发动机曲轴疲劳极限载荷预测方法研究
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摘要
发动机曲轴的应力集中现象严重,特别是在曲柄销圆角和主轴颈圆角部位的应力集中现象尤为突出,曲轴疲劳破坏往往发生于这些区域。随着发动机强化程度的提高,对于曲轴强度要求也越来越高,传统的通过曲轴形状系数和经验公式计算曲轴疲劳强度的方法已经无法满足发动机机高可靠性、低重量、低成本的设计要求。因此,分析结构参数和处理工艺对曲轴疲劳强度的影响,研究准确预测构件的疲劳极限载荷的方法,探讨如何对曲轴疲劳试验数据进行有效的统计分析,对于研究曲轴的疲劳强度可靠性具有实际意义。
为此,本文围绕曲轴疲劳强度可靠性研究主题,主要开展了以下工作：
(1)曲轴结构关键参数对疲劳强度的影响分析。基于iSIGHT-FD平台和DOE方法,将有限元分析、变结构参数设计与试验设计相结合,分析了曲轴关键结构参数对疲劳强度的影响。
(2)处理工艺对曲轴疲劳强度的影响分析。应用“F”检验法、“t”检验和秩和法,分析了氮化时间和滚压工艺对曲轴疲劳强度的影响。
(3)基于裂纹模拟技术与试验数据结合的曲轴疲劳极限载荷预测方法研究。通过某种型号曲轴疲劳试验数据推导出该零件等效标准裂纹体材料的扩展门槛值△Kth,并利用得到的ΔKth值,通过曲轴与标准裂纹体等效关系,预测曲轴的疲劳极限载荷。
(4)基于缺口件等效与渐进插值法预测曲轴的疲劳极限载荷方法研究。采用应力梯度拟合方法将曲轴应力集中等效为标准缺口件,并通过渐进插值法,引入虚拟短裂纹进行短裂纹修正,预测曲轴的疲劳极限载荷。
(5)曲轴疲劳试验数据处理技术研究。对曲轴的疲劳试验数据分布进行数据统计回归分析,对各种分布规律与曲轴疲劳试验数据的吻合程度进行拟合效果评价,并将极大似然法用于曲轴弯曲疲劳性能曲线测定。
通过上述工作,获得了以下主要结论：
(1)在需要提高曲轴疲劳强度时,增大圆角半径或增大曲柄厚度比改变重叠度和曲柄半径的效果要显著。氮化时间长短对曲轴疲劳强度有一定的影响,但影响效果不大,滚压工艺能改善曲轴疲劳强度性能。
(2)曲轴应力集中可以较好地等效为标准裂纹体模型,等效裂纹体扩展门槛值ΔKth的确定与预测曲轴疲劳极限载荷的准确性密切相关,通过已有试验数据推导出门槛值ΔKth,能比较准确的预测曲轴疲劳极限载荷。
(3)裂纹体与实际构件之间有本质不同,标准缺口件与实际构件的疲劳强度同属于应力集中问题,标准缺口件与实际构件等效比裂纹体与实际构件等效效果更好,标准缺口件等效的优势在于可以将经过工艺处理的实际构件等效为相同工艺处理的标准缺口件。
(4)曲轴疲劳强度试验数据与6种统计分布包括两参数威布尔分布、三参数威布尔分布、正态分布、对数正态分布、极大值分布、极小值分布拟合达到很高的吻合度,极大似然法能应用于曲轴疲劳强度性能曲线的测定,但存在较大的误差。
The phenomenon of engine crankshaft stress concentration is serious, especially in the crankpin round and spindle neck round. The fatigue damage of crankshaft often occurs in these areas. Along with the rising of engine aggrandizement degree, the demand for crankshaft fatigue strength is also growing higher. The traditional method calculating crankshaft fatigue strength by the crankshaft shape coefficients and experience formula has failed to meet the design requirements of high reliability, low weight and low cost. Therefore, the researches including the fatigue strength influence analysis of crankshaft structure and process parameters, the accurate predicting study of component fatigue limit load, and the discussion for how to analyze the crankshaft fatigue test data effectively, have the practical significance for studying the crankshaft fatigue strength reliability.
Therefore, around the research topic of crankshaft fatigue strength reliability, this paper mainly carries out the following contents:
The impact analysis of key structure parameters on crankshaft fatigue strength. Based on the multi-disciplinary collaborative design optimization platform, combining the finite element analysis, variable structure parameters of design and design of experiment, the impact of crankshaft key structure parameters on fatigue strength is analyzed.
The impact analysis of processing technic on crankshaft fatigue strength. By use of the parent standard deviation test-"f'test, parent average test-"t"test and rank sum test, the impact of nitridation time and rolling process on crankshaft fatigue strength is analyzed.
Prediction of crankshaft fatigue limit load by integrated crack-modeling technique with test data. The standard crack growth threshold value-△Kth which is equivalent to the stress concentration of real component, is derived through the fatigue test data of a type of crankshaft. And by use of the value-△Kth and through the equivalent relationship between crankshaft with standard crack body, the fatigue limit load of the different crankshaft, which is made of the same material and has the same processing technic, can be predicted.
Component fatigue limit prediction based on the integrated method of notched specimen equivalence and asymptotic interpolation. By the stress gradient matching method, the crankshaft stress concentration can be equivalent with the standard notched specimen, and through the asymptotic interpolation and introduction of virtual short crack correction, the fatigue limit load of crankshaft is predicted.
Statistical analysis of crankshaft fatigue strength test data. Based on the experimental data, the statistical regression analysis is carried out. The degree of fitting effect between the experimental data with the statistical distributions is evaluated. And the crankshaft fatigue property curve is determined by the method of maximum likelihood estimation.
The main conclusions were as follows
In order to improve the crankshaft fatigue strength, the effect should be more significant by increasing fillet radius or crank thickness than changing overlapping degree or crank radius. And it can be concluded that the length of nitriding time has little impact on the crankshaft fatigue strength and the rolling process can improve the performance of crankshaft fatigue strength.
The crankshaft stress concentration can be equivalent to the standard crack model. The prediction accuracy of crankshaft fatigue limit load is closely related to the standard crack growth threshold value-△Kth And the prediction of the crankshaft fatigue limit load is accurate by the standard crack growth threshold value-△Kth, which is derived through the fatigue strength test data.
Crack body and actual component differ in nature, the fatigue strength of actual component belonging to the stress concentration problem, is the same as the standard notched specimen. The equivalent fitting effect between actual component with standard notched specimen is better than the fitting effect between actual component with standard crack body. The advantage of standard notched specimen equivalence lies in that the actual component with processing technic can be equivalent to the standard notched specimen with the same processing technic.
The six kinds of statistical distributions, including weibull(two-and three-parameter), normal, lognormal, extreme minimum value, extreme maximum value, have good fitting effect. And the crankshaft fatigue property curve can be determined by the method of maximum likelihood estimation with certain error.
为此,本文围绕曲轴疲劳强度可靠性研究主题,主要开展了以下工作：
(1)曲轴结构关键参数对疲劳强度的影响分析。基于iSIGHT-FD平台和DOE方法,将有限元分析、变结构参数设计与试验设计相结合,分析了曲轴关键结构参数对疲劳强度的影响。
(2)处理工艺对曲轴疲劳强度的影响分析。应用“F”检验法、“t”检验和秩和法,分析了氮化时间和滚压工艺对曲轴疲劳强度的影响。
(3)基于裂纹模拟技术与试验数据结合的曲轴疲劳极限载荷预测方法研究。通过某种型号曲轴疲劳试验数据推导出该零件等效标准裂纹体材料的扩展门槛值△Kth,并利用得到的ΔKth值,通过曲轴与标准裂纹体等效关系,预测曲轴的疲劳极限载荷。
(4)基于缺口件等效与渐进插值法预测曲轴的疲劳极限载荷方法研究。采用应力梯度拟合方法将曲轴应力集中等效为标准缺口件,并通过渐进插值法,引入虚拟短裂纹进行短裂纹修正,预测曲轴的疲劳极限载荷。
(5)曲轴疲劳试验数据处理技术研究。对曲轴的疲劳试验数据分布进行数据统计回归分析,对各种分布规律与曲轴疲劳试验数据的吻合程度进行拟合效果评价,并将极大似然法用于曲轴弯曲疲劳性能曲线测定。
通过上述工作,获得了以下主要结论：
(1)在需要提高曲轴疲劳强度时,增大圆角半径或增大曲柄厚度比改变重叠度和曲柄半径的效果要显著。氮化时间长短对曲轴疲劳强度有一定的影响,但影响效果不大,滚压工艺能改善曲轴疲劳强度性能。
(2)曲轴应力集中可以较好地等效为标准裂纹体模型,等效裂纹体扩展门槛值ΔKth的确定与预测曲轴疲劳极限载荷的准确性密切相关,通过已有试验数据推导出门槛值ΔKth,能比较准确的预测曲轴疲劳极限载荷。
(3)裂纹体与实际构件之间有本质不同,标准缺口件与实际构件的疲劳强度同属于应力集中问题,标准缺口件与实际构件等效比裂纹体与实际构件等效效果更好,标准缺口件等效的优势在于可以将经过工艺处理的实际构件等效为相同工艺处理的标准缺口件。
(4)曲轴疲劳强度试验数据与6种统计分布包括两参数威布尔分布、三参数威布尔分布、正态分布、对数正态分布、极大值分布、极小值分布拟合达到很高的吻合度,极大似然法能应用于曲轴疲劳强度性能曲线的测定,但存在较大的误差。
The phenomenon of engine crankshaft stress concentration is serious, especially in the crankpin round and spindle neck round. The fatigue damage of crankshaft often occurs in these areas. Along with the rising of engine aggrandizement degree, the demand for crankshaft fatigue strength is also growing higher. The traditional method calculating crankshaft fatigue strength by the crankshaft shape coefficients and experience formula has failed to meet the design requirements of high reliability, low weight and low cost. Therefore, the researches including the fatigue strength influence analysis of crankshaft structure and process parameters, the accurate predicting study of component fatigue limit load, and the discussion for how to analyze the crankshaft fatigue test data effectively, have the practical significance for studying the crankshaft fatigue strength reliability.
Therefore, around the research topic of crankshaft fatigue strength reliability, this paper mainly carries out the following contents:
The impact analysis of key structure parameters on crankshaft fatigue strength. Based on the multi-disciplinary collaborative design optimization platform, combining the finite element analysis, variable structure parameters of design and design of experiment, the impact of crankshaft key structure parameters on fatigue strength is analyzed.
The impact analysis of processing technic on crankshaft fatigue strength. By use of the parent standard deviation test-"f'test, parent average test-"t"test and rank sum test, the impact of nitridation time and rolling process on crankshaft fatigue strength is analyzed.
Prediction of crankshaft fatigue limit load by integrated crack-modeling technique with test data. The standard crack growth threshold value-△Kth which is equivalent to the stress concentration of real component, is derived through the fatigue test data of a type of crankshaft. And by use of the value-△Kth and through the equivalent relationship between crankshaft with standard crack body, the fatigue limit load of the different crankshaft, which is made of the same material and has the same processing technic, can be predicted.
Component fatigue limit prediction based on the integrated method of notched specimen equivalence and asymptotic interpolation. By the stress gradient matching method, the crankshaft stress concentration can be equivalent with the standard notched specimen, and through the asymptotic interpolation and introduction of virtual short crack correction, the fatigue limit load of crankshaft is predicted.
Statistical analysis of crankshaft fatigue strength test data. Based on the experimental data, the statistical regression analysis is carried out. The degree of fitting effect between the experimental data with the statistical distributions is evaluated. And the crankshaft fatigue property curve is determined by the method of maximum likelihood estimation.
The main conclusions were as follows
In order to improve the crankshaft fatigue strength, the effect should be more significant by increasing fillet radius or crank thickness than changing overlapping degree or crank radius. And it can be concluded that the length of nitriding time has little impact on the crankshaft fatigue strength and the rolling process can improve the performance of crankshaft fatigue strength.
The crankshaft stress concentration can be equivalent to the standard crack model. The prediction accuracy of crankshaft fatigue limit load is closely related to the standard crack growth threshold value-△Kth And the prediction of the crankshaft fatigue limit load is accurate by the standard crack growth threshold value-△Kth, which is derived through the fatigue strength test data.
Crack body and actual component differ in nature, the fatigue strength of actual component belonging to the stress concentration problem, is the same as the standard notched specimen. The equivalent fitting effect between actual component with standard notched specimen is better than the fitting effect between actual component with standard crack body. The advantage of standard notched specimen equivalence lies in that the actual component with processing technic can be equivalent to the standard notched specimen with the same processing technic.
The six kinds of statistical distributions, including weibull(two-and three-parameter), normal, lognormal, extreme minimum value, extreme maximum value, have good fitting effect. And the crankshaft fatigue property curve can be determined by the method of maximum likelihood estimation with certain error.
引文
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