WO2021004083A1 - 结构热处理-硬度分布的定量匹配设计方法 - Google Patents

结构热处理-硬度分布的定量匹配设计方法 Download PDF

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WO2021004083A1
WO2021004083A1 PCT/CN2020/079198 CN2020079198W WO2021004083A1 WO 2021004083 A1 WO2021004083 A1 WO 2021004083A1 CN 2020079198 W CN2020079198 W CN 2020079198W WO 2021004083 A1 WO2021004083 A1 WO 2021004083A1
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hardness
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stress
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卢曦
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上海理工大学
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  • the invention relates to the field of structural hardness design in mechanical design, and is suitable for the hardness design of black, non-ferrous and other metal mechanical structures and parts.
  • the existing hardness distribution design of the mechanical structure and parts is based on the hardness matching design of the dangerous section stress distribution only, and the surface hardness, the depth of the hardened layer and the core hardness are obtained through methods such as analogy and experience. Therefore, in the design process of the hardness distribution of mechanical parts, there is no quantitative theoretical and technical basis for the design and formulation of the depth of the heat treatment hardened layer and the hardness gradient distribution, and the heat treatment process requirements are not organically linked with the processing of mechanical parts. As a result, the hardness quantitative matching design cannot be carried out in the hardness design process of the mechanical structure and parts.
  • the present invention proposes the concept of strength field, realizes the quantitative matching design method of structural heat treatment-hardness distribution, converts the stress field into the strength field and then into the hardness field, and then combines the material and heat treatment to obtain the actual hardness distribution of the dangerous section of the structure.
  • the technical problem to be solved by the present invention is the hardness mismatch problem existing in the existing mechanical structure and component hardness design process based on the overall strength viewpoint.
  • the technical solution of the present invention is to provide a quantitative matching design method of structural heat treatment-hardness distribution, which is characterized in that it includes the following steps:
  • Step 1 Determine the most dangerous limit static load that may occur during the use of the structure to be designed for the quantitative matching of the heat treatment-hardness distribution, and obtain the highest static stress and the direction of the static stress gradient at the dangerous section of the structure under the limit static load Stress distribution;
  • Step 2 Determine the ideal static strength field distribution of the structure according to the highest static stress and static stress gradient direction distribution obtained in Step 1.
  • the static strength of any point on the dangerous section of the structure is greater than the stress at that point, according to the stress-strength interference theory ,
  • the ideal strength design at any point of the dangerous section of the mechanical structure and parts is the fatigue stress amplitude at that point multiplied by the safety factor;
  • Step 3 Convert the ideal static strength distribution of the dangerous section of the structure to the ideal hardness distribution of the dangerous section of the structure according to the strength-hardness correspondence conversion relationship of black or non-ferrous metals or the strength-hardness correspondence relationship obtained by the test;
  • Step 4 Target the ideal hardness distribution of the dangerous section of the structure, match the material and heat treatment method of the structure, and adjust the depth of the hardened layer so that the actual surface hardness, actual subsurface hardness, and actual core hardness of the structure are greater than or equal to the corresponding point Ideal target hardness;
  • Step 5 According to the core hardness requirements of the heat treatment surface hardness of the structure, combined with the lowest and highest hardness of the material along the depth distribution curve, the depth of the hardened layer is determined to ensure that the actual hardness of the entire field is greater than or equal to the ideal hardness, and finally the dangerous section of the structure is obtained. Actual hardness distribution.
  • the highest static stress at the dangerous section of the structure and the stress distribution in the direction of the static stress gradient are calculated using material mechanics or finite element methods.
  • the highest static stress and the stress distribution in the static stress gradient direction are the highest surface stress at the structural dangerous section and the distribution of the stress at the structural dangerous section along the depth.
  • the ideal strength field is enlarged in proportion to the maximum static stress and the stress distribution in the direction of the static stress gradient.
  • step 4 if the actual core hardness is too high, use a material with a lower carbon content and surface carburization for adjustment; the actual subsurface hardness is adjusted by the depth of the hardened layer; the actual surface hardness is adjusted by carburizing Carbon or increasing the depth of the hardened layer increases.
  • the present invention can actively perform local strength matching according to materials and heat treatment, and solve the problem of local excessive hardness caused by mismatch with local hardness caused by the original design based on the overall strength viewpoint. Realize the quantitative matching design of the hardness distribution of the mechanical structure and parts.
  • Figure 1 is the size of the solid shaft.
  • Figure 2 is a flow chart of the implementation of the present invention.
  • Figure 3 shows the torsional stress distribution of the dangerous section
  • Figure 4 shows the torsional stress and ideal strength distribution
  • Figure 5 shows the ideal hardness along the depth of the dangerous section
  • Figure 6 shows the actual hardness distribution of the dangerous section of the structure.
  • the torsion of a solid shaft under a torsional load is taken as an example.
  • the material of the shaft is 40Cr steel, the minimum diameter of the shaft is 26.5 mm, the maximum diameter is 30.5 mm, and the shaft length is 468 mm.
  • the ultimate torsional load is 3500Nm, and the dimensions are shown in Figure 1.
  • the present invention provides a structural heat treatment-hardness distribution quantitative matching design method, which is characterized in that it includes the following steps:
  • the most dangerous limit torsional load is 3500Nm.
  • the dangerous section has the smallest torsional modulus (that is, the smallest diameter) at the outer surface diameter of 26.5mm, and the highest stress is:
  • the maximum gradient direction of the highest static stress is that the outer surface with a diameter of 26.5mm points to the axis, and the stress at any point in the cross section away from the axis is:
  • Ty is the torque in Nm
  • I p is the polar moment of inertia of the section, in m 4
  • y is the distance from the center of the shaft on the cross section.
  • the ideal static strength field distribution of the structure can be determined, and the ideal strength field is proportional to the maximum static stress and its gradient direction distribution.
  • the static strength of any point on the dangerous section of the structure is greater than the stress at that point.
  • the ideal strength of any point on the dangerous section of mechanical structures and parts is designed to be the fatigue stress amplitude of that point multiplied by the safety factor.
  • the ideal static strength distribution on the dangerous section of the mechanical structure and parts there is no excess strength, and the strength utilization rate reaches the maximum.
  • the ideal strength design is that the ideal strength of any point of the dangerous section of the structure is greater than the ultimate stress of that point.
  • the ratio of the ideal strength to the ultimate stress is a constant, which is the safety factor, which is related to the load, material properties and other factors.
  • the safety factor of the static strength design is 1.2, and the ideal torsional strength field distribution under the overall strength is shown in Fig. 4, and the ultimate stress distribution of the corresponding points is also given in Fig. 4.
  • the ideal static strength distribution of the dangerous section of the structure is converted into the ideal hardness distribution of the dangerous section of the structure.
  • the ideal hardness distribution of the dangerous section of the structure can be obtained by applying the strength-hardness conversion relationship and the third strength theory.
  • the hardness of any point of the dangerous section can be obtained according to the ideal strength of the point. So, as shown in formula (3):
  • the heat treatment requirements of the structure include parameters such as heat treatment method, surface hardness, core hardness, etc., aiming at the ideal hardness distribution of the dangerous section, matching the material and heat treatment method of the structure, adjusting the depth of the hardened layer, and making the surface hardness and core of the actual structure
  • the hardness is greater than or equal to the ideal target hardness of the corresponding point. If the core hardness is too high, materials with lower carbon content and surface carburization can be used; the secondary surface hardness can be adjusted by the depth of the hardened layer; the surface hardness can be increased by carburizing or increasing the depth of the hardened layer.
  • the ideal hardness distribution of the dangerous section is a linear distribution with a surface hardness of 55HRC and a core hardness of 0; taking into account the product process matching, the material in this example is 40Cr and the heat treatment method is intermediate frequency quenching; the minimum surface hardness is 55HRC , The core hardness is not more than 30HRC.
  • the depth of the hardened layer is determined to ensure that the actual hardness is greater than or equal to the ideal hardness, and finally the actual hardness distribution of the dangerous section of the structure is obtained .
  • the heat treatment method of this embodiment is intermediate frequency quenching, the minimum surface hardness is 55HRC, the core hardness is not more than 30HRC, and the minimum and maximum hardness of the bonding material is along the depth distribution curve.
  • the depth of the hardened layer By adjusting the depth of the hardened layer to ensure that the actual hardness of the entire field is greater than or equal to the ideal hardness, it is finally determined that the actual surface hardness of the dangerous section of the structure is 57-62HRC, and the depth of the hardened layer with a hardness above 50HRC is between 4.8-8mm, and the core hardness is not Above 30HRC, the actual hardness distribution of the dangerous section of the structure is shown in Figure 6.

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Abstract

针对现有的按照整体强度观点进行的结构硬度设计过程中硬度失配现象，本发明提出了结构热处理-硬度分布的定量匹配设计方法。具体方法为根据结构危险截面的极限静应力分布，确定结构危险截面的理想静强度场分布；利用强度-硬度转换关系，确定结构危险截面的理想硬度分布；结合材料和热处理方式，确定表面硬度、芯部硬度等热处理要求；根据材料端淬曲线和热处理要求，确定结构危险截面的实际硬度分布。

Description

结构热处理-硬度分布的定量匹配设计方法 技术领域
本发明涉及机械设计中结构硬度设计领域，适用于黑色、有色等金属机械结构和零部件的硬度设计。
背景技术
现有的机械结构和零部件的硬度分布设计是仅以危险截面应力分布进行硬度匹配设计，通过类比、经验等方法得到表面硬度、淬硬层深度以及芯部硬度。因此，在机械零件硬度分布的设计过程中，其热处理淬硬层深度、硬度梯度分布的设计和制定没有定量的理论和技术依据，热处理工艺要求与机械零件的加工没有进行有机的联系起来，从而造成机械结构和零部件的硬度设计过程中不能进行硬度定量匹配设计。本发明提出强度场的概念，实现了结构热处理-硬度分布的定量匹配设计方法，将应力场转化为强度场再转化到硬度场，再结合材料和热处理得到结构危险截面的实际硬度分布。
发明内容
本发明要解决的技术问题是：现有的按照整体强度观点进行的机械结构和零部件硬度设计过程中存在的硬度失配问题。
为了解决上述技术问题，本发明的技术方案是提供了一种结构热处理-硬度分布的定量匹配设计方法，其特征在于，包括以下步骤：
步骤1、确定拟进行热处理-硬度分布的定量匹配设计的结构在使用过程中可能出现的最危险的极限静载荷，在该极限静载荷下获得结构危险截面处的最高静应力及静应力梯度方向应力分布；
步骤2、根据步骤1得到的最高静应力及静应力梯度方向分布，确定结构的理想静强度场分布，结构危险截面上的任一点的静强度都大于该点的应力，按照应力-强度干涉理论，机械结构和零部件危险截面任一点的理想强度设计为该点的疲劳应力幅值乘以安全系数；
步骤3、根据黑色或有色金属的强度—硬度对应转换关系或试验得到的强度—硬度对应关系，把结构危险截面的理想静强度分布转化为结构危险截面的理想硬度分布；
步骤4、以结构危险截面的理想硬度分布为目标，匹配结构的材料和热处理方式，调整淬硬层深度，使得结构的实际表面硬度、实际次表面硬度、实际芯部硬度都大于等于相应点的理想目标硬度；
步骤5、根据结构的热处理表面硬度芯部硬度要求，结合材料的端淬最低和最高硬度沿深度分布曲线，通过确定淬硬层深度确保全场实际硬度大于等于理想硬度，最终得到结构危险截面的实际硬度分布。
优选地，步骤1中，利用材料力学或有限元方法，计算出结构危险截面处的所述最高静应力及所述静应力梯度方向应力分布。
优选地，步骤1中，在简单载荷下，所述最高静应力及所述静应力梯度方向应力分布为结构危险截面处的表面最高应力和结构危险截面处的应力沿深度的分布。
优选地，步骤2中，所述理想强度场与所述最高静应力及所述静应力梯度方向应力分布成比例放大。
优选地，步骤4中，若实际芯部硬度过高，采用含碳量更低材料和表面渗碳来进行调节；所述实际次表面硬度通过淬硬层深度调节；所述实际表面硬度通过渗碳或增加淬硬层深度增加。
本发明相比于传统的硬度分布匹配设计方法，可以根据材料和热处理等主动进行局部强度匹配，解决原有按整体强度观点进行设计所导致的与局部硬度不匹配而产生的局部硬度过剩问题，实现机械结构和零部件的硬度分布的定量匹配设计。
附图说明
图1为实心轴尺寸图，图1中，Φ1＝28.5mm，Φ2＝26.5mm，Φ3＝29.2mm，Φ4＝30.5mm，Φ5＝26.6mm，Φ6＝27.1mm，L＝468mm；
图2为本发明的实施流程图；
图3为危险截面扭转应力分布；
图4为扭转应力和理想强度分布；
图5为危险截面理想硬度沿深度分布；
图6为结构危险截面的实际硬度分布。
具体实施方式
下面结合附图，进一步阐述本发明。应理解，这些实施例仅用于说明本发明而不用于限制本发明的范围。此外应理解，在阅读了本发明讲授的内容之后，本领域技术人员可以对本发明作各种改动或修改，这些等价形式同样落于本申请所附权利要求书所限定的范围。
本实施例以实心轴在扭转载荷下的扭转为例，轴的材料为40Cr钢、轴的最小直径为26.5mm、最大直径为30.5mm、轴长468mm。承受的极限扭转载荷为3500Nm，尺寸如图1所示。结合图2，本发明提供的一种结构热处理-硬度分布的定量匹配设计方法，其特征在于，包括以下步骤：
1)确定极限静载荷下结构危险截面的最高静应力及其梯度分布；
在结构使用过程中可能出现最危险的极限静载荷下，应用材料力学或有限元方法，计算出结构危险截面处的最高静应力及其梯度方向应力分布。在简单载荷下，最高静应力及其梯度方向应力分布即为结构危险截面处的表面最高应力和该处应力沿深度的分布。
对于本实施例，最危险的极限扭转载荷为3500Nm，应用材料力学方法，对于本例危险截面在扭转模量最小(即直径最小)的外表面直径26.5mm处，最高应力为：
Figure PCTCN2020079198-appb-000001
式(1)中，T为扭矩，单位为Nm；W t为抗扭截面系数，单位为m 3。
最高静应力最大梯度方向是直径为26.5mm的外表面指向轴心，横截面距轴心任一点的应力为：
Figure PCTCN2020079198-appb-000002
式(2)中：Ty为扭矩，单位为Nm；I p为截面极惯性矩，单位为m 4；y为横截面上距轴中心距离的距离。本实施例计算得到的危险截面扭转应力分布如图3所示。
2)根据最高静应力及其梯度分布，确定结构危险截面的理想静强度分布；
根据结构使用过程中极限静载荷下的最高静应力及静应力梯度方向分布，可以确定结构的理想静强度场分布，理想强度场与最高静应力及其梯度方向分布成比例放大。结构危险截面上的任一点的静强度都大于该点的应力，按照应力-强度干涉理论，机械结构和零部件危险截面任一点的理想强度设计为该点的疲劳应力幅值乘以安全系数。机械结构和零部件危险截面上的理想静强度分布，不存在强度过剩，强度利用率达到最大。
在本实施例中，理想强度设计是结构危险截面任一点的理想强度都大于该点的极限应力，理想强度与极限应力之比值为常数，该常数为安全系数，它与载荷、材料性能等因素相关。本例中静强度设计的安全系数取1.2，整体强度下理想扭转强度场分布如图4所示，图4中同时给出了相应点的极限应力分布。
3)利用强度-硬度转换关系，确定结构危险截面的理想硬度分布；
根据黑色或有色金属的强度—硬度对应转换关系或试验得到的强度—硬度对应关系，把结构危险截面的理想静强度分布转化为结构危险截面的理想硬度分布。
本实施例中，根据设计得到的结构理想静强度分布，应用强度—硬度转换关系以及第三强度理论可以得到结构危险截面的理想硬度分布，危险截面任意点的硬度可根据该点的理想强度求得，如式(3)所示：
Figure PCTCN2020079198-appb-000003
式(3)中，τ d——深度d点处的扭转强度，单位为MPa；H d——深度d点处的硬度，单位为HRC。由式(3)得到的危险截面任意点沿深度分布的理想硬度如图5所示。
4)结合材料和热处理方式，确定表面硬度、芯部硬度等热处理要求
结构的热处理要求包括热处理方式、表面硬度、芯部硬度等参数，以危险截面的理想硬度分布为目标，匹配结构的材料和热处理方式，调整淬硬层深度，使得实际结构的表面硬度、芯部硬度都大于等于相应点的理想目标硬度。芯部硬度过高，可以采用含碳量更低材料和表面渗碳；次表面硬度可以通过淬硬层深度调节；表面硬度可以通过渗碳或增加淬硬层深度增加。
对于本实施例中，危险截面的理想硬度分布为表面硬度为55HRC、芯部硬 度为0的线性分布；兼顾产品工艺过程匹配出本例材料为40Cr、热处理方式为中频淬火；表面硬度最小值55HRC，芯部硬度不大于30HRC。
5)根据材料端淬曲线和热处理要求，确定结构危险截面的实际硬度分布
根据结构的热处理表面硬度芯部硬度要求，结合材料的端淬最低和最高硬度沿深度分布曲线，通过确定淬硬层深度确保全场实际硬度大于等于理想硬度，最终得到结构危险截面的实际硬度分布。
本实施例的热处理方式为中频淬火，表面硬度最小值为55HRC，芯部硬度不大于30HRC，结合材料的端淬最低和最高硬度沿深度分布曲线。通过调整淬硬层深度确保全场的实际硬度大于等于理想硬度，最终确定结构危险截面的实际表面硬度为57-62HRC，硬度为50HRC以上的硬化层深度在4.8-8mm之间，芯部硬度不大于30HRC，结构危险截面的实际硬度分布如图6所示。

Claims (5)

  1. 一种结构热处理-硬度分布的定量匹配设计方法，其特征在于，包括以下步骤：
    步骤1、确定拟进行热处理-硬度分布的定量匹配设计的结构在使用过程中可能出现的最危险的极限静载荷，在该极限静载荷下获得结构危险截面处的最高静应力及静应力梯度方向应力分布；
    步骤2、根据步骤1得到的最高静应力及静应力梯度方向分布，确定结构的理想静强度场分布，结构危险截面上的任一点的静强度都大于该点的应力，按照应力-强度干涉理论，机械结构和零部件危险截面任一点的理想强度设计为该点的疲劳应力幅值乘以安全系数；
    步骤3、根据黑色或有色金属的强度—硬度对应转换关系或试验得到的强度—硬度对应关系，把结构危险截面的理想静强度分布转化为结构危险截面的理想硬度分布；
    步骤4、以结构危险截面的理想硬度分布为目标，匹配结构的材料和热处理方式，调整淬硬层深度，使得结构的实际表面硬度、实际次表面硬度、实际芯部硬度都大于等于相应点的理想目标硬度；
    步骤5、根据结构的热处理表面硬度芯部硬度要求，结合材料的端淬最低和最高硬度沿深度分布曲线，通过确定淬硬层深度确保全场实际硬度大于等于理想硬度，最终得到结构危险截面的实际硬度分布。
  2. 如权利要求1所述的一种结构热处理-硬度分布的定量匹配设计方法，其特征在于，步骤1中，利用材料力学或有限元方法，计算出结构危险截面处的所述最高静应力及所述静应力梯度方向应力分布。
  3. 如权利要求1所述的一种结构热处理-硬度分布的定量匹配设计方法，其特征在于，步骤1中，在简单载荷下，所述最高静应力及所述静应力梯度方向应力分布为结构危险截面处的表面最高应力和结构危险截面处的应力沿深度的分布。
  4. 如权利要求1所述的一种结构热处理-硬度分布的定量匹配设计方法，其特征在于，步骤2中，所述理想强度场与所述最高静应力及所述静应力梯度方向应力分布成比例放大。
  5. 如权利要求1所述的一种结构热处理-硬度分布的定量匹配设计方法，其特征在于，步骤4中，若实际芯部硬度过高，采用含碳量更低材料和表面渗碳来进行调节；所述实际次表面硬度通过淬硬层深度调节；所述实际表面硬度通过渗碳 或增加淬硬层深度增加。
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