目的 探究铝合金薄壁件喷丸后沿层深方向残余应力场的重新分布和变形规律。方法 通过ABAQUS构建了FEM-DEM耦合的铝合金薄壁件喷丸成形模型,通过实验验证了模型预测2024-T3铝合金薄壁件残余应力和变形量的准确性,并在仿真模型中通过对工艺参数的调整,探究了铝合金薄壁件应力释放前后沿层深方向残余应力场的重新分布规律以及铝合金薄壁件喷丸后的变形规律。结果 最大残余压应力误差为‒7.6%,表面残余压应力误差为‒0.7%,饱和弧高误差为4.7%,这从应力和变形两个方面证实了模型具有良好的准确性。弹丸速度、弹丸直径、弹丸数量的增大都会导致喷丸后表面残余压应力增大,薄壁件去除约束后由于应力释放会使得表面残余压应力有所衰减,这种衰减的最大比例为50%左右。去除约束后薄壁件次表面出现一定的残余拉应力以平衡上表面的残余压应力,当次表面出现的残余拉应力达到10 MPa左右时,薄壁件深层区域还会出现较小的残余压应力,但其数值大小明显小于上表面。结论 研究了铝合金薄壁件喷丸后的变形规律,以及经过喷丸的薄壁件去除约束后应力释放过程中残余应力场的重新分布规律,丰富了铝合金薄壁件喷丸成形过程的有关理论,为实际生产中的工艺优化和质量控制提供有力的支持。
Abstract
In order to elucidate the deformation law of aluminum alloy thin-walled parts after shot peening (SP) and uncover the redistribution of residual stress fields along the depth direction during deformation, a FEM-DEM coupled SP model for aluminum alloy thin-walled parts was established based on ABAQUS finite element software. SP induced plastic deformation on the surface of thin-walled parts through the impact of numerous shots, introducing a compressive residual stress field. The residual stress generated by SP in the thin-walled parts was released by modifying the boundary conditions after SP, resulting in deformation and the accuracy of the model in predicting the residual stress after SP and deformation characteristics was thoroughly verified through a series of meticulously conducted experiments. The simulation model was employed to investigate the residual stress field of these parts and the deformation they underwent after SP. Furthermore, a detailed analysis was carried out to examine the deformation and the redistribution of the residual stress field. This analysis was conducted by systematically varying the process parameters, including shot velocity, shot diameter, and the number of shots, in order to gain a comprehensive understanding of their impact on the material's behavior. Compared with the experimental results, the simulation results achieved satisfactory accuracy with minimal errors: the error of maximum compressive residual stress ($\sigma_{\mathrm{Max}}^{\mathrm{RS}}$) was ‒7.6%, the error of surface compressive residual stress ($\sigma_{\mathrm{Surf}}^{\mathrm{RS}}$) was ‒0.7%, and the error of arc height at saturation was 4.7%. These results confirmed the model's good accuracy of both residual stress and deformation. The increase of shot velocity, shot diameter and number of shots enhanced the SP strength, which led to the increase of $\sigma_{\mathrm{Surf}}^{\mathrm{RS}}$. However, this compressive stress attenuated due to the redistribution of residual stress field upon constraint release, with the maximum attenuation reaching approximately 50%. Upon release of external constraints, a characteristic tensile residual stress field was generated within the subsurface region of the thin-walled specimen to mechanically equilibrate the near-surface compressive residual stress. When the induced subsurface tensile stress attained a magnitude of approximately 10 MPa, a tertiary compressive stress regime became manifest in deeper material zones, exhibiting significantly diminished stress intensity relative to the primary surface compressive field. There was an obvious diminishing marginal benefit of increasing the SP effect by increasing shot velocity, shot diameter and number of shots. Under the given peening conditions (shot velocity = 80 m/s, shot mass flow rate = 0.4 kg/min, shot diameter = 0.5 mm), the analysis demonstrated that when the number of shots increased from 10 000 to 20 000, the maximum longitudinal deformation rose by 67%. In comparison, a similar increase in the number of shots from 30 000 to 40 000 resulted in only 22% growth in deformation, revealing a distinct nonlinear response characteristic. Therefore, it was not advisable to blindly increase these parameters in engineering to improve the SP effects. In summary, the investigation has been conducted on the deformation law of aluminum alloy thin-walled parts after SP and the redistribution law of the residual stress field during the stress release process after the release of constraints from peened thin-walled parts, enhancing the relevant theories of SP process of aluminum alloy thin-walled parts and providing a digital research approach.
关键词
喷丸成形 /
FEM-DEM耦合模型 /
铝合金薄壁件喷丸 /
残余应力分布 /
喷丸成形变形规律 /
精确喷丸成形
Key words
shot peening (SP) forming process /
coupled FEM-DEM model /
SP of aluminum alloy thin-walled parts /
residual stress distribution /
deformation law of SP forming process /
precision peen forming
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基金
国家自然科学基金（52371335）; 新疆职业大学校内科研课题（XJZD24ZKZ01）
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