Analysis and Discussion on the Relationship between Residual Stress and Deformation of Aluminum Alloy Forgings
-
摘要: 铝合金锻件在锻造、切削、热处理等加工过程会产生残余应力,当金属内部残余应力平衡时,金属组织性能较高,当金属内部残余应力失衡时,金属内应力发生释放产生变形现象,金属组织性能将有所下降。本文以变形铝合金锻件为研究对象,对残余应力和变形之间的关系分析,并提出预防措施和消除变形的方法。Abstract: Aluminium alloy forgings will produce residual stress in the process of forging, cutting, heat treatment and other processes. When the internal residual stress of metal is in balance, the performance of metal structure is higher. When the internal residual stress of metal is unbalanced, the internal stress will be released to produce deformation phenomenon, and the performance of metal structure will be reduced. Taking the wrought aluminiumalloy forgings as the research object, this paper analyses the relationship between residual stress and deformation, and put forward preventive measures and methods to eliminate deformation.
-
Key words:
- aluminum alloy forging /
- residual stress /
- deformation
-
表 1 机械性能试验报告
序号 图号 材料牌号 炉批号 抗拉强度/(kg·m−2) 屈服点/(kg·m−2) 延伸率/% 是否变形 1 XX-04**-8 2A50-CS $ {4{\text{-}}1463}_{\mathrm{M}71}^{1{\text{-}}20} $ 43.2 ~ 43.7 33.6 ~ 34.9 14.8 ~ 16.8 否 2 $ {3{\text{-}}1233}_{\mathrm{M}69}^{2{\text{-}}24} $ 42.3 33.2 ~ 34.8 16.2 ~ 20.1 否 3 $ {3{\text{-}}168}_{\mathrm{M}60}^{1{\text{-}}46} $ 45.3 ~ 46.5 37.2 ~ 37.6 12.4 ~ 13.8 是 性能指标 ≥39 ≥28 ≥10 − 表 2 刀具的典型切削参数
操作 材料 切削性类别 切削速度Vc/(m·min−1) 副后角α′/(°) 纵向前角γ/(°) 进给量f/(mm·r−1) 切削深度ap/mm 冷却剂 粗车 高速钢 Ⅰ
Ⅱ200 ~ 400
100 ~ 2509 ~ 12
8 ~ 1030 ~ 40
20 ~ 30≤1
0.2 ~ 0.53 ~ 15
3 ~ 15无
无硬质合金 Ⅰ
Ⅱ600 ~ 1200
200 ~ 4007 ~ 10
7 ~ 1020 ~ 30
10 ~ 200.3 ~ 0.6
0.25 ~ 0.63 ~ 15
3 ~ 15无
无精车 高速钢 Ⅰ
Ⅱ400 ~ 900
200 ~ 5008 ~ 10
7 ~ 940 ~ 50
30 ~ 400.05 ~ 0.3
0.03 ~ 0.250.3 ~ 2.5
0.3 ~ 2.5乳液
或切削油硬质合金 Ⅰ
Ⅱ≤2400
250 ~ 7008 ~ 10
7 ~ 920 ~ 30
10 ~ 20≤0.15
0.05 ~ 0.10.3 ~ 2.5
0.3 ~ 2.5乳液
或切削油表 3 铝合金的典型铣削参数
操作 材料 切削性类别 铣削速度
Vc/(m·min−1)主间隙角
α/(°)倾斜角
γ/(°)进给量
f/(mm·r−1)铣削深度
ap/mm螺旋线角
γ/(°)冷却剂 粗铣 高速钢 Ⅰ
Ⅱ300 ~ 600
150 ~ 4008
625
200.1 ~ 0.5
0.1 ~ 0.52 ~ 20
2 ~ 2030 ~ 40
≤30无
乳液硬质合金 Ⅰ
Ⅱ≤2500
300 ~ 8008
620
150.1 ~ 0.6
0.1 ~ 0.62 ~ 20
2 ~ 2030 ~ 40
≤30无
无精铣 高速钢 Ⅰ
Ⅱ≤1500
250 ~ 80012
1030
250.03 ~ 0.1
0.03 ~ 0.1≤0.5
≤0.530 ~ 40
≤30乳液
乳液或油硬质合金 Ⅰ
Ⅱ≤3000
500 ~ 150012
1025
200.03 ~ 0.1
0.03 ~ 0.1≤0.5
≤0.530 ~ 40
≤30乳液
乳液或油 -
[1] 孙燕杰, 龚海, 刘瑶琼, 等. 分步冷压对7050铝合金T形锻件残余应力的影响[J]. 热加工工艺, 2022, 51(1): 65-69 doi: 10.14158/j.cnki.1001-3814.20193715SUN Y J, GONG H, LIU Y Q, et al. Influence of sectional cold pressing on residual stress of 7050 aluminum alloy T-shaped forgings[J]. Hot Working Technology, 2022, 51(1): 65-69 (in Chinese) doi: 10.14158/j.cnki.1001-3814.20193715 [2] 王华敏, 陶江, 秦国华, 等. 毛坯开槽方式中零件加工变形的演变机理与控制方法[J]. 工程力学, 2022, 39(5): 233-247 doi: 10.6052/j.issn.1000-4750.2021.03.0172WANG H M, TAO J, QIN G H, et al. Evolution mechanism and control strategy of workpiece machining deformation in blank slotting method[J]. Engineering Mechanics, 2022, 39(5): 233-247 (in Chinese) doi: 10.6052/j.issn.1000-4750.2021.03.0172 [3] 秦国华, 林锋, 叶海潮, 等. 基于残余应力释放的航空结构件加工变形模型与结构优化方法[J]. 工程力学, 2018, 35(9): 214-222 + 231 doi: 10.6052/j.issn.1000-4750.2017.06.0433QIN G H, LIN F, YE H C, et al. Machining deformation model and structural optimization of aeronautical monolithic components based on relaxation of initial residual stress[J]. Engineering Mechanics, 2018, 35(9): 214-222 + 231 (in Chinese) doi: 10.6052/j.issn.1000-4750.2017.06.0433 [4] LIU H W, ZHENG J X, GUO Y L, et al. Residual stresses in high-speed two-dimensional ultrasonic rolling 7050 aluminum alloy with thermal-mechanical coupling[J]. International Journal of Mechanical Sciences, 2020, 186: 105824 doi: 10.1016/j.ijmecsci.2020.105824 [5] NERVI S, SZABÓ B A. On the estimation of residual stresses by the crack compliance method[J]. Computer Methods in Applied Mechanics and Engineering, 2007, 196(37-40): 3577-3584 doi: 10.1016/j.cma.2006.10.037 [6] WANG T H, SHUKLA S, GWALANI B, et al. Effect of reactive alloy elements on friction stir welded butt joints of metallurgically immiscible magnesium alloys and steel[J]. Journal of Manufacturing Processes, 2019, 39: 138-145 doi: 10.1016/j.jmapro.2019.02.009 [7] 姚诗杰, 夏伟军, 袁武华, 等. 基于分段冷压法7050大型铝合金锻件残余应力的消减[J]. 机械工程材料, 2018, 42(1): 84-88 doi: 10.11973/jxgccl201801017YAO S J, XIA W J, YUAN W H, et al. Residual stress reduction of 7050 large-scale aluminum alloy forging based on segmented cold-pressing method[J]. Materials for Mechanical Engineering, 2018, 42(1): 84-88 (in Chinese) doi: 10.11973/jxgccl201801017 [8] YANG X W, FENG W Y, LI W Y, et al. Microstructure and properties of probeless friction stir spot welding of AZ31 magnesium alloy joints[J]. Transactions of Nonferrous Metals Society of China, 2019, 29(11): 2300-2309 doi: 10.1016/S1003-6326(19)65136-8 [9] ZHOU H, LIU J S, ZHOU D W, et al. Effect of Al-foil addition on microstructure and temperature field of laser fusion welded joints of DP590 dual-phase steel and AZ31B magnesium alloy[J]. Transactions of Nonferrous Metals Society of China, 2020, 30(10): 2669-2680 doi: 10.1016/S1003-6326(20)65411-5 [10] 邓文英, 郭晓鹏, 邢忠文. 金属工艺学[M]. 6版. 北京: 高等教育出版社, 2017: 1-6DENG W Y, GUO X P, XING Z W. Technology of metals[M]. 6th ed. Beijing: Higher Education Press, 2017: 1-6 (in Chinese) [11] 李晨, 张新全, 向阳, 等. 波纹曲面冷压对7050铝合金带筋厚板残余应力的影响[J]. 锻压技术, 2022, 47(4): 119-125LI C, ZHANG X Q, XIANG Y, et al. Influence of cold pressing with corrugated surface on residual stress for 7050 aluminum alloy thick plate with ribs[J]. Forging & Stamping Technology, 2022, 47(4): 119-125 (in Chinese) [12] 张鹏飞. 国产铝合金构件横截面残余应力分布研究——6061-T6焊接成型箱型截面[D]. 西安: 西安工业大学, 2021: 18-22ZHANG P F. Research on residual stress distribution of cross section of domestic aluminum alloy components——6061-T6 box-section[D]. Xi'an: Xi'an Technological University, 2021: 18-22 (in Chinese) [13] 张福全, 杨重, 袁武华, 等. 7050铝合金淬火残余应力及消减工艺研究[J]. 热加工工艺, 2018, 47(24): 177-180 + 185 doi: 10.14158/j.cnki.1001-3814.2018.24.044ZHANG F Q, YANG C, YUAN W H, et al. Study on quenching residual stress and reducing process of 7050 aluminum alloy[J]. Hot Working Technology, 2018, 47(24): 177-180 + 185 (in Chinese) doi: 10.14158/j.cnki.1001-3814.2018.24.044 [14] 李晨, 张新全, 谢林军, 等. 淬火水温对7050铝合金残余应力及力学性能的影响[J]. 轻合金加工技术, 2022, 50(5): 60-64 doi: 10.13979/j.1007-7235.2022.05.011LI C, ZHANG X Q, XIE L J, et al. Effect of water quenching temperature on residual stress and mechanical properties of 7050 aluminum alloy[J]. Light Alloy Fabrication Technology, 2022, 50(5): 60-64 (in Chinese) doi: 10.13979/j.1007-7235.2022.05.011 [15] 张洪静, 卢潇涵, 竭艳丽, 等. 2A12方板裂纹原因分析[J]. 世界有色金属, 2019(6): 185 + 187 doi: 10.3969/j.issn.1002-5065.2019.06.100ZHANG H J, LU X H, JIE Y L, et al. The analysis of the cracks on 2A12 square plate[J]. World Nonferrous Metals, 2019(6): 185 + 187 (in Chinese) doi: 10.3969/j.issn.1002-5065.2019.06.100 [16] 张旭. 某型飞机主起支撑主要切削工艺的研究[D]. 哈尔滨: 哈尔滨工业大学, 2019: 13-14ZHANG X. Research on the main cutting technology of the main lifting support of a certain aircraft[D]. Harbin: Harbin Institute of Technology, 2019: 13-14 (in Chinese) [17] YE H C, QIN G H, WANG H M, et al. A machining position optimization approach to workpiece deformation control for aeronautical monolithic components[J]. The International Journal of Advanced Manufacturing Technology, 2020, 109(1-2): 299-313 doi: 10.1007/s00170-020-05588-0