基于小范围屈服断裂的连杆胀断参数研究及应用
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摘要
连杆胀断技术(也称裂解)突破传统的机械切削分离加工及配合定位理念,采用定向控制断裂实现连杆体和盖的分离加工,并利用胀断后的自然断裂面实现胀断连杆体和盖的精确定位合装,可减少加工工序、节省精加工设备、节材节能、降低生产成本,并能提高连杆体和盖的定位精度、装配质量及工作中的连杆承载能力,对提高发动机生产技术水平和整机性能具有重要作用。
由于连杆胀断后要实现杆和盖的精确合装,保证连杆胀断后续精加工,满足胀断连杆在发动机运行中杆和盖结合面的承载及定位要求,因此连杆胀断加工的关键是限制胀断过程中连杆大头孔的塑性变形和确保胀断后断裂面较好的三维凹凸形态。但连杆胀断是弹塑性缺口构件在冲击加载下的三维动态断裂过程,断裂过程复杂,影响因素众多,且用于研究连杆胀断的弹塑性断裂力学理论本身还并不十分完善,以至于在实际生产中连杆胀断的力学参数及预制应力槽参数等还主要靠经验来确定,为此,本文结合国家自然科学基金项目(50375066)等课题的研究内容,从连杆胀断断裂本质分析入手,建立相关理论模型,对连杆胀断参数选择进行了相关理论分析和有限元数值模拟研究,并进行了相关试验验证,主要取得了如下研究成果:
1.通过试验确定胀断前连杆材料的机械和断裂性能参数,分析连杆胀断加工的大头孔塑性变形公差限制,根据连杆胀断加载条件,依据断裂力学相关理论确定连杆胀断的断裂本质为——韧性材料具有双侧预制应力槽构件在动态冲击加载下的小范围屈服后的弹塑性I型断裂。
2.分析弹塑性断裂特点,定义弹塑性断裂的裂纹体概念,给出弹塑性断裂裂纹体J积分的物理意义为流入裂纹体的总能量,即为驱动裂纹体弹塑性变形及断裂的总驱动能。提出弹塑性断裂后的裂纹体局部弹性能耗散概念。定义发生弹塑性断裂时的弹塑性裂纹体临界J积分为裂纹体的临界线弹性J积分和临界塑性J积分之和,在断裂后,临界塑性J积分转化为裂纹体的塑性变形能,临界弹性J积分转化为形成裂纹新表面的裂纹能以及断裂后的裂纹体弹性耗散能。据此可统一线弹性和非线性断裂问题的临界J积分概念及其物理意义。提出了可作为弹塑性断裂时裂纹体屈服范围大小度量的裂纹体相对塑性概念,定义其为临界塑性J积分与临界弹性J积分之比。参考裂纹体相对塑性,通过理论计算分析确定了小范围屈服断裂的载荷极限,以此为参考确定了连杆胀断设计载荷为连杆胀断有效承载截面整体屈服载荷的1/2,并通过捷达轿车EA113发动机连杆胀断拉伸试验进行了验证。
3.依据弗里特曼联合强度理论提出大范围或整体屈服后断裂的Mises等效应力断裂判据和小范围屈服后正断的最大拉应力断裂判据,并通过单边U型和V型缺口板拉伸试验、捷达轿车胀断连杆拉伸试验、以及有限元数值模拟计算进行了验证。依据小范围屈服后正断的最大拉应力判据,在连杆胀断设计载荷的基础上,根据拉削和线切割加工特点建立拉削和线切割预制应力槽的胀断连杆有限元模型,通过有限元数值模拟计算确定了拉削加工预制应力槽的根部圆角半径公差和线切割加工预制应力槽的深度公差。
4.在研究激光加工预制应力槽断面微观特征,槽周围局部重铸层特征及槽周围局部显微硬度特征的基础上,分析了激光加工预制应力槽的断裂本质,提出了激光加工预制应力槽的简化理想裂纹模型以及激光加工预制应力槽的等效临界应力强度因子和等效临界J积分概念,并用连杆激光预制应力槽加工参数加工单边槽进行了板拉伸试验,通过试验数据估计了激光加工预制应力槽的等效临界J积分,以此为判据确定了激光加工预制应力槽的深度公差。
5.分析了连杆胀断两侧预制应力槽深度差与斜连杆的两侧不对称结构对连杆胀断两侧断裂同步性的影响,即随着两侧断裂时间延迟的增加,后断裂侧发生弯曲变形增大,连杆胀断中的大头孔塑性变形增大。通过有限元数值模拟分析了连杆胀断的盖端锁紧对减小连杆胀断大头孔变形的作用。在直、斜连杆的不对称槽深胀断数值模拟及连杆胀断应变电测试验基础上,定量研究了不对称槽深对直、斜连杆胀断的影响。对直连杆,可通过限制两侧预制应力槽的差深比来保证连杆胀断后的大头孔变形要求。对斜连杆,可通过优化两侧槽深差来改善由于斜连杆设计先天而来的两侧不对称结构对两侧胀断同步性的影响。
6.确定楔形机械自锁机构实现连杆胀断盖端锁紧。选择楔入式胀断的连杆胀断加载方式,分析确定了楔入式胀断的设备载荷和连杆胀断设计载荷的计算关系,确定了楔入式胀断的设备设计载荷计算方法,并分别针对捷达轿车EA113发动机(1.6升排量)用连杆、卡车8.6升排量柴油机用36D连杆和重卡及特种车13升排量柴油机用53D连杆,计算了需要的相应胀断设备设计载荷,在此基础上设计了轿车、卡车和重卡及特种车发动机用连杆的小、中、重型连杆胀断设备,并在相关连杆生产企业获得应用,取得良好效果。
The fracture splitting of connecting rod, which broke through the traditional design idea of separating by machining process、positioning and assembling parts, can make the cap separate from the connecting rod by the controlled directional fracture with fewer procedures and equipment investment, lower costs, better-quality products, etc. The fracture surface of the connecting rod and cap after fracture splitting can provide the higher assembly precision and the stronger loading capacity, as a result, it can improve the engine performance. The fracture splitting processing of connecting rod has advantage over the other traditional methods.
During fracture splitting connecting rod, the most important thing is to make the cap brittle fracture split from the connecting rod with little or no plastic deformation and achieve appropriate three-dimensional fracture face. Because plastic deformation can alter the fracture surface topography and lead to deformation and distortion of the inner bore so that it can not make the connecting rod and the cap after fracture splitting contiguously and accurately fit together to achieve subsequent finishing processes. As a result it would affect assembly precision and loading capacity of connecting rod in the engine. Fracture splitting connecting rod is a complicated and instantaneous three-dimensional crack propagation course and is influenced by many factors. The elastic-plastic fracture mechanics theory which could be used to study fracture splitting connecting rod is now developing. Therefore the parameters of fracture splitting were always determined by experiences from the past. So supported by the national natural science foundation(50375066) and based on the fracture nature of fracture splitting connecting rod, the relevant theoretical models of fracture splitting connecting rod were established and by these models, the theoretical analysis and FEA numerical simulations were carried out and the relevant parameters of fracture splitting were determined. And testes were done to validate these parameters. The major research is summarized as follows:
1. The mechanics and fracture properties of the connecting rod material before fracture splitting were determined by the uniaxial tensile and the linear-elastic plane-strain fracture toughness tests. The effect of the bearing hole plastic deformation after fracture splitting of the connecting rod on roundness accuracy、assembly precision、subsequent finish machining and engine working were analyzed. Based on these testing data and analysis, according to the related theories of line-elastic fracture mechanics and elastic-plastic fracture mechanics, this paper concluded that connecting rod before fracture splitting is a elastic-plastic structure with two side starting-notches, that the load for fracture splitting is dynamic and impactive, and that the nature of fracture splitting connecting rod is a mode I fracture course after small scale yielding.
2. Elastic-plastic fracture characteristics were analyzed. The crack body of elastic-plastic fracture was defined. J-integral of the non-linear crack body is equal to the total energy flowing into the crack body, which drives the crack body elastic-plastic deformation and fracture. The elastic energy dissipation of elastic-plastic crack body after fracture is defined. When the fracture is in the critical point, the critical J-integral of the non-linear crack body is equal to the total critical energy driving the crack body fracture after elastic-plastic deformation. Because J-integral of elastic-plastic crack body is sum of linear-elastic J-integral and plastic J-integral, so when the fracture happen, the critical linear-elastic J-integral is converted to the energy for forming the new crack surfaces and the crack body elastic energy dissipation, and the critical plastic J-integral is converted to plastic deformation energy of the crack body. According to this, the physical meaning of J-integral of linear elastic and elastic-plastic fracture can be consistent. When the fracture of the elastic-plastic crack body was starting, the elastic-plastic crack body relatively plastic was defined, which could be used as a measure of the scale of crack body yielding. Based on the crack body relatively plastic, the limit of load for fracture after small scale yield was calculated by fracture mechanics theory. As a reference and by FEA numerical simulations of fracture splitting connecting rod, the theory design load of fracture splitting connecting rod was identified as half of the overall yield load of the effective cross-section of bearing load. The theory design load was verified by the tensile test of Jetta EA113 engine connecting rod with V-starting-notches.
3. According to Freterman's theory on joint strength, the fracture mechanism after the large-scale or overall yielding is different from after small scale yielding. So Mises equivalent stress fracture criterion after the large-scale fracture and the overall yield fracture and the maximum tensile stress fracture criterion after the small scale yielding fracture were presented and verified by the experiment and finite element calculations. Referring to the design load of fracture splitting and by reasonably simplifying the V-notch by broaching and the U-notch by wire cut electrical discharge and establishing the connecting rod geometric models for fracture splitting, the fracture finite element numerical simulation were carried out. The parameters and tolerances of the V-notch root radius and the U-notch depth were determined by the maximum tensile stress fracture criterion after the small scale yielding fracture.
4. As for the starting-notch by laser processing, the microscopic geometric, the composition and the micro-hardness distribution of local metal structure surrounding the notch were analyzed. Referring to the energy method of linear elastic fracture mechanics and to avoid dealing with the complex geometry of the starting-notch by laser, the paper defined the equivalent critical stress intensity factor and the equivalent critical J-integral for the starting-notch by laser and estimated the equivalent critical J-integral, which provided a reference to determine the depth parameter and the tolerance of the starting-notch by laser for fracture splitting connecting rod.
5. There is the different depth of starting-notches at both sides of connecting rod. And the structure of oblique incision connecting rod is asymmetric. The difference depth and the asymmetric structure affect on the order and the time lag of fracture splitting at both sides of connecting rod. The time lag of fracture splitting is the longer at both sides of connecting rod, and there is the bigger bending deformation at the side of later fracture, and there is the more plastic deformation during fracture splitting connecting rod. The FEA models of one side fracture splitting of connecting rod were established and the FEA simulation were done to study the role of clamping the connecting cap during fracture splitting. The results showed that clamping the connecting cap could restrict the connecting cap rotation during fracture splitting and weaken the influence of asymmetric factors on fracture splitting. The FEA models of flat and oblique incision connecting rod with different crack depth on both sides were established and the FEA simulation were done. The experiments of fracture splitting connecting rod were carried out by electrometric method. Based on the results of the above simulations and the experiments, the paper obtained the quantitative effects of the asymmetric starting-notch depth on fracture splitting the flat and the oblique incision connecting rod. When fracture splitting the flat incision connecting rod, the bearing hole plastic deformation after fracture splitting might be limited by controlling the ratio of depth difference to shallower depth of the two starting-notches of flat incision connecting rod in the reasonable range. When fracture splitting the oblique incision connecting rod, the optimization of the depth parameters on both sides of starting-notch could reduce the effect of the asymmetric structure on fracture splitting of the oblique incision connecting rod.
6. The wedge block mechanism with self-locking function was chose to achieve clamping the connecting cap. The load of fracture splitting equipment of connecting rod were obtained by the wedge block which was driven and could duplicate the load direct by the hydraulic cylinder. The relation between the load of fracture splitting equipment and the theory design load was determined. The design method of the load of fracture splitting equipment was proposed. By this method, the loads of fracture splitting EA113 engine(1.6L) connecting rod of Jetta car, 8.6L diesel engine 36D connecting rod of the truck and 13L diesel engine 53D connecting rod of the heavy truck and special vehicles were calculated. Based on these loads, the equipments for fracture splitting the connecting rod for the engine of car、light and heavy truck were made. These equipments have already applied mass production of connecting rod and achieved good economic benefits.
由于连杆胀断后要实现杆和盖的精确合装,保证连杆胀断后续精加工,满足胀断连杆在发动机运行中杆和盖结合面的承载及定位要求,因此连杆胀断加工的关键是限制胀断过程中连杆大头孔的塑性变形和确保胀断后断裂面较好的三维凹凸形态。但连杆胀断是弹塑性缺口构件在冲击加载下的三维动态断裂过程,断裂过程复杂,影响因素众多,且用于研究连杆胀断的弹塑性断裂力学理论本身还并不十分完善,以至于在实际生产中连杆胀断的力学参数及预制应力槽参数等还主要靠经验来确定,为此,本文结合国家自然科学基金项目(50375066)等课题的研究内容,从连杆胀断断裂本质分析入手,建立相关理论模型,对连杆胀断参数选择进行了相关理论分析和有限元数值模拟研究,并进行了相关试验验证,主要取得了如下研究成果:
1.通过试验确定胀断前连杆材料的机械和断裂性能参数,分析连杆胀断加工的大头孔塑性变形公差限制,根据连杆胀断加载条件,依据断裂力学相关理论确定连杆胀断的断裂本质为——韧性材料具有双侧预制应力槽构件在动态冲击加载下的小范围屈服后的弹塑性I型断裂。
2.分析弹塑性断裂特点,定义弹塑性断裂的裂纹体概念,给出弹塑性断裂裂纹体J积分的物理意义为流入裂纹体的总能量,即为驱动裂纹体弹塑性变形及断裂的总驱动能。提出弹塑性断裂后的裂纹体局部弹性能耗散概念。定义发生弹塑性断裂时的弹塑性裂纹体临界J积分为裂纹体的临界线弹性J积分和临界塑性J积分之和,在断裂后,临界塑性J积分转化为裂纹体的塑性变形能,临界弹性J积分转化为形成裂纹新表面的裂纹能以及断裂后的裂纹体弹性耗散能。据此可统一线弹性和非线性断裂问题的临界J积分概念及其物理意义。提出了可作为弹塑性断裂时裂纹体屈服范围大小度量的裂纹体相对塑性概念,定义其为临界塑性J积分与临界弹性J积分之比。参考裂纹体相对塑性,通过理论计算分析确定了小范围屈服断裂的载荷极限,以此为参考确定了连杆胀断设计载荷为连杆胀断有效承载截面整体屈服载荷的1/2,并通过捷达轿车EA113发动机连杆胀断拉伸试验进行了验证。
3.依据弗里特曼联合强度理论提出大范围或整体屈服后断裂的Mises等效应力断裂判据和小范围屈服后正断的最大拉应力断裂判据,并通过单边U型和V型缺口板拉伸试验、捷达轿车胀断连杆拉伸试验、以及有限元数值模拟计算进行了验证。依据小范围屈服后正断的最大拉应力判据,在连杆胀断设计载荷的基础上,根据拉削和线切割加工特点建立拉削和线切割预制应力槽的胀断连杆有限元模型,通过有限元数值模拟计算确定了拉削加工预制应力槽的根部圆角半径公差和线切割加工预制应力槽的深度公差。
4.在研究激光加工预制应力槽断面微观特征,槽周围局部重铸层特征及槽周围局部显微硬度特征的基础上,分析了激光加工预制应力槽的断裂本质,提出了激光加工预制应力槽的简化理想裂纹模型以及激光加工预制应力槽的等效临界应力强度因子和等效临界J积分概念,并用连杆激光预制应力槽加工参数加工单边槽进行了板拉伸试验,通过试验数据估计了激光加工预制应力槽的等效临界J积分,以此为判据确定了激光加工预制应力槽的深度公差。
5.分析了连杆胀断两侧预制应力槽深度差与斜连杆的两侧不对称结构对连杆胀断两侧断裂同步性的影响,即随着两侧断裂时间延迟的增加,后断裂侧发生弯曲变形增大,连杆胀断中的大头孔塑性变形增大。通过有限元数值模拟分析了连杆胀断的盖端锁紧对减小连杆胀断大头孔变形的作用。在直、斜连杆的不对称槽深胀断数值模拟及连杆胀断应变电测试验基础上,定量研究了不对称槽深对直、斜连杆胀断的影响。对直连杆,可通过限制两侧预制应力槽的差深比来保证连杆胀断后的大头孔变形要求。对斜连杆,可通过优化两侧槽深差来改善由于斜连杆设计先天而来的两侧不对称结构对两侧胀断同步性的影响。
6.确定楔形机械自锁机构实现连杆胀断盖端锁紧。选择楔入式胀断的连杆胀断加载方式,分析确定了楔入式胀断的设备载荷和连杆胀断设计载荷的计算关系,确定了楔入式胀断的设备设计载荷计算方法,并分别针对捷达轿车EA113发动机(1.6升排量)用连杆、卡车8.6升排量柴油机用36D连杆和重卡及特种车13升排量柴油机用53D连杆,计算了需要的相应胀断设备设计载荷,在此基础上设计了轿车、卡车和重卡及特种车发动机用连杆的小、中、重型连杆胀断设备,并在相关连杆生产企业获得应用,取得良好效果。
The fracture splitting of connecting rod, which broke through the traditional design idea of separating by machining process、positioning and assembling parts, can make the cap separate from the connecting rod by the controlled directional fracture with fewer procedures and equipment investment, lower costs, better-quality products, etc. The fracture surface of the connecting rod and cap after fracture splitting can provide the higher assembly precision and the stronger loading capacity, as a result, it can improve the engine performance. The fracture splitting processing of connecting rod has advantage over the other traditional methods.
During fracture splitting connecting rod, the most important thing is to make the cap brittle fracture split from the connecting rod with little or no plastic deformation and achieve appropriate three-dimensional fracture face. Because plastic deformation can alter the fracture surface topography and lead to deformation and distortion of the inner bore so that it can not make the connecting rod and the cap after fracture splitting contiguously and accurately fit together to achieve subsequent finishing processes. As a result it would affect assembly precision and loading capacity of connecting rod in the engine. Fracture splitting connecting rod is a complicated and instantaneous three-dimensional crack propagation course and is influenced by many factors. The elastic-plastic fracture mechanics theory which could be used to study fracture splitting connecting rod is now developing. Therefore the parameters of fracture splitting were always determined by experiences from the past. So supported by the national natural science foundation(50375066) and based on the fracture nature of fracture splitting connecting rod, the relevant theoretical models of fracture splitting connecting rod were established and by these models, the theoretical analysis and FEA numerical simulations were carried out and the relevant parameters of fracture splitting were determined. And testes were done to validate these parameters. The major research is summarized as follows:
1. The mechanics and fracture properties of the connecting rod material before fracture splitting were determined by the uniaxial tensile and the linear-elastic plane-strain fracture toughness tests. The effect of the bearing hole plastic deformation after fracture splitting of the connecting rod on roundness accuracy、assembly precision、subsequent finish machining and engine working were analyzed. Based on these testing data and analysis, according to the related theories of line-elastic fracture mechanics and elastic-plastic fracture mechanics, this paper concluded that connecting rod before fracture splitting is a elastic-plastic structure with two side starting-notches, that the load for fracture splitting is dynamic and impactive, and that the nature of fracture splitting connecting rod is a mode I fracture course after small scale yielding.
2. Elastic-plastic fracture characteristics were analyzed. The crack body of elastic-plastic fracture was defined. J-integral of the non-linear crack body is equal to the total energy flowing into the crack body, which drives the crack body elastic-plastic deformation and fracture. The elastic energy dissipation of elastic-plastic crack body after fracture is defined. When the fracture is in the critical point, the critical J-integral of the non-linear crack body is equal to the total critical energy driving the crack body fracture after elastic-plastic deformation. Because J-integral of elastic-plastic crack body is sum of linear-elastic J-integral and plastic J-integral, so when the fracture happen, the critical linear-elastic J-integral is converted to the energy for forming the new crack surfaces and the crack body elastic energy dissipation, and the critical plastic J-integral is converted to plastic deformation energy of the crack body. According to this, the physical meaning of J-integral of linear elastic and elastic-plastic fracture can be consistent. When the fracture of the elastic-plastic crack body was starting, the elastic-plastic crack body relatively plastic was defined, which could be used as a measure of the scale of crack body yielding. Based on the crack body relatively plastic, the limit of load for fracture after small scale yield was calculated by fracture mechanics theory. As a reference and by FEA numerical simulations of fracture splitting connecting rod, the theory design load of fracture splitting connecting rod was identified as half of the overall yield load of the effective cross-section of bearing load. The theory design load was verified by the tensile test of Jetta EA113 engine connecting rod with V-starting-notches.
3. According to Freterman's theory on joint strength, the fracture mechanism after the large-scale or overall yielding is different from after small scale yielding. So Mises equivalent stress fracture criterion after the large-scale fracture and the overall yield fracture and the maximum tensile stress fracture criterion after the small scale yielding fracture were presented and verified by the experiment and finite element calculations. Referring to the design load of fracture splitting and by reasonably simplifying the V-notch by broaching and the U-notch by wire cut electrical discharge and establishing the connecting rod geometric models for fracture splitting, the fracture finite element numerical simulation were carried out. The parameters and tolerances of the V-notch root radius and the U-notch depth were determined by the maximum tensile stress fracture criterion after the small scale yielding fracture.
4. As for the starting-notch by laser processing, the microscopic geometric, the composition and the micro-hardness distribution of local metal structure surrounding the notch were analyzed. Referring to the energy method of linear elastic fracture mechanics and to avoid dealing with the complex geometry of the starting-notch by laser, the paper defined the equivalent critical stress intensity factor and the equivalent critical J-integral for the starting-notch by laser and estimated the equivalent critical J-integral, which provided a reference to determine the depth parameter and the tolerance of the starting-notch by laser for fracture splitting connecting rod.
5. There is the different depth of starting-notches at both sides of connecting rod. And the structure of oblique incision connecting rod is asymmetric. The difference depth and the asymmetric structure affect on the order and the time lag of fracture splitting at both sides of connecting rod. The time lag of fracture splitting is the longer at both sides of connecting rod, and there is the bigger bending deformation at the side of later fracture, and there is the more plastic deformation during fracture splitting connecting rod. The FEA models of one side fracture splitting of connecting rod were established and the FEA simulation were done to study the role of clamping the connecting cap during fracture splitting. The results showed that clamping the connecting cap could restrict the connecting cap rotation during fracture splitting and weaken the influence of asymmetric factors on fracture splitting. The FEA models of flat and oblique incision connecting rod with different crack depth on both sides were established and the FEA simulation were done. The experiments of fracture splitting connecting rod were carried out by electrometric method. Based on the results of the above simulations and the experiments, the paper obtained the quantitative effects of the asymmetric starting-notch depth on fracture splitting the flat and the oblique incision connecting rod. When fracture splitting the flat incision connecting rod, the bearing hole plastic deformation after fracture splitting might be limited by controlling the ratio of depth difference to shallower depth of the two starting-notches of flat incision connecting rod in the reasonable range. When fracture splitting the oblique incision connecting rod, the optimization of the depth parameters on both sides of starting-notch could reduce the effect of the asymmetric structure on fracture splitting of the oblique incision connecting rod.
6. The wedge block mechanism with self-locking function was chose to achieve clamping the connecting cap. The load of fracture splitting equipment of connecting rod were obtained by the wedge block which was driven and could duplicate the load direct by the hydraulic cylinder. The relation between the load of fracture splitting equipment and the theory design load was determined. The design method of the load of fracture splitting equipment was proposed. By this method, the loads of fracture splitting EA113 engine(1.6L) connecting rod of Jetta car, 8.6L diesel engine 36D connecting rod of the truck and 13L diesel engine 53D connecting rod of the heavy truck and special vehicles were calculated. Based on these loads, the equipments for fracture splitting the connecting rod for the engine of car、light and heavy truck were made. These equipments have already applied mass production of connecting rod and achieved good economic benefits.
引文
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