目的 建立外螺纹根部超声滚压仿真模型,结合试验和仿真,研究超声滚压静压力、超声振幅和滚压遍数对34CrNiMo6钢外螺纹根部表层残余应力的影响。方法 在MTS809.25型250 kN拉扭疲劳试验系统及分离式霍普金森压杆试验系统上,对34CrNiMo6钢的Johnson-Cook（J-C）本构模型参数进行标定,通过Hypermesh、Matlab联合建立带螺纹升角的螺纹有限元模型,基于赫兹接触理论给出静态力压下深度,从而建立外螺纹根部超声滚压仿真模型,通过试验对该模型进行有效性验证,并研究不同工艺参数对强化后螺纹根部残余应力的影响。结果 所建仿真模型残余应力计算结果与试验结果趋势相吻合,平均误差为11.4%。对外螺纹根部进行超声滚压仿真,发现最大残余压应力随着静压力、超声振幅的增大而增大,随着滚压遍数的增加呈先增大后减小的趋势。当其他参数相同时,残余压应力分别在静压力1 kN、振幅10 μm、滚压4遍时达到最大值,分别为-719.54、-723.61、-691.03 MPa。结论 通过超声滚压强化可以显著提高34CrNiMo6钢外螺纹根部的残余压应力,所建仿真模型能够有效预测强化后螺纹根部的应力分布。针对因根部圆角半径较小无法通过试验准确测量残余应力的螺纹,提供了一种仿真分析获取残余应力的方法。
Abstract
The fatigue resistance of threaded components can be enhanced through ultrasonic rolling surface strengthening, which improves the surface morphology of thread roots and introduces residual compressive stresses. However, ultrasonic strengthening of thread roots has been insufficiently investigated in existing literature, and no simulation studies on ultrasonic rolling processes for thread roots have been conducted. Therefore, a simulation model for ultrasonic rolling of external thread roots is developed. The combined experimental and simulation approach is employed to investigate the effects of static pressure, ultrasonic amplitude, and rolling passes on the residual stress distribution in the subsurface layer of 34CrNiMo6 steel external thread roots.
A quasi-static tensile test is first conducted with a MTS809.25 250 kN tension-torsion fatigue test system. Dynamic tensile tests are then conducted under three strain rates (1 000 s-1, 2 000 s-1, and 3 000 s-1) through a split Hopkinson pressure bar system to determine the Johnson-Cook constitutive model parameters for 34CrNiMo6 steel. A cylindrical mesh with predefined pitch is first generated in HyperMesh software, followed by extraction of nodal coordinates. The mesh geometry is then transformed into thread-specific nodal configurations through Matlab algorithms, enabling the finite element model of the threaded structure to be established. Based on the Hertz contact theory, the indentation depth under static loading is calculated, and a helical ultrasonic rolling simulation model considering the thread lead angle is established. Boundary conditions are subsequently defined in accordance with actual machining operational requirements. In addition, the experimental residual stress data are fitted using Origin software and subsequently imported into the finite element model through the Abaqus user subroutine sigini. Validation is performed by comparing simulated residual stresses with experimental results under identical processing parameters, showing consistent trends with an average error of 11.4%.
Three process parameters-static pressure, ultrasonic amplitude, and number of rolling passes-are selected for conducting ultrasonic rolling simulations on external thread roots. It is found through the simulations that the maximum residual compressive stress is found to increase proportionally with static pressure and ultrasonic amplitude, while demonstrating an initial increase followed by subsequent decrease with additional rolling passes. When other parameters are maintained constant, the maximum residual compressive stresses are obtained under the following individual parameter settings: -719.54 MPa is attained when the static pressure is set to 1 000 N; -723.61 MPa is achieved with the ultrasonic amplitude adjusted to 10 μm; -691.03 MPa is attained after the number of rolling passes is increased to 4. Furthermore, the depth of maximum residual stress is observed to shift from 50 μm to 150 μm below the surface when static pressure increased from 200 N to 1 000 N. Similar depth variations are recorded with ultrasonic amplitude enhancement (4 μm to 10 μm) and rolling pass increments (1 to 4 passes).
Significant enhancement of residual compressive stresses in 34CrNiMo6 steel external thread roots can be achieved through ultrasonic rolling surface strengthening, along with a progressive shift of the maximum residual compressive stress location to greater subsurface depths. The developed simulation methodology, incorporating actual thread geometry and initial stress states, provides reliable prediction of post-treatment stress fields. The maximum residual compressive stress is increased with higher static pressure and ultrasonic amplitude, but is first increased then decreased as rolling passes are added. For threads where residual stresses cannot be accurately measured experimentally due to small root fillet radii, a simulation-based method for residual stress determination is provided.
关键词
J-C本构模型 /
超声强化 /
螺纹根部 /
数值模拟 /
残余应力场
Key words
J-C constitutive model /
ultrasonic strengthening /
thread root /
numerical simulation /
residual stress field
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基金
国家自然科学基金重点项目（12432004）
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