金属蜂窝夹芯结构的疲劳行为研究
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摘要
蜂窝夹芯结构具有轻质高强和可设计性强等优点,是航空航天、船舶、汽车、建筑等领域不可缺少的材料之一。在实际工程应用中,经常面临循环载荷作用,并且蜂窝夹芯结构力学性能极易受到载荷、环境等因素的影响。为了探索钎焊金属蜂窝夹芯结构的力学行为,尤其是疲劳行为,揭示结构破坏模式,对结构性能进行宏观预测和评价,论文主要开展了以下研究工作：
对两种金属蜂窝夹芯结构系统开展了侧向拉伸、平压、三点弯曲、四点弯曲、SHPB冲击压缩性能实验研究工作,考虑试件几何尺寸、芯子排列方向、实验温度等条件对结构宏观性能的影响,借助数码相机和光学体式显微镜,对结构在不同实验条件下的失效模式和机理进行了详细的探讨。
利用四点弯曲装置,分别研究了结构完整的钢质蜂窝夹芯试件和带有初始芯面脱焊缺陷的试件在室温下的疲劳行为,得到反映疲劳寿命的S-N曲线和疲劳强度极限,并讨论了不同缺陷尺寸对疲劳寿命的影响。系统地研究了钢质蜂窝夹芯结构的高温三点弯曲、四点弯曲疲劳行为。在试件的三点弯曲疲劳实验研究中,通过改变环境温度(200,300,400℃)来近似模拟实际工程中可能出现的高温、热力耦合的情况,得到各温度下循环次数与载荷水平的关系,并讨论了芯子排列方向对疲劳强度的影响；在四点弯曲疲劳实验研究中,重点开展了300℃下蜂窝夹芯结构疲劳寿命研究。分析了以上加载条件下蜂窝夹芯结构疲劳失效的主要模式。
论文提出了以下几种蜂窝夹芯结构疲劳寿命预测方法。即：直接S-N曲线方法、刚度退化方法、强度折减方法,系统地建立了蜂窝夹芯结构的弯曲疲劳模型。建立了基于刚度退化的钢质蜂窝夹芯结构弯曲疲劳模型,与实验结果进行比较；对模型进行修正,使其适合预测结构高温弯曲疲劳行为。考虑芯子不同排列方向,推导得出两个非线性累计损伤模型,并与Miner损伤准则进行比较。基于强度折减法,分别针对完好试件和局部缺陷试件的弯曲疲劳实验结果,对Burman公式的适用性展开讨论,并在此基础上提出修正模型,合理地预测了室温弯曲疲劳寿命。
论文最后借助三种无损检测技术对蜂窝夹芯结构的宏观性能进行评价。采用激光剪切散斑技术进行层合板表面及内部缺陷无损检测,探讨了错位量、缺陷尺寸、深度等因素对检测结果的影响,并利用该技术完成了蜂窝夹芯结构芯面脱焊的检测,利用像素标定技术,得到缺陷尺寸信息。编制了均值、中值、小波滤波等时域空域图像处理程序,并对得到的缺陷条纹图进行优化分析。提出一种基于数字图像相关技术的蜂窝夹芯结构面内弹性模量测试方法,编制计算程序,并探讨了搜索模板尺寸及不同算法对结果的影响,与传统机测法结果比较证明了提出方法的正确性。采用声发射技术,借助三点弯曲试验,对含有初始缺陷的蜂窝夹芯试件进行破坏及损伤分析,建立了三种不同载荷工况下,AE特征参数随加载时间、位置等变化规律。这些参数可以反映结构的损伤和断裂过程,实验结果与分析结果一致性较好。
Due to advantages of light weight, high stiffness and strength ration, design flexibility, etc, honeycomb sandwich structures are attractive structural components and are therefore widely used in aerospace, shipbuilding, automobile, civil engineering and other areas. In practical engineering applications, generally honeycomb sandwich structures are designed to carry cyclic loading. Moreover, mechanical properties can be influenced by loading and service conditions. In order to explore the mechanical behaviors of brazed metal honeycomb sandwich structures, especially to investigate fatigue behavior and reveal different failure modes, also to evaluate the macro structural performance, some research works were carried out as following:
Mechanical properties of two kinds of metal honeycomb sandwich structures, such as lateral tension, flatwise compression, three-point bending, four-point bending, SHPB impact compression were experimental investigated in detail. The results show mechanical properties are sensitively influenced by geometries of specimen, different cell orientation, experiment temperatures and so on. With digital cameras and optical stereo microscope, different failure modes were analyzed and discussed in detail.
The fatigue behavior of honeycomb sandwich beams was experimentally investigated through four-point bending tests. Two kinds of specimens, initially undamaged and damaged by interface debonding, have been tested. The fatigue tests results were presented in standard SN diagrams and the fatigue limit was obtained. Meanwhile the influence of different debonding size on fatigue life was discussed. Fatigue behaviors of three-point bending and four-point bending at high temperature were investigated in detail. During the three-point bending fatigue experiments, by changing the service temperature (ranges from 200 to 400℃), high temperature, coupled thermal and mechanics limit conditions of actual engineering were simulated. Curves between number of cycles and load level were acquired. Also based on the above results, the effects of cell orientations on the fatigue strength were studied. In the four-point bending fatigue tests, the experimental temperature was focused on 300℃. Different failure modes of the above loading conditions were carried out.
Several fatigue life prediction methods were presented in this thesis. Namely:direct SN curve method, stiffness degradation method and strength reduction method. The results between experiments and established method based on stiffness degradation were contrasted. Meanwhile, appropriate corrected work on the stiffness model was finished in order that it can fit for life prediction of honeycomb structure under high temperature. Two non-linear cumulative damage models derived from the chosen stiffness degradation equations, were examined in context with the linear Miner's damage criterion and compared with available experimental results. For the strength reduction method, the effectiveness formula used by Burman was studied for undamaged specimens and damaged by interface debonding specimens. A corrected model was proposed to get a reasonable prediction of bending fatigue life for honeycomb sandwich specimens at room temperature.
Finally in this thesis, three non-destructive testing methods were employed to evaluate the macro performance of honeycomb sandwich structures. Surface and inner defects of laminated wood panel were detected by ESSPI. The influence of shearography size, defect geometry, depth and other factors on the detection results were analyzed. Debonding between face layer and honeycomb core and defect information were successfully accomplished by pixel and displacement calibration technique. Program with mean, median, wavelet domain spatial filtering functions was compiled and used to optimize the speckle patterns. Introduced a method based on digital image correlation to obtain the in-plane elastic modulus of honeycomb sandwich structure. Special calculation programs were compiled. Results acquired from different search template size and subpixel algorithms were contrasted and studied. Meanwhile compared results with the traditional machine measurement method proved the validity of the proposed method. Using acoustic emission technique, with the three-point bending test, the damage analysis of honeycomb sandwich with the initial defects was monitored. Variation rules of AE parameters with the load time, different location under three different load conditions were developed. These AE characteristic parameters indicated the damage and fracture process of the steel sandwich beam specimens. A good agreement was found between the experimental and analytical results.
对两种金属蜂窝夹芯结构系统开展了侧向拉伸、平压、三点弯曲、四点弯曲、SHPB冲击压缩性能实验研究工作,考虑试件几何尺寸、芯子排列方向、实验温度等条件对结构宏观性能的影响,借助数码相机和光学体式显微镜,对结构在不同实验条件下的失效模式和机理进行了详细的探讨。
利用四点弯曲装置,分别研究了结构完整的钢质蜂窝夹芯试件和带有初始芯面脱焊缺陷的试件在室温下的疲劳行为,得到反映疲劳寿命的S-N曲线和疲劳强度极限,并讨论了不同缺陷尺寸对疲劳寿命的影响。系统地研究了钢质蜂窝夹芯结构的高温三点弯曲、四点弯曲疲劳行为。在试件的三点弯曲疲劳实验研究中,通过改变环境温度(200,300,400℃)来近似模拟实际工程中可能出现的高温、热力耦合的情况,得到各温度下循环次数与载荷水平的关系,并讨论了芯子排列方向对疲劳强度的影响；在四点弯曲疲劳实验研究中,重点开展了300℃下蜂窝夹芯结构疲劳寿命研究。分析了以上加载条件下蜂窝夹芯结构疲劳失效的主要模式。
论文提出了以下几种蜂窝夹芯结构疲劳寿命预测方法。即：直接S-N曲线方法、刚度退化方法、强度折减方法,系统地建立了蜂窝夹芯结构的弯曲疲劳模型。建立了基于刚度退化的钢质蜂窝夹芯结构弯曲疲劳模型,与实验结果进行比较；对模型进行修正,使其适合预测结构高温弯曲疲劳行为。考虑芯子不同排列方向,推导得出两个非线性累计损伤模型,并与Miner损伤准则进行比较。基于强度折减法,分别针对完好试件和局部缺陷试件的弯曲疲劳实验结果,对Burman公式的适用性展开讨论,并在此基础上提出修正模型,合理地预测了室温弯曲疲劳寿命。
论文最后借助三种无损检测技术对蜂窝夹芯结构的宏观性能进行评价。采用激光剪切散斑技术进行层合板表面及内部缺陷无损检测,探讨了错位量、缺陷尺寸、深度等因素对检测结果的影响,并利用该技术完成了蜂窝夹芯结构芯面脱焊的检测,利用像素标定技术,得到缺陷尺寸信息。编制了均值、中值、小波滤波等时域空域图像处理程序,并对得到的缺陷条纹图进行优化分析。提出一种基于数字图像相关技术的蜂窝夹芯结构面内弹性模量测试方法,编制计算程序,并探讨了搜索模板尺寸及不同算法对结果的影响,与传统机测法结果比较证明了提出方法的正确性。采用声发射技术,借助三点弯曲试验,对含有初始缺陷的蜂窝夹芯试件进行破坏及损伤分析,建立了三种不同载荷工况下,AE特征参数随加载时间、位置等变化规律。这些参数可以反映结构的损伤和断裂过程,实验结果与分析结果一致性较好。
Due to advantages of light weight, high stiffness and strength ration, design flexibility, etc, honeycomb sandwich structures are attractive structural components and are therefore widely used in aerospace, shipbuilding, automobile, civil engineering and other areas. In practical engineering applications, generally honeycomb sandwich structures are designed to carry cyclic loading. Moreover, mechanical properties can be influenced by loading and service conditions. In order to explore the mechanical behaviors of brazed metal honeycomb sandwich structures, especially to investigate fatigue behavior and reveal different failure modes, also to evaluate the macro structural performance, some research works were carried out as following:
Mechanical properties of two kinds of metal honeycomb sandwich structures, such as lateral tension, flatwise compression, three-point bending, four-point bending, SHPB impact compression were experimental investigated in detail. The results show mechanical properties are sensitively influenced by geometries of specimen, different cell orientation, experiment temperatures and so on. With digital cameras and optical stereo microscope, different failure modes were analyzed and discussed in detail.
The fatigue behavior of honeycomb sandwich beams was experimentally investigated through four-point bending tests. Two kinds of specimens, initially undamaged and damaged by interface debonding, have been tested. The fatigue tests results were presented in standard SN diagrams and the fatigue limit was obtained. Meanwhile the influence of different debonding size on fatigue life was discussed. Fatigue behaviors of three-point bending and four-point bending at high temperature were investigated in detail. During the three-point bending fatigue experiments, by changing the service temperature (ranges from 200 to 400℃), high temperature, coupled thermal and mechanics limit conditions of actual engineering were simulated. Curves between number of cycles and load level were acquired. Also based on the above results, the effects of cell orientations on the fatigue strength were studied. In the four-point bending fatigue tests, the experimental temperature was focused on 300℃. Different failure modes of the above loading conditions were carried out.
Several fatigue life prediction methods were presented in this thesis. Namely:direct SN curve method, stiffness degradation method and strength reduction method. The results between experiments and established method based on stiffness degradation were contrasted. Meanwhile, appropriate corrected work on the stiffness model was finished in order that it can fit for life prediction of honeycomb structure under high temperature. Two non-linear cumulative damage models derived from the chosen stiffness degradation equations, were examined in context with the linear Miner's damage criterion and compared with available experimental results. For the strength reduction method, the effectiveness formula used by Burman was studied for undamaged specimens and damaged by interface debonding specimens. A corrected model was proposed to get a reasonable prediction of bending fatigue life for honeycomb sandwich specimens at room temperature.
Finally in this thesis, three non-destructive testing methods were employed to evaluate the macro performance of honeycomb sandwich structures. Surface and inner defects of laminated wood panel were detected by ESSPI. The influence of shearography size, defect geometry, depth and other factors on the detection results were analyzed. Debonding between face layer and honeycomb core and defect information were successfully accomplished by pixel and displacement calibration technique. Program with mean, median, wavelet domain spatial filtering functions was compiled and used to optimize the speckle patterns. Introduced a method based on digital image correlation to obtain the in-plane elastic modulus of honeycomb sandwich structure. Special calculation programs were compiled. Results acquired from different search template size and subpixel algorithms were contrasted and studied. Meanwhile compared results with the traditional machine measurement method proved the validity of the proposed method. Using acoustic emission technique, with the three-point bending test, the damage analysis of honeycomb sandwich with the initial defects was monitored. Variation rules of AE parameters with the load time, different location under three different load conditions were developed. These AE characteristic parameters indicated the damage and fracture process of the steel sandwich beam specimens. A good agreement was found between the experimental and analytical results.
引文
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