喷砂强化对铝合金薄壁框架件形状的影响及应用
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摘要
铝合金薄壁框架件铣削加工后会有不同程度的变形,表面喷砂强化既可以提高构件的机械性能,也可以对铣削加工后构件的变形进行矫正,这对构件的变形控制和形状稳定性都具有积极作用.本文针对薄壁件形状特点(壁厚2 mm),分别对构件底部和薄壁进行喷砂处理,并通过X-ray表面应力测试、表面硬度和变形测试,对喷砂后构件的变形状况进行分析.研究发现,改变喷砂粒度、空气压力和表面全喷覆次数,对材料表面应力进行调节,可使铣削加工后构件的变形得以调整,一定条件下,其变形矫直率达85%以上.分析认为,薄壁件形状特点与初始内应力水平使得表面应力在薄壁框架件变形中发挥了主要作用.因而,可以在不同位置采用差异化喷砂工艺,对材料表面应力分布进行针对性调节,使喷砂件的形变达到预期要求,最终通过喷砂表面强化实现对薄壁构件变形的调控.
It is known that deformation always occurs after milling processing for the Al-based thin-walled components. Shot peening(SP) can not only improve the mechanical properties of components, but also makes this deformation recover, which plays a positive role in the deformation control and shape stability of components. In this study, based on the shape character with 2 mm wall, the deformation of components is investigated by X-ray stress determination, surface hardness and shape measurement experiments via SP treatment on bottom and wall. It is found that altering the particles size, air pressure and 100% coverage time can regulate the surface stress, which can adjust the deformation of milling component straighten to 85%. The conclusions show that the shape character and initial stress level determines the surface stress, which plays a key role in the component deformation. SP treatment can be used on different places of the component to adjust the surface stress distribution, which makes the recovery of deformation to get the expected goal and achieves the control of recovery.
It is known that deformation always occurs after milling processing for the Al-based thin-walled components. Shot peening(SP) can not only improve the mechanical properties of components, but also makes this deformation recover, which plays a positive role in the deformation control and shape stability of components. In this study, based on the shape character with 2 mm wall, the deformation of components is investigated by X-ray stress determination, surface hardness and shape measurement experiments via SP treatment on bottom and wall. It is found that altering the particles size, air pressure and 100% coverage time can regulate the surface stress, which can adjust the deformation of milling component straighten to 85%. The conclusions show that the shape character and initial stress level determines the surface stress, which plays a key role in the component deformation. SP treatment can be used on different places of the component to adjust the surface stress distribution, which makes the recovery of deformation to get the expected goal and achieves the control of recovery.
引文
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[16] 张庆阳.6061铝合金高速铣削过程温度场及残余应力场研究[D].上海:上海交通大学,2014.ZHANG Qingyang.High-speed milling temperature and residual stress distribution study of 6061 aluminiumalloy[D].Shanghai:Shanghai Jiaotong University,2014.
[17] 唐志涛,刘战强,艾兴.高速铣削加工铝合金表面残余应力研究[J].中国机械工程,2008,19(6):699-703.TANG Zhitao,LIU Zhanqiang,AI Xing.Experrimentationon the superficial residual stresses generated by high-speed milling aluminum alloy[J].China Mechanical Engineering,2008,19(6):699-703.
[18] LIB,JIANG X,YANG J,et al.Effects of depth of cut on the redistribution of residual stress anddistortion during the milling of thin-walled part[J].Journal of Materials Processing Technology,2015,216:223-233.DOI:10.1016/j.jmatprotec.2014.09.016
[19] YOUNG K A.Machining induced residual stress and distortion of thin parts[D].Seattle:Washington University,2005.
[20] 王晓燕,吴运新,龚海,等.铣削加工对铝合金薄壁件残余应力的影响[J].热加工工艺,2012,41(10):10-13.WANG Xiaoyan,WU Yunxin,GONG Hai,et al.Influence of milling on residual stress of aluminum alloy thin-walled package[J].Material & Heat Treatment,2012,41(10):10-13.DOI:10.14158/j.cnki.1001-3814.2012.10.014
[21] 王强,张炜,乔明杰.喷丸处理对高强度7150铝合金弯曲形变的影响[J].材料工程,2013,3(12):59-62.WANG Qiang,ZHANG Wei,QIAO Mingjie.Effect of shot peening on bending deformation of high strength 7150 aluminum alloy[J].Journal of Materials Engineering,2013,3(12):59-62.DOI:10.3969/jssn.1001-4381.2013.12.011
[22] HB/Z 26-2011,航空零件喷丸强化工艺[S].北京:国家国防科技工业局,2011.
[23] REDDY T R,THYAGARAJAN K,MONTERO O A,et al.X-ray diffraction,electron paramagnetic resonance and optical absorption study of bauxite[J].Journal of Minerals & Materials Characterization & Engineering,2014,02(2):114-120.DOI:10.4236/jmmce.2014.22015
[2] LV Y,LEI L,SUN L.Influence of different combined severe shot peening and laser surface melting treatments on the fatigue performance of 20CrMnTi steel gear[J].Materials Science & Engineering A,2016,658:77-85.DOI:10.1016/j.msea.2016.01.050
[3] ZHANG X H,LIU D X.Effect of shot peening on fretting fatigue of Ti811 alloy at elevated temperature[J].International Journal of Fatigue,2009,31(5):899-893.DOI:10.1016/j.ijfatigue.2008.10.004
[4] 叶作彦.新型铝合金的腐蚀行为及表面改性的影响[D].西安:西北工业大学,2015.YE Zuoyan.Corrosion behavior of new aluminnum alloy and the effect of surface modification[D].Xian:Northwestern Polytechnical University,2015.
[5] MIAO H Y,DEMERS D,LAROSE S,et al.Experimental study of shot peening and stress peen forming[J].Journal of Materials Processing Technology,2010,210(15):2089-2102.DOI:10.1016/j.jmatprotec.2010.07.016
[6] 阴晓宁.TC4钛合金喷丸强化表面完整性研究[D].大连:大连理工大学,2015.YIN Xiaoning.Surface integrity study on shot peened Ti-6Al-4V titanium alloy[D].Dalian:Dalian University of Technology,2015.
[7] 汝继刚,李超,王亮,等.喷丸强化对7A12铝合金微观组织和疲劳性能的影响[J].航空材料学报,2013,33(6):51-56.RU Jigang,LI Chao,WANG Liang,et al.Effect of shot peening on microstructure and fatigue life of 7A12 aluminum[J].Journal of Aeronautical Materials,2013,33(6):51-56.DOI:10.3969/j.issn.1005-5053.2013.6.009
[8] ZANINIA.Optimizing roughness and residual stresses through controlled shot peening and isotropic finishing of surfaces[J].Contact & Surface,2013,65(3):279-286.DOI:10.2495/SECM130241
[9] 张峥.飞机弱刚性铝合金结构件的残余应力和加工变形控制技术研究[D].南京:南京航空航天大学,2016.ZHANG Zheng.Research on residual stress and machining distortion of aeronautic weak rigidity in aluminum structure[D].Nanjing:Nanjing University of Aeronautics and Astronautics,2016.
[10] 于春涛.航空薄壁构件加工变形研究[D].上海:上海交通大学,2014.YU Chuntao.Reaserch on deformation method of aerospace thin-walled structures[D].Shanghai:Shanghai Jiaotong University,2014.
[11] HUANG X,SUN J,LI J.Finite element simulation and experimental investigation on the residual stress related monolithic component deformation [J].The International Journal of Advanced Manufacturing Technology,2015,77(5):1035-1041.DOI:10.1007/s00170-014-6533-9
[12] 袁望姣,吴运新.基于预拉伸工艺的铝合金厚板残余应力消除机理[J].中南大学学报(自然科学版),2011,42(8):2303-2308.YUAN Wangjiao,WU Yunxin.Mechanics about eliminating residual stress of aluminum alloy thicken-plates based on pre-stretching technology[J].Journal of Central South University (Science and Technology),2011,42(8):2303-2308.
[13] 李名扬,张朋朋,郑骥,等.振动时效在大型铝合金薄壁环中的应用[J].金属热处理,2015,40(6):145-148.LI Mingyang,ZHANG Pengpeng,ZHENG Ji,et al.Application of vibration stress relief for large thin-walled aluminum ring[J].Heat Treatment of Metals,2015,40(6):145-148.DOI:10.13251/j.Issn.0254-6051.2015.06.033
[14] 王民,刘宇男,孙国智,等.初始残余应力和切削残余应力对薄壁件加工变形的影响[J].北京工业大学学报,2017,43(7):55-61.WANG Min,LIU Yunan,SUN Guozhi,et al.Influence of initial residual stress and cutting stress on machining deformation of thin-walled parts[J].Jounal of Beijing University of Technology,2017,43(7):55-61.DOI:10.11936/bjutxb2016040066
[15] 魏慧.2A14铝合金薄壁件高速铣削参数优化研究[D].哈尔滨:哈尔滨工业大学,2016.WEI Hui.Optimization of high speed milling parameters for 2A14 aluminum alloy thin-walled component[D].Harbin:Harbin Institute of Technology,2016.
[16] 张庆阳.6061铝合金高速铣削过程温度场及残余应力场研究[D].上海:上海交通大学,2014.ZHANG Qingyang.High-speed milling temperature and residual stress distribution study of 6061 aluminiumalloy[D].Shanghai:Shanghai Jiaotong University,2014.
[17] 唐志涛,刘战强,艾兴.高速铣削加工铝合金表面残余应力研究[J].中国机械工程,2008,19(6):699-703.TANG Zhitao,LIU Zhanqiang,AI Xing.Experrimentationon the superficial residual stresses generated by high-speed milling aluminum alloy[J].China Mechanical Engineering,2008,19(6):699-703.
[18] LIB,JIANG X,YANG J,et al.Effects of depth of cut on the redistribution of residual stress anddistortion during the milling of thin-walled part[J].Journal of Materials Processing Technology,2015,216:223-233.DOI:10.1016/j.jmatprotec.2014.09.016
[19] YOUNG K A.Machining induced residual stress and distortion of thin parts[D].Seattle:Washington University,2005.
[20] 王晓燕,吴运新,龚海,等.铣削加工对铝合金薄壁件残余应力的影响[J].热加工工艺,2012,41(10):10-13.WANG Xiaoyan,WU Yunxin,GONG Hai,et al.Influence of milling on residual stress of aluminum alloy thin-walled package[J].Material & Heat Treatment,2012,41(10):10-13.DOI:10.14158/j.cnki.1001-3814.2012.10.014
[21] 王强,张炜,乔明杰.喷丸处理对高强度7150铝合金弯曲形变的影响[J].材料工程,2013,3(12):59-62.WANG Qiang,ZHANG Wei,QIAO Mingjie.Effect of shot peening on bending deformation of high strength 7150 aluminum alloy[J].Journal of Materials Engineering,2013,3(12):59-62.DOI:10.3969/jssn.1001-4381.2013.12.011
[22] HB/Z 26-2011,航空零件喷丸强化工艺[S].北京:国家国防科技工业局,2011.
[23] REDDY T R,THYAGARAJAN K,MONTERO O A,et al.X-ray diffraction,electron paramagnetic resonance and optical absorption study of bauxite[J].Journal of Minerals & Materials Characterization & Engineering,2014,02(2):114-120.DOI:10.4236/jmmce.2014.22015