WO2021004506A1 - Full-field structural lightweight quantitative evaluation method based on static strength - Google Patents
Full-field structural lightweight quantitative evaluation method based on static strength Download PDFInfo
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- WO2021004506A1 WO2021004506A1 PCT/CN2020/101077 CN2020101077W WO2021004506A1 WO 2021004506 A1 WO2021004506 A1 WO 2021004506A1 CN 2020101077 W CN2020101077 W CN 2020101077W WO 2021004506 A1 WO2021004506 A1 WO 2021004506A1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N3/08—Investigating strength properties of solid materials by application of mechanical stress by applying steady tensile or compressive forces
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N3/22—Investigating strength properties of solid materials by application of mechanical stress by applying steady torsional forces
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N3/40—Investigating hardness or rebound hardness
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- the invention relates to the field of structural static strength design and static strength evaluation in mechanical design, and is suitable for the static strength design and static strength evaluation of black, non-ferrous and other metal mechanical structures and parts.
- the evaluation method is to judge and evaluate the static strength lightweight only based on the strength requirements of the dangerous section.
- the static strength of the mechanical structure and parts is treated as a whole, and only the relationship between the highest stress of the dangerous section and the overall static strength is considered. The highest stress is compared with the overall strength.
- the stress of the structure is the concept of field and locality.
- the stress distribution of the dangerous section of the structure and parts can be accurately solved through material mechanics or finite element. In addition to the simple tension and compression load, the stress at different positions of the dangerous section of the structure different.
- the existing design methods for the maximum stress and overall strength of the dangerous points of the mechanical structure and parts cannot avoid the excessive local strength of the dangerous section, nor can it further quantitatively match the materials and heat treatments that affect the static strength of the dangerous section, and the mechanical structure cannot be carried out.
- Quantitative evaluation of light weight in the whole field based on static strength of parts and components The present invention proposes the concept of strength field, and realizes the quantitative evaluation of structural lightweight based on static strength field.
- the stress field is transformed into an ideal strength field, and the hardness field obtained through the end quenching curve of the material and the heat treatment requirement is transformed into the actual strength field.
- Quantitative evaluation of the overall weight reduction is carried out through the relationship between the value ratio of the actual strength field and the stress field and the safety factor.
- the technical problem to be solved by the present invention is that the existing lightweight design methods cannot perform full-field quantitative lightweight evaluation.
- the technical solution of the present invention is to provide a static strength-based quantitative evaluation method for the whole-field lightweight structure, which is characterized in that the static strength field of the structure is matched with the structural stress field to perform the whole-field lightening of the structure.
- Quantitative evaluation includes the following steps:
- Step 1 Determine the most dangerous ultimate static load that may occur during the use of the structure that is to be subjected to full-field lightweight quantitative evaluation, and obtain the highest static stress at the dangerous section of the structure and the gradient direction stress distribution of the static stress under the ultimate static load ;
- Step 2 According to the highest static stress at the dangerous section of the structure and the gradient direction stress distribution of the static stress, carry out the ideal static strength field distribution design of the dangerous section, so that the static strength of any point on the dangerous section of the structure is greater than the stress at that point. According to the theory of stress-strength interference, the ideal strength of any point of the dangerous section of the mechanical structure and parts is designed as the stress at that point multiplied by the safety factor;
- Step 3 Determine the lowest and highest hardness of the dangerous section of the structure and the gradient distribution of the hardness according to the structural heat treatment requirements and the end quenching curve of the material;
- Step 4 According to the hardness-static strength conversion relationship, determine the lowest actual static strength and the highest actual static strength of the dangerous section of the structure and the gradient distribution of the actual static strength;
- Step 5 Apply the stress-strength interference model to ensure that the strength of any point is greater than or equal to the ultimate stress of the point.
- the whole site at the dangerous position of the structure is lightweight and quantified Evaluation-Lightweight quantitative evaluation of the surface and its depth distribution, that is, the ratio of the actual static strength at any point to the highest stress at that point.
- the highest static stress and the gradient direction stress distribution are calculated by material mechanics or finite element method.
- the highest static stress is the highest surface stress at the dangerous section of the structure;
- the gradient direction stress distribution is the distribution of the surface stress at the dangerous section of the structure along the depth.
- the ideal static strength field distribution of the structure is determined according to the highest static stress under the ultimate static load during the use of the structure and the gradient direction stress distribution of the static stress.
- the strength field is proportional to the maximum static stress and the stress distribution in the gradient direction of the static stress.
- the ideal strength of any point in the dangerous section of the mechanical structure and parts is designed as the stress at that point multiplied by the safety factor, and the structure The ideal static strength distribution on the dangerous section, there is no excess strength, and the strength utilization rate reaches the maximum.
- the step 3 includes the following steps:
- the lowest hardness and the highest hardness and the hardness gradient distribution curve of the dangerous section of the structure are determined.
- step 5 when the lightweight quantitative evaluation is performed, if the ratio of the actual static strength at any point to the highest stress at that point is less than the safety factor, the static strength is insufficient, the static strength design is unreasonable, and the strength is increased; The ratio of the actual static strength to the highest stress at this point is greater than the safety factor, and the strength is surplus. The larger the value, the lower the weight reduction.
- the present invention can perform quantitative lightweight evaluation at any point in the entire field, thereby further improving the material utilization rate and exerting the lightweight potential through the improvement of process and materials.
- 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 stress distribution of the dangerous section
- Figure 4 shows the torsional stress and ideal strength distribution
- Figure 5 shows the end quenching curve of 38B3 material
- Figure 6 shows the actual strength distribution of the 38B3 solid shaft
- Figure 7 shows the overall lightweight quantitative evaluation.
- the shaft material is 38B3 steel
- the heat treatment is surface intermediate frequency quenching
- the surface hardness is 57-62HRC
- the depth of the hardened layer with a hardness of 500HV is 4.8-8mm.
- the core hardness is less than or equal to 30HRC
- the size of the solid shaft is shown in Figure 1.
- the invention provides a static strength-based quantitative assessment method for full-field lightweight structure including the following steps:
- the most dangerous ultimate static load pure torsional load is 4500Nm.
- the dangerous section is at the smallest torsional modulus (that is, the smallest diameter) outer surface diameter is 27mm, and the highest stress ⁇ max is calculated as Formula (1) shows:
- ⁇ y is the stress at a point on the cross section at a distance y from the axis
- Ty T is the torque at a point on the cross section at a distance of y from the axis, in Nm
- I p is the polar moment of inertia of the section ,
- the unit is m 4 .
- the stress gradient distribution of the dangerous section calculated in this embodiment is shown in FIG. 3.
- the ideal static strength field distribution of the structure can be determined.
- the ideal strength field is proportional to the highest 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, and the ratio of the static strength at any point to the stress at that point is a constant, which is the safety factor.
- the ideal static strength distribution on the dangerous section of the structure 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.
- the ideal torsional strength field distribution under the overall strength is shown in Figure 4, and the ultimate stress distribution is also given in Figure 4.
- the lowest dangerous section of the structure can be determined And the highest hardness and its gradient distribution curve.
- the material of the solid shaft is 38B3 steel
- the heat treatment is surface medium frequency quenching
- the surface hardness is 57-62HRC
- the depth of the hardened layer with a hardness of 500HV is 4.8-8mm
- the core hardness ⁇ 30HRC According to the curve of the lowest and highest end quenching distribution along the depth of 38B3 steel, the lowest and highest hardness of the dangerous section of the structure and its gradient distribution are shown in Figure 5.
- the lowest and highest hardness of the dangerous section of the structure and its gradient distribution curve are converted into the lowest and highest actual static strength of the dangerous section of the structure And its gradient distribution curve.
- the full-field stress-strength interference model is applied to ensure that the strength of any point is greater than or equal to the ultimate stress of the point.
- the overall weight of the dangerous position of the structure is reduced.
- Quantitative evaluation-lightweight quantitative evaluation of the surface and its depth distribution that is, the ratio of the actual static strength at any point to the highest stress at that point.
- the ratio of the actual strength at any point to the stress at that point is less than the safety factor, the static strength is not enough, the static strength design is unreasonable, and the strength needs to be increased; the ratio of the actual strength at any point to the stress at that point is greater than the safety factor, and the strength is surplus.
- the larger the value the lower the degree of lightweight.
- the full-field stress-intensity interference model means that the intensity at any point is greater than the stress
- the stress distribution and actual intensity distribution in this example are represented under the same coordinates, as shown in Figure 7:
- the relationship between actual minimum torsional strength, torsional stress, and ideal torsional strength that is, the relationship between actual torsional strength and actual torsional stress and ideal torsional strength at any point, through the ratio of actual torsional strength at any point to the actual stress at that point, The level of weight reduction at this point can be evaluated.
- four points, including the surface and subsurface hardening turning point 4.8mm, the internal heat treatment turning point 8mm, and the center point, are used for evaluation:
- the actual torsional static strength of the surface is 1631MPa, the design ideal static strength is 1393MPa, and the torsional stress is 1161MPa, then the ratio of the actual torsional static strength to the torsional stress is 1.41; greater than the design safety factor of 1.2, exceeding the safety factor of 0.21, it has a certain potential for lightweighting .
- the actual torsional static strength of 4.8mm subsurface hardening turning point is 1474MPa
- the design ideal static strength is 1092MPa
- the torsional stress is 910MPa.
- the ratio of the actual torsional static strength to the torsional stress is 1.61; greater than the design safety factor of 1.2, exceeding the safety factor of 0.41,
- the light weight potential is greater, and the strength and weight reduction design can be carried out by reducing the depth of the hardened layer to realize the light weight potential.
- the internal heat treatment turning point 8mm the actual torsional strength is 783MPa, the design ideal static strength is 534MPa, and the torsional stress is 445MPa, then the ratio of the actual torsional static strength to the torsional stress is 1.75; greater than the design safety factor of 1.2, exceeding the safety factor of 0.55, this point is determined by the material
- the heat treatment characteristics are determined, and the strength and weight reduction design can be carried out through the depth of the hardened layer to realize the light weight potential.
- the actual torsional strength of the center point is 702MPa, the design ideal static strength and torsional stress are both 0, and the static strength at this point is infinitely excessive. If the process conditions permit, the excessive torsional static strength of the core can be reduced by using a hollow structure.
- the static stress distribution curve and the actual minimum torsional static strength distribution curve first intersect on the surface.
- the static strength of the surface is the most dangerous relative to its static load.
- the strength is quantitatively evaluated as the overall lightweight level, and the subsurface and core are determined by the material and its heat treatment characteristics.
- the ideal static strength design requirement of this example is 1396MPa, which is equivalent to a static torsional load of 4500Nm; but the actual static strength can reach 1631MPa, which is equivalent to a static torsional load of 5257Nm. Therefore, the surface static strength is surplus of 235MPa, which is 21% surplus, which has a certain potential for lightweighting.
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Abstract
A full-field structural lightweight quantitative evaluation method based on static strength, performing full-field structural lightweight quantitative evaluation by matching a structural static strength field with a structural stress field. The method comprises: determining the ideal static strength field distribution of a dangerous structural section according to the highest stress distribution of the dangerous structural section; determining the static strength distribution of the dangerous structural section according to structure heat treatment requirements, an end quenching curve of the material and a strength-hardness transformation relation; and applying a stress-strength interference model to perform horizontal full-field lightweight quantitative evaluation on the dangerous structural section.
Description
本发明涉及机械设计中结构静强度设计和静强度评价领域，适用于黑色、有色等金属机械结构和零部件的静强度设计和静强度评价。The invention relates to the field of structural static strength design and static strength evaluation in mechanical design, and is suitable for the static strength design and static strength evaluation of black, non-ferrous and other metal mechanical structures and parts.
现有基于静强度的轻量化
评价方法是仅以危险截面强度要求进行静强度轻量化判断评价，把机械结构和零部件的静强度作为整体来处理，只考虑了危险截面最高应力与整体静强度之间的关系，把危险点的最高应力和整体的强度进行比较。结构的应力是场和局部的概念，可以通过材料力学或有限元可以精确求解结构和零部件危险截面全场下的应力分布，结构除了承受简单拉压载荷外，结构危险截面不同位置处的应力不同。因此，现有机械结构和零部件的危险点最高应力和整体强度的设计方法无法避免危险截面的局部强度过剩，也无法进一步进行影响危险截面静强度的材料、热处理的定量匹配，不能进行机械结构和零部件基于静强度的全场轻量化定量评价。本发明提出了强度场的概念，实现了基于静强度场的结构轻量化定量评价，由应力场转化为理想强度场，通过材料的端淬曲线和热处理要求得到的硬度场转化为实际强度场，通过实际强度场与应力场的数值比值与安全系数的关系进行全场轻量化的定量评价。
Existing lightweight based on static strength The evaluation method is to judge and evaluate the static strength lightweight only based on the strength requirements of the dangerous section. The static strength of the mechanical structure and parts is treated as a whole, and only the relationship between the highest stress of the dangerous section and the overall static strength is considered. The highest stress is compared with the overall strength. The stress of the structure is the concept of field and locality. The stress distribution of the dangerous section of the structure and parts can be accurately solved through material mechanics or finite element. In addition to the simple tension and compression load, the stress at different positions of the dangerous section of the structure different. Therefore, the existing design methods for the maximum stress and overall strength of the dangerous points of the mechanical structure and parts cannot avoid the excessive local strength of the dangerous section, nor can it further quantitatively match the materials and heat treatments that affect the static strength of the dangerous section, and the mechanical structure cannot be carried out. Quantitative evaluation of light weight in the whole field based on static strength of parts and components The present invention proposes the concept of strength field, and realizes the quantitative evaluation of structural lightweight based on static strength field. The stress field is transformed into an ideal strength field, and the hardness field obtained through the end quenching curve of the material and the heat treatment requirement is transformed into the actual strength field. Quantitative evaluation of the overall weight reduction is carried out through the relationship between the value ratio of the actual strength field and the stress field and the safety factor.
发明内容Summary of the invention
本发明要解决的技术问题是：现有的轻量化设计方法存在的无法进行全场定量的轻量化评价。The technical problem to be solved by the present invention is that the existing lightweight design methods cannot perform full-field quantitative lightweight evaluation.
为了解决上述技术问题，本发明的技术方案是提供了一种基于静强度的结构全场轻量化定量评价方法，其特征在于，使用结构静强度场与结构应力场进行匹配，进行结构全场轻量化定量评价，包括以下步骤：In order to solve the above technical problems, the technical solution of the present invention is to provide a static strength-based quantitative evaluation method for the whole-field lightweight structure, which is characterized in that the static strength field of the structure is matched with the structural stress field to perform the whole-field lightening of the structure. Quantitative evaluation includes the following steps:
步骤1、确定拟进行全场轻量化定量评价的结构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的梯度方向应力分布；Step 1. Determine the most dangerous ultimate static load that may occur during the use of the structure that is to be subjected to full-field lightweight quantitative evaluation, and obtain the highest static stress at the dangerous section of the structure and the gradient direction stress distribution of the static stress under the ultimate static load ；
步骤2、根据结构危险截面处的最高静应力及静应力的梯度方向应力分布，进行危险截面的理想静强度场分布设计，使得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应力乘以安全系数； Step 2. According to the highest static stress at the dangerous section of the structure and the gradient direction stress distribution of the static stress, carry out the ideal static strength field distribution design of the dangerous section, so that the static strength of any point on the dangerous section of the structure is greater than the stress at that point. According to the theory of stress-strength interference, the ideal strength of any point of the dangerous section of the mechanical structure and parts is designed as the stress at that point multiplied by the safety factor;
步骤3、根据结构热处理要求和材料的端淬曲线，确定结构危险截面的最低硬度和最高硬度以及硬度的梯度分布； Step 3. Determine the lowest and highest hardness of the dangerous section of the structure and the gradient distribution of the hardness according to the structural heat treatment requirements and the end quenching curve of the material;
步骤4、根据硬度-静强度转换关系，确定结构危险截面的最低实际静强度和最高实际静强度以及实际静强度的梯度分布； Step 4. According to the hardness-static strength conversion relationship, determine the lowest actual static strength and the highest actual static strength of the dangerous section of the structure and the gradient distribution of the actual static strength;
步骤5、应用应力-强度干涉模型保证任一点的强度大于等于该点的极限应力，通过结构危险位置处的实际静强度的梯度分布和极限静应力分布，进行结构危险位置处全场轻量化定量评价——表面及其深度分布的轻量化定量评价，即任意一点的实际静强度和该点的最高应力之比。Step 5. Apply the stress-strength interference model to ensure that the strength of any point is greater than or equal to the ultimate stress of the point. Through the gradient distribution of the actual static strength and the ultimate static stress distribution at the dangerous position of the structure, the whole site at the dangerous position of the structure is lightweight and quantified Evaluation-Lightweight quantitative evaluation of the surface and its depth distribution, that is, the ratio of the actual static strength at any point to the highest stress at that point.
优选地，步骤1中，采用材料力学或有限元方法计算得到所述最高静应力及所述梯度方向应力分布。Preferably, in step 1, the highest static stress and the gradient direction stress distribution are calculated by material mechanics or finite element method.
优选地，步骤1中，所述最高静应力为结构危险截面处的表面最高应力；所述梯度方向应力分布为结构危险截面处的表面应力沿深度的分布。Preferably, in step 1, the highest static stress is the highest surface stress at the dangerous section of the structure; the gradient direction stress distribution is the distribution of the surface stress at the dangerous section of the structure along the depth.
优选地，步骤2中，进行危险截面的理想静强度场分布设计时，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的梯度方向应力分布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静应力的梯度方向应力分布成比例放大，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应力乘以安全系数，且结构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。Preferably, in step 2, when designing the ideal static strength field distribution of the dangerous section, the ideal static strength field distribution of the structure is determined according to the highest static stress under the ultimate static load during the use of the structure and the gradient direction stress distribution of the static stress. The strength field is proportional to the maximum static stress and the stress distribution in the gradient direction of the static stress. According to the stress-strength interference theory, the ideal strength of any point in the dangerous section of the mechanical structure and parts is designed as the stress at that point multiplied by the safety factor, and the structure The ideal static strength distribution on the dangerous section, there is no excess strength, and the strength utilization rate reaches the maximum.
优选地，所述步骤3包括以下步骤：Preferably, the step 3 includes the following steps:
根据结构热处理要求中的热处理形式和给定的硬度参数，结合材料的端淬最低硬度和最高硬度沿深度分布的曲线，确定结构危险截面的最低硬度和最高硬度及硬度梯度分布曲线。According to the heat treatment form in the structural heat treatment requirements and the given hardness parameters, combined with the curve of the lowest hardness and the highest hardness of the material along the depth distribution of the end quenching, the lowest hardness and the highest hardness and the hardness gradient distribution curve of the dangerous section of the structure are determined.
优选地，步骤5中，进行所述轻量化定量评价时，若任意一点的实际静强度与该点的最高应力之比值小于安全系数，静强度不够，静强度设计不合理，增加强度；任意一点的实际静强度与该点的最高应力之比值大于安全系数，强度富余，该值越大，轻量化程度越低。Preferably, in step 5, when the lightweight quantitative evaluation is performed, if the ratio of the actual static strength at any point to the highest stress at that point is less than the safety factor, the static strength is insufficient, the static strength design is unreasonable, and the strength is increased; The ratio of the actual static strength to the highest stress at this point is greater than the safety factor, and the strength is surplus. The larger the value, the lower the weight reduction.
本发明相比于现有的轻量化评价方法，可对全场任意一点进行定量的轻量化 评价，从而通过工艺和材料的改进，进一步提高材料利用率，发挥轻量化潜能。Compared with the existing lightweight evaluation method, the present invention can perform quantitative lightweight evaluation at any point in the entire field, thereby further improving the material utilization rate and exerting the lightweight potential through the improvement of process and materials.
图1为实心轴尺寸图，图1中，Φ1＝28.5mm，Φ2＝27mm，Φ3＝29.2mm，Φ4＝30.5mm，Φ5＝26.6mm，Φ6＝27.1mm，L＝468mm；Figure 1 is the size of the solid shaft. In Figure 1, Φ1=28.5mm, Φ2=27mm, 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；Figure 2 is a flow chart of the implementation of the present invention;
图3为危险截面的应力分布；Figure 3 shows the stress distribution of the dangerous section;
图4为扭转应力和理想强度分布；Figure 4 shows the torsional stress and ideal strength distribution;
图5为38B3材料的端淬曲线；Figure 5 shows the end quenching curve of 38B3 material;
图6为38B3实心轴实际强度分布；Figure 6 shows the actual strength distribution of the 38B3 solid shaft;
图7为全场轻量化定量评价。Figure 7 shows the overall lightweight quantitative evaluation.
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。The present invention will be further explained below in conjunction with the drawings. It should be understood that these embodiments are only used to illustrate the present invention and not to limit the scope of the present invention. In addition, it should be understood that after reading the teachings of the present invention, those skilled in the art can make various changes or modifications to the present invention, and these equivalent forms also fall within the scope defined by the appended claims of the present application.
以实心轴在扭转载荷下的扭转为例来进一步说明本发明，轴的材料为38B3钢，热处理为表面中频淬火，表面硬度为57-62HRC，硬度为500HV的淬硬层深度为4.8-8mm，芯部硬度≤30HRC，实心轴的尺寸如图1所示。Taking the torsion of a solid shaft under a torsional load as an example to further illustrate the present invention, the shaft material is 38B3 steel, the heat treatment is surface intermediate frequency quenching, the surface hardness is 57-62HRC, and the depth of the hardened layer with a hardness of 500HV is 4.8-8mm. The core hardness is less than or equal to 30HRC, and the size of the solid shaft is shown in Figure 1.
如图2所示，本发明提供的一种基于静强度的结构全场轻量化定量评价方法包括以下步骤：As shown in Figure 2, the invention provides a static strength-based quantitative assessment method for full-field lightweight structure including the following steps:
1)确定极限静载荷下结构危险位置的最高静应力及其梯度分布1) Determine the highest static stress and its gradient distribution at the dangerous position of the structure under ultimate static load
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静应力的梯度方向应力分布，在简单载荷下，最高静应力及静应力的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。Under the most dangerous limit static load that may occur during the use of the structure, apply material mechanics or finite element methods to calculate the highest static stress at the dangerous section of the structure and the gradient direction stress distribution of the static stress. Under simple load, the highest static stress The stress distribution in the gradient direction of the static stress is the highest surface stress at the dangerous section of the structure and the stress distribution along the depth.
对于本实施例，最危险的极限静载纯扭转载荷为4500Nm，应用材料力学，对于本实施例危险截面在扭转模量最小(即直径最小)的外表面直径27mm处，最高应力τ
max计算如式(1)所示：
For this embodiment, the most dangerous ultimate static load pure torsional load is 4500Nm. Using material mechanics, for this embodiment, the dangerous section is at the smallest torsional modulus (that is, the smallest diameter) outer surface diameter is 27mm, and the highest stress τ max is calculated as Formula (1) shows:
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。
In formula (1), T is the torque, in Nm; W t is the torsion section coefficient, in m 3 .
最高静应力最大梯度方向是危险截面的外表面指向轴心，危险截面上任一点的应力计算如式(2)所示：The direction of the maximum gradient of the highest static stress is that the outer surface of the dangerous section points to the axis, and the stress calculation at any point on the dangerous section is shown in equation (2):
式中，τ
y为横截面上距轴心的距离为y的一点的应力；Ty T为横截面上距轴心的距离为y的一点的扭矩，单位为Nm；I
p为截面极惯性矩，单位为m
4。
In the formula, τ y is the stress at a point on the cross section at a distance y from the axis; Ty T is the torque at a point on the cross section at a distance of y from the axis, in Nm; I p is the polar moment of inertia of the section , The unit is m 4 .
本实施例计算得到的危险截面应力梯度分布如图3所示。The stress gradient distribution of the dangerous section calculated in this embodiment is shown in FIG. 3.
2)根据结构最高静应力及其梯度分布，进行危险截面的理想静强度场分布设计2) According to the highest static stress of the structure and its gradient distribution, design the ideal static strength field distribution of the dangerous section
根据结构使用过程中极限静载荷下的最高静应力及其梯度方向分布，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，且任一点的静强度与该点的应力之比为常数，该数为安全系数。结构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。According to the highest static stress and its gradient direction distribution under the ultimate static load during the use of the structure, the ideal static strength field distribution of the structure can be determined. The ideal strength field is proportional to the highest 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, and the ratio of the static strength at any point to the stress at that point is a constant, which is the safety factor. The ideal static strength distribution on the dangerous section of the structure, there is no excess strength, and the strength utilization rate reaches the maximum.
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，整体强度下的理想扭转强度场分布如图4所示，图4中同时给出了极限应力分布。In this embodiment, 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. Related. In this example, the safety factor of the static strength design is 1.2. The ideal torsional strength field distribution under the overall strength is shown in Figure 4, and the ultimate stress distribution is also given in Figure 4.
3)根据结构热处理要求和材料的端淬曲线，确定结构危险截面的硬度及其梯度分布3) Determine the hardness and its gradient distribution of the dangerous section of the structure according to the heat treatment requirements of the structure and the end quenching curve of the material
根据结构热处理要求中的热处理形式和给定的表面硬度、淬硬层深度、芯部硬度等单个硬度参数，结合材料的端淬最低和最高硬度沿深度分布的曲线，可以确定结构危险截面的最低和最高硬度及其梯度分布曲线。According to the heat treatment form in the structural heat treatment requirements and the given surface hardness, hardened layer depth, core hardness and other individual hardness parameters, combined with the curve of the lowest and highest hardness of the material along the depth distribution, the lowest dangerous section of the structure can be determined And the highest hardness and its gradient distribution curve.
在本实施例中，实心轴的材料为38B3钢，热处理为表面中频淬火，表面硬 度为57-62HRC，硬度为500HV的淬硬层深度为4.8-8mm，芯部硬度≤30HRC。根据38B3钢的端淬最低和最高沿深度分布的曲线，确定结构危险截面的最低和最高硬度及其梯度分布如图5所示。In this embodiment, the material of the solid shaft is 38B3 steel, the heat treatment is surface medium frequency quenching, the surface hardness is 57-62HRC, the depth of the hardened layer with a hardness of 500HV is 4.8-8mm, and the core hardness ≤ 30HRC. According to the curve of the lowest and highest end quenching distribution along the depth of 38B3 steel, the lowest and highest hardness of the dangerous section of the structure and its gradient distribution are shown in Figure 5.
4)根据硬度-静强度转换关系，确定结构危险截面的实际静强度及其梯度分布4) According to the hardness-static strength conversion relationship, determine the actual static strength and its gradient distribution of the dangerous section of the structure
根据黑色或有色金属的硬度-静强度对应转换关系或试验得到的硬度-静强度对应关系，把结构危险截面的最低和最高硬度及其梯度分布曲线转化为结构危险截面的最低和最高实际静强度及其梯度分布曲线。According to the hardness-static strength correspondence conversion relationship of ferrous or non-ferrous metals or the hardness-static strength correspondence relationship obtained by the test, the lowest and highest hardness of the dangerous section of the structure and its gradient distribution curve are converted into the lowest and highest actual static strength of the dangerous section of the structure And its gradient distribution curve.
根据38B3钢的硬度分布曲线，应用强度-硬度转换关系以及第三强度理论，可以得到本例结构的扭转强度分布，任意点扭转强度计算如式(3)所示：According to the hardness distribution curve of 38B3 steel, applying the strength-hardness conversion relationship and the third strength theory, the torsional strength distribution of the structure of this example can be obtained. The torsional strength calculation at any point is shown in formula (3):
式(3)中，τ为结构任一点的扭转强度，单位为MPa；H
d为结构任一点的硬度，单位为HRC。
In formula (3), τ is the torsional strength at any point of the structure, in MPa; H d is the hardness at any point in the structure, in HRC.
由式(3)得到的本例结构的实际扭转强度分布如图6所示。The actual torsional strength distribution of the structure of this example obtained from equation (3) is shown in Figure 6.
5)应用应力-强度干涉模型，进行结构危险截面的全场轻量化水平定量评价5) Apply the stress-strength interference model to quantitatively evaluate the overall lightweight level of structural dangerous sections
应用全场应力-强度干涉模型即强度设计保证任一点的强度大于等于该点的极限应力，通过结构危险位置处的实际静强度场分布和极限静应力分布，进行结构危险位置处全场轻量化定量评价——表面及其深度分布的轻量化定量评价，即任意一点的实际静强度和该点的最高应力之比。任意一点的实际强度与该点的应力之比值小于安全系数，静强度不够，静强度设计不合理，需要增加强度；任意一点的实际强度与该点的应力之比值大于安全系数，强度富余，该值越大，轻量化程度越低。The full-field stress-strength interference model is applied to ensure that the strength of any point is greater than or equal to the ultimate stress of the point. Through the actual static strength field distribution and the ultimate static stress distribution at the dangerous position of the structure, the overall weight of the dangerous position of the structure is reduced. Quantitative evaluation-lightweight quantitative evaluation of the surface and its depth distribution, that is, the ratio of the actual static strength at any point to the highest stress at that point. The ratio of the actual strength at any point to the stress at that point is less than the safety factor, the static strength is not enough, the static strength design is unreasonable, and the strength needs to be increased; the ratio of the actual strength at any point to the stress at that point is greater than the safety factor, and the strength is surplus. The larger the value, the lower the degree of lightweight.
在本实施例中，全场应力-强度干涉模型是指任一点的强度大于应力，把本例的应力分布和实际强度分布在同一坐标下表示，如图7所示：从图中可以看出，实际最低扭转强度、扭转应力、理想扭转强度间的相互关系，即任意一点实际扭转强度与实际扭转应力、理想扭转强度的关系，通过任意一点的实际扭转强度与该点的实际应力之比，可以评价该点的轻量化水平。本例中以表面、次表面淬硬转折点4.8mm、内部热处理转折点8mm、中心点等四点进行评价：In this embodiment, the full-field stress-intensity interference model means that the intensity at any point is greater than the stress, and the stress distribution and actual intensity distribution in this example are represented under the same coordinates, as shown in Figure 7: , The relationship between actual minimum torsional strength, torsional stress, and ideal torsional strength, that is, the relationship between actual torsional strength and actual torsional stress and ideal torsional strength at any point, through the ratio of actual torsional strength at any point to the actual stress at that point, The level of weight reduction at this point can be evaluated. In this example, four points, including the surface and subsurface hardening turning point 4.8mm, the internal heat treatment turning point 8mm, and the center point, are used for evaluation:
表面实际扭转静强度为1631MPa、设计理想静强度为1393MPa、扭转应力 为1161MPa，则实际扭转静强度与扭转应力之比为1.41；大于设计安全系数1.2，超过安全系数0.21，具有一定的轻量化潜能。The actual torsional static strength of the surface is 1631MPa, the design ideal static strength is 1393MPa, and the torsional stress is 1161MPa, then the ratio of the actual torsional static strength to the torsional stress is 1.41; greater than the design safety factor of 1.2, exceeding the safety factor of 0.21, it has a certain potential for lightweighting .
次表面淬硬转折点4.8mm实际扭转静强度为1474MPa、设计理想静强度为1092MPa、扭转应力为910MPa，则实际扭转静强度与扭转应力之比为1.61；大于设计安全系数1.2，超过安全系数0.41，轻量化潜能更大，可通过减少硬化层深度进行强度轻量化设计，发挥轻量化潜能。The actual torsional static strength of 4.8mm subsurface hardening turning point is 1474MPa, the design ideal static strength is 1092MPa, and the torsional stress is 910MPa. The ratio of the actual torsional static strength to the torsional stress is 1.61; greater than the design safety factor of 1.2, exceeding the safety factor of 0.41, The light weight potential is greater, and the strength and weight reduction design can be carried out by reducing the depth of the hardened layer to realize the light weight potential.
内部热处理转折点8mm实际扭转强度为783MPa、设计理想静强度为534MPa、扭转应力为445MPa，则实际扭转静强度与扭转应力之比为1.75；大于设计安全系数1.2，超过安全系数0.55，该点由材料热处理特性确定，可通过淬硬层深度进行强度轻量化设计，发挥轻量化潜能。The internal heat treatment turning point 8mm, the actual torsional strength is 783MPa, the design ideal static strength is 534MPa, and the torsional stress is 445MPa, then the ratio of the actual torsional static strength to the torsional stress is 1.75; greater than the design safety factor of 1.2, exceeding the safety factor of 0.55, this point is determined by the material The heat treatment characteristics are determined, and the strength and weight reduction design can be carried out through the depth of the hardened layer to realize the light weight potential.
中心点实际扭转强度为702MPa、设计理想静强度和扭转应力都为0，该点的静强度过剩无穷，工艺条件允许的话可以通过使用空心结构减少芯部扭转静强度过剩。The actual torsional strength of the center point is 702MPa, the design ideal static strength and torsional stress are both 0, and the static strength at this point is infinitely excessive. If the process conditions permit, the excessive torsional static strength of the core can be reduced by using a hollow structure.
对于本实施例中，随着极限静载荷增加，静应力分布曲线和实际最低扭转静强度分布曲线首先在表面相交，表面的静强度相对其静载荷最危险，以表面的理想静强度和实际静强度作为全场轻量化水平定量评价，次表面和芯部由材料和材料的热处理特性确定。本例的理想静强度设计要求为1396MPa，相当于静扭转载荷4500Nm；但实际静强度可达1631MPa，相当于静扭转载荷5257Nm，因此，表面静强度过剩235MPa，过剩21％，具有一定的轻量化潜能。For this embodiment, as the ultimate static load increases, the static stress distribution curve and the actual minimum torsional static strength distribution curve first intersect on the surface. The static strength of the surface is the most dangerous relative to its static load. The strength is quantitatively evaluated as the overall lightweight level, and the subsurface and core are determined by the material and its heat treatment characteristics. The ideal static strength design requirement of this example is 1396MPa, which is equivalent to a static torsional load of 4500Nm; but the actual static strength can reach 1631MPa, which is equivalent to a static torsional load of 5257Nm. Therefore, the surface static strength is surplus of 235MPa, which is 21% surplus, which has a certain potential for lightweighting.
Claims (6)
- 一种基于静强度的结构全场轻量化定量评价方法，其特征在于，使用结构静强度场与结构应力场进行匹配，进行结构全场轻量化定量评价，包括以下步骤：A static strength-based quantitative evaluation method for full-field structural lightweighting, which is characterized by matching the structural static strength field with the structural stress field to perform the full-field lightweight quantitative evaluation of the structure, including the following steps:步骤1、确定拟进行全场轻量化定量评价的结构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的梯度方向应力分布；Step 1. Determine the most dangerous ultimate static load that may occur during the use of the structure that is to be subjected to full-field lightweight quantitative evaluation, and obtain the highest static stress at the dangerous section of the structure and the gradient direction stress distribution of the static stress under the ultimate static load ；步骤2、根据结构危险截面处的最高静应力及静应力的梯度方向应力分布，进行危险截面的理想静强度场分布设计，使得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应力乘以安全系数；Step 2. According to the highest static stress at the dangerous section of the structure and the gradient direction stress distribution of the static stress, carry out the ideal static strength field distribution design of the dangerous section, so that the static strength of any point on the dangerous section of the structure is greater than the stress at that point. According to the theory of stress-strength interference, the ideal strength of any point of the dangerous section of the mechanical structure and parts is designed as the stress at that point multiplied by the safety factor;步骤3、根据结构热处理要求和材料的端淬曲线，确定结构危险截面的最低硬度和最高硬度以及硬度的梯度分布；Step 3. Determine the lowest and highest hardness of the dangerous section of the structure and the gradient distribution of the hardness according to the structural heat treatment requirements and the end quenching curve of the material;步骤4、根据硬度-静强度转换关系，确定结构危险截面的最低实际静强度和最高实际静强度以及实际静强度的梯度分布；Step 4. According to the hardness-static strength conversion relationship, determine the lowest actual static strength and the highest actual static strength of the dangerous section of the structure and the gradient distribution of the actual static strength;步骤5、应用应力-强度干涉模型保证任一点的强度大于等于该点的极限应力，通过结构危险位置处的实际静强度的梯度分布和极限静应力分布，进行结构危险位置处全场轻量化定量评价——表面及其深度分布的轻量化定量评价，即任意一点的实际静强度和该点的最高应力之比。Step 5. Apply the stress-strength interference model to ensure that the strength of any point is greater than or equal to the ultimate stress of the point. Through the gradient distribution of the actual static strength and the ultimate static stress distribution at the dangerous position of the structure, the whole site at the dangerous position of the structure is lightweight and quantified Evaluation-Lightweight quantitative evaluation of the surface and its depth distribution, that is, the ratio of the actual static strength at any point to the highest stress at that point.
- 如权利要求1所述的一种基于静强度的结构全场轻量化定量评价方法，其特征在于，步骤1中，采用材料力学或有限元方法计算得到所述最高静应力及所述梯度方向应力分布。The method of claim 1, wherein the static strength-based full-field lightweight quantitative evaluation method of the structure is characterized in that, in step 1, the highest static stress and the gradient direction stress are calculated by using material mechanics or finite element methods. distributed.
- 如权利要求1所述的一种基于静强度的结构全场轻量化定量评价方法，其特征在于，步骤1中，所述最高静应力为结构危险截面处的表面最高应力；所述梯度方向应力分布为结构危险截面处的表面应力沿深度的分布。The method of claim 1, wherein the static strength-based full-field lightweight quantitative evaluation method for structures is characterized in that, in step 1, the highest static stress is the highest surface stress at the dangerous section of the structure; the gradient direction stress The distribution is the distribution of the surface stress along the depth of the dangerous section of the structure.
- 如权利要求1所述的一种基于静强度的结构全场轻量化定量评价方法，其特征在于，步骤2中，进行危险截面的理想静强度场分布设计时，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的梯度方向应力分布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静应力的梯度方向应力分布成比例放大，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应力乘以安全系数，且结构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。As claimed in claim 1, a static strength-based full-field lightweight quantitative evaluation method for structures, characterized in that, in step 2, when designing the ideal static strength field distribution of the dangerous section, according to the ultimate static load during the use of the structure The maximum static stress and the gradient direction stress distribution of the static stress determine the ideal static strength field distribution of the structure. The ideal strength field is proportional to the maximum static stress and the gradient direction stress distribution of the static stress. According to the stress-strength interference theory, the mechanical structure The ideal strength design for any point of the dangerous section of the component is the stress at that point multiplied by the safety factor, and the ideal static strength distribution on the dangerous section of the structure, there is no excess strength, and the strength utilization rate reaches the maximum.
- 如权利要求1所述的一种基于静强度的结构全场轻量化定量评价方法，其特征在于，所述步骤3包括以下步骤：According to claim 1, a static strength-based quantitative evaluation method for full-field structural lightweighting, wherein said step 3 comprises the following steps:根据结构热处理要求中的热处理形式和给定的硬度参数，结合材料的端淬最低硬度和最高硬度沿深度分布的曲线，确定结构危险截面的最低硬度和最高硬度及硬度梯度分布曲线。According to the heat treatment form in the structural heat treatment requirements and the given hardness parameters, combined with the curve of the lowest hardness and the highest hardness of the material along the depth distribution of the end quenching, the lowest hardness and the highest hardness and the hardness gradient distribution curve of the dangerous section of the structure are determined.
- 如权利要求1所述的一种基于静强度的结构全场轻量化定量评价方法，其特征在于，步骤5中，进行所述轻量化定量评价时，若任意一点的实际静强度与该点的最高应力之比值小于安全系数，静强度不够，静强度设计不合理，增加强度；任意一点的实际静强度与该点的最高应力之比值大于安全系数，强度富余，该值越大，轻量化程度越低。As claimed in claim 1, a static strength-based full-field structural lightweight quantitative evaluation method, wherein in step 5, when the lightweight quantitative evaluation is performed, if the actual static strength at any point is The ratio of the highest stress is less than the safety factor, the static strength is not enough, the static strength design is unreasonable, increase the strength; the ratio of the actual static strength at any point to the highest stress at that point is greater than the safety factor, the strength is surplus, the greater the value, the lighter The lower.
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| JP2017140653A (en) * | 2016-02-05 | 2017-08-17 | 新日鐵住金株式会社 | Moldability evaluation method, program and recording medium |
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| DE10105994A1 (en) * | 2001-02-09 | 2002-09-05 | Ettemeyer Ag | Method for optimizing the correctness of theoretical predictions of the deformation of a workpiece used in strength and stress calculations associated with the design and testing of new parts for mass production |
| CN103711804A (en) * | 2014-01-02 | 2014-04-09 | 上海理工大学 | High-bending inherent frequency guiding-type rotary swaging shaft lightweight design method |
| JP2017140653A (en) * | 2016-02-05 | 2017-08-17 | 新日鐵住金株式会社 | Moldability evaluation method, program and recording medium |
| CN107885961A (en) * | 2017-12-08 | 2018-04-06 | 徐工集团工程机械有限公司 | Machine Components Strength evaluation method |
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