目的 针对A100钢材料,研究喷丸强化对其表面参数和疲劳性能的影响。方法 通过表面完整性测试,分析喷丸强化对其表面形貌、表面粗糙度、残余应力的影响。开展疲劳试验,观察疲劳断口形貌,分析喷丸强化对裂纹产生和扩展的影响。引入实测的粗糙度和残余应力数据,建立基于ABAQUS和FE-SAFE的疲劳仿真模型,对未喷丸和喷丸试件的疲劳寿命进行仿真计算,并与疲劳试验结果进行对比分析。结果 喷丸强化后,试件表面产生明显的塑性形变,表面粗糙度增大,形成了深度约175 µm的残余压应力层。未喷丸试件具有多个裂纹源,喷丸试件只有1个裂纹源。喷丸试件裂纹扩展区面积略大于未喷丸试件,表明其裂纹扩展时间更长。喷丸试件的疲劳条带更为细密,表明单位疲劳载荷下裂纹扩展的距离更小。喷丸试件瞬断区的韧窝更大更深,表明其塑性变形能力更强。疲劳试验与仿真结果表明,未喷丸和喷丸试件的疲劳危险部位均位于缺口根部,喷丸试件较未喷丸试件的试验和仿真平均疲劳寿命均有显著增加,其增幅分别为70.69%和70.01%。试验与仿真疲劳寿命平均误差为8.83%,仿真疲劳寿命与试验疲劳寿命吻合较好。结论 喷丸强化能够显著提高A100钢疲劳性能,可采用仿真模拟的方法对其疲劳寿命进行预测。
Abstract
The work aims to study the effect of shot peening on the surface parameters and fatigue properties of A100 steel material. The effect of shot peening on surface morphology, surface roughness, and residual stress was analyzed through surface integrity testing. The fatigue tests were conducted to observe the morphology of fatigue fracture surfaces, and analyze the effect of shot peening on crack generation and propagation. A fatigue simulation model based on ABAQUS and FE-SAFE was established by introducing measured roughness and residual stress data. The fatigue life of non shot peened and shot peened specimens was simulated and compared with the fatigue test results. After shot peening, obvious plastic deformation was generated on the specimen surface, the surface roughness increased, and a residual compressive stress layer with a depth of approximately 175 µm was formed. Multiple crack initiation sites were observed in the non shot peened specimen, whereas only one crack initiation site was found in the shot peened specimen. The area of the crack propagation region of the shot peened specimen was slightly larger than that of the non shot peened specimen, which indicated that a longer crack propagation time was achieved. Finer fatigue striations were formed in the shot peened specimen, demonstrating that a smaller crack propagation distance was obtained under unit fatigue load. Larger and deeper dimples were present in the final fracture zone of the shot peened specimen, showing that a stronger capacity for plastic deformation was attained. The fatigue test and simulation results revealed that the fatigue critical locations of both non shot peened and shot peened specimens were located at the notch root. Significant increases in the average experimental and simulated fatigue lives were observed for the shot peened specimen compared with the non shot peened specimen, with growth rates of 70.69% and 70.01%, respectively. The average error between experimental and simulated fatigue lives was 8.83%, and good agreement was achieved between simulated and experimental fatigue lives. Shot peening can significantly improve the fatigue life of A100 steel, and simulation methods can be used to predict its fatigue life.
关键词
A100钢 /
喷丸 /
粗糙度 /
残余应力 /
疲劳寿命 /
仿真
Key words
A100 steel /
shot peening /
roughness /
residual stress /
fatigue life /
simulation
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