表面粗糙度Ra≤0.1μm。
  3. 根据权利要求1所述所述激光冲击和超声振动挤压协同强化装置，其特征在于，所述换能器(18)包括换能器前盖板(27)、预紧力螺钉(28)、压电陶瓷(29)、电极片(30)、换能器后端盖(31)、绝缘管(32)和绝缘片(33)；
    所述芯棒(1)的连接段(101)与换能器前盖板(27)螺纹连接，换能器前盖板(27)上方依次安装绝缘片(33)、电极片(30)、压电陶瓷(29)，每对压电陶瓷(29)间都安 装有电极片(30)，最上方的压电陶瓷(29)依次与电极片(30)、绝缘片(33)、换能器后端盖(31)相连，换能器(13)各个部分之间由预紧力螺钉(28)相连接，预紧力螺钉(28)外表面套有绝缘管(32)。
  4. 一种根据权利要求1所述的激光冲击和超声振动挤压协同强化装置的方法，其特征在于，采用激光冲击强化和超声振动挤压强化同时对金属板料(5)上已开的孔(7)进行强化，所述芯棒(1)与孔(7)成间隙配合状态以对孔(7)进行约束，在激光冲击金属板料(5)外表面时，孔(7)中的芯棒(1)施加超声振动，利用功率超声与激光冲击波产生相互作用，在孔(7)的孔壁附近形成三维的压应力分布，具体包括以下步骤：
    S1.对已开孔(7)的金属板料(5)外表面进行预处理，在所述金属板料(5)外表面先设置吸收层(2)，再在吸收层(2)上设置约束层(3)；
    S2.根据所述孔(7)的尺寸选择芯棒(1)型号尺寸，芯棒配合段(103)与孔(7)间隙配合；
    S3.将所述芯棒(1)的轴线与孔(7)轴线对准后使芯棒(1)穿过孔(7)，芯棒(1)的连接段(101)与换能器(13)连接，换能器后盖板(31)与液压组件的活塞杆连接；
    S4.超声波发生器(18)与换能器(13)电连接，设置超声波发生器(18)的振动模态和参数，打开超声波发生器(18)，使芯棒(1)产生模态的超声振动；
    S5.调节在金属板料(5)上方的激光器(14)的光斑形状、光斑大小及激光功率密度，在芯棒(1)产生模态的超声振动的同时对孔(7)四周的外表面进行激光冲击强化；
    S6.完成激光冲击后，打开液压泵站(26)，启动液压组件，将芯棒(1)匀速缓慢挤压的通过孔(7)，关闭超声波发生器(18)，完成激光冲击和超声振动挤压协同强化。
  5. 根据权利要求4所述所述激光冲击和超声振动挤压协同强化方法的装置，其特征在于，所述步骤S1中的吸收层为(2)铝箔，约束层(3)为水。
  6. 根据权利要求4所述的激光冲击和超声振动挤压协同强化方法，其特征在于，所述步骤S2中配合段(103)与孔(7)的配合公差为H6/h5、H7/h6、H8/h7或H9/h9。
  7. 根据权利要求4所述的激光冲击和超声振动挤压协同强化方法，其特征在于，所述步骤S4中超声波发生器(18)采用呼吸式振动；超声振动频率为15～60kHz，交替式径向振幅为2～40μm；芯棒(1)通过孔(7)的速度为10～50mm/min。
  8. 根据权利要求4所述的激光冲击和超声振动挤压协同强化方法，其特征在于，所述步骤S5中激光器(14)的激光冲击位置为绕孔(7)的孔周进行，周向光斑搭接率和径向光斑搭接率均大于50％。
  9. 根据权利要求4所述所述激光冲击和超声振动挤压协同强化方法，其特征在于，所 述步骤S5中激光器(14)的激光入射角(401)大于60°。
  10. 根据权利要求4所述的激光冲击和超声振动挤压协同强化方法，其特征在于，所述步骤S6中芯棒(1)与孔(7)之间超声挤压强化通过芯棒(1)的工作环(105)与孔(7)相互挤压完成，超声挤压余量保持在1％～6％。
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