基于载荷谱进行汽车前轴寿命估算方法研究
摘要
本文针对载重车前轴疲劳强度问题,主要解决了前轴疲劳寿命预估中的三个问题,即结构承受的载荷谱问题、真实结构的P-S-N统计数据问题、如何进行疲劳寿命预估问题。通过用户使用调查,总结归纳了用户车辆使用状况,依据用户使用状况,对载重车前轴在不同路况下的真实载荷谱进行了测试,经载荷谱数据处理与统计规律分析,得到了可用于前轴疲劳寿命预估载荷谱,解决了以往前轴疲劳寿命预估时缺乏真实结构载荷谱的问题;利用成组试验法与寿命对数正态统计法,对研究的真实载重车前轴在不同载荷作用下的疲劳寿命进行了台架试验与寿命统计分析,得到了真实结构的P-S-N参数,解决了结构寿命预估的P-S-N参数问题,较通过材料疲劳特性参数获得的结构P-S-N参数更准确;通过结构疲劳累积损伤理论的比较分析,应用线性疲劳累积损伤理论对汽车前轴在实际测试地区的使用寿命进行了估算,得到了与实际较吻合的寿命估计结果。本文所研究的前轴寿命估算方法可适应于载荷车前轴的寿命预测与结构改进参考。
With furious competition in automobile market ,user’s requirements for the reliability、harshness & safety become stronger and stronger , the complexity of component structure、the multiplicity and the irregularity of component service condition leads to more difficulty in its development process, the reliability of components has greater effect on economic benefit of enterprise ,all these mentioned above require that product development departments should apply modern fatigue & reliability design method in product design process ,to increase compete power in product market .
Based on above causes ,the project is presented, the purposes of this paper are as follows:
To predict product failure state、find and solve weak place of components in design as quickly as possible ,efficiently combining fatigue reliability test、structure analysis、reliability design works and etc. ,to produce a set of fatigue reliability development techniques of product ,to establish a kind of design & calculation method process basing on statistics and probability . all these works are done according to actual load spectra and fatigue life of automobile components.
This paper has measured and got a long-8km-distance load spectra of automobile front axle under actual vehicle service condition, measured and got its P-S-N fatigue characteristic curve parameters, and predicted its service life , so that a strong support for design of automobile front axle has given.
Main tasks of this project:
Determined calibration coefficient of load vs. strain for measuring position using multi-direction load calibration method ;measured each load condition parameters for simulation automobile users ;packed up and concluded multi-load spectra correlative to user service distance ,basing on investigation of user service condition and actual measuring load parameters of automobile components ,determined load levels and load magnitude for test rig of getting P-S-N fatigue characteristic curve parameters, produced P-S-N fatigue characteristic curve parameters by using group test method、determining least test samples for each level load、dealing with strange data and valid test data ,regressed all kind of P-S-N fatigue characteristic curve of different probability using power function for three parameters to deal with fatigue life test data of front axle , basing on the life under different level load of test rig, predicted service life of automobile front axle under a long-80,000km-distance load spectra of user service condition using fatigue liner accumulative damage thesis.
With furious competition in automobile market ,user’s requirements for the reliability、harshness & safety become stronger and stronger , the complexity of component structure、the multiplicity and the irregularity of component service condition leads to more difficulty in its development process, the reliability of components has greater effect on economic benefit of enterprise ,all these mentioned above require that product development departments should apply modern fatigue & reliability design method in product design process ,to increase compete power in product market .
Based on above causes ,the project is presented, the purposes of this paper are as follows:
To predict product failure state、find and solve weak place of components in design as quickly as possible ,efficiently combining fatigue reliability test、structure analysis、reliability design works and etc. ,to produce a set of fatigue reliability development techniques of product ,to establish a kind of design & calculation method process basing on statistics and probability . all these works are done according to actual load spectra and fatigue life of automobile components.
This paper has measured and got a long-8km-distance load spectra of automobile front axle under actual vehicle service condition, measured and got its P-S-N fatigue characteristic curve parameters, and predicted its service life , so that a strong support for design of automobile front axle has given.
Main tasks of this project:
Determined calibration coefficient of load vs. strain for measuring position using multi-direction load calibration method ;measured each load condition parameters for simulation automobile users ;packed up and concluded multi-load spectra correlative to user service distance ,basing on investigation of user service condition and actual measuring load parameters of automobile components ,determined load levels and load magnitude for test rig of getting P-S-N fatigue characteristic curve parameters, produced P-S-N fatigue characteristic curve parameters by using group test method、determining least test samples for each level load、dealing with strange data and valid test data ,regressed all kind of P-S-N fatigue characteristic curve of different probability using power function for three parameters to deal with fatigue life test data of front axle , basing on the life under different level load of test rig, predicted service life of automobile front axle under a long-80,000km-distance load spectra of user service condition using fatigue liner accumulative damage thesis.
引文
[1] 姚卫星. 结构疲劳寿命分析国防工业出版社. 2003
[2] 高镇同. 熊峻江. 疲劳可靠性. 北京航空航天大学出版社. 2000
[3] 刘惟辛. 机械可靠性设计. 清华大学出版社. 1995
[4] 张义民. 汽车零部件靠性设计. 北京理工大学出版社. 2000
[5] Peter J.Heyes‘林晓彬 泽.基于有限元的疲劳设计分析系统 MSC/FATIGUE,中国机械工程,1998,9(11):12—15.
[6] 林晓彬.一套完整的疲劳分析设计试验管理系统 nSoft.中国机械工程,1998,9(11):8—11
[7] 冯根宁,诸德培,林富甲.随机裁荷下的疲劳寿命的估算.机械科学与技术,1996,15(6):879—882
[8] 曾春华,邹十践编译.疲劳分析方法及应用.北京:国防工业出版社,1991.
[9] 徐滴编著.疲劳强度设计.北京:机械工丛出版社,1981.
[10] 吕文阁,谢里阳,徐 酒.及杂教行下的囊劳舞命估算,东北大学学报,1996,12(6):633—636
[11] 倪侃.随机变幅下疲劳强度可靠性分折.上海交通大学学报,1996,30(2):23-28
[12] Collins J A.Failure of Matenals in Mechamcal Design John Weily&Sons‘Inc.1981
[13] Jan M.Austen,林晓斌 译.工程中的一体化疲劳耐久管理,中国机拭工程,1998,9(11):3—11.
[14] 宋 云,陈全世,王宵锋.轻型电动车车身—车架的有限元结构分折及试验研究.汽车技术,1997(10):23 —27.
[15] 张维锋,戴冠军,刘万锋.汽车零部件动态应变场的模态分折法,汽车工程,1997,19(4):221-225.
[16] 石章俊,石若芳.发动机曲铀事曲疲劳强度的可靠性分析.汽车技术,1996(1):16-20
[17] 王志明,张卧波,张元毅。复杂载荷下曲轴疲劳强度的可靠性.汽车技术,1996(3):14—18
[18] 赵幼平,许可芳.有限元法在轻型车真空助力器壳体结构优化设计中的应用,汽车研究与开发,1997(1):12—17
[19]郦明,奥脱。布克斯鲍姆,哈茨·罗华克著.结构抗疲劳设计,机械工业出版社,1987:227-230
[20]吕澎民.随机载荷下机车车辆承载构件可靠性疲劳设计计算方法研究.西南交通大学博士学位论文,1995
[21]张立民.高速动力车客车转向架构架随机疲劳强度与寿命分析.西南交通大学博士学位论文,1996
[22]中宏伟.疲劳损伤概率模型及应用.铁道部科学研究院,1999
[23]安俊平.疲劳累积损伤统计理论及其应用.北京航空航大人学博士学位论文,1991
[24]廖敏.概率疲劳及概率断裂力学研究.西北_I 一业大学博十学位论文,1993
[25]丁丽娟 数值计算方法.北京:北京理工大学出版社,1997:112-116
[26]孙荣恒 随机过程及其应用.北京:清华人学出版社,2004:179-180
[27]倪振华 振动力学.西安:西安交通人学出版社,1989: 242, 84-85
[28]Fairbairn, W. Experiments to determine the effect of impact, vibratory action, and long continued changes of load on wrought iron girders. Philosophical Transactions of the Royal Society, London 154, 1864:311
[29]Gerber,H.Bestimmung der zulassigen Spannungen in Eisen-konstructionen. Zeitschrift des Bayerischen Architeckten and Ingenieur-Vereins 6, 1874:101 一110
[30]Goodman. J. Mechanics Applied to Engineering. London: Longmans Green
[31]王成国,孟广伟,原亮明,刘敬辉。新型高速客车构架的疲劳寿命数值仿真分析.中国铁道科学,2001(3)
[32]孟广伟,王成国,刘敬辉,原亮明。用虚拟疲劳样机技术分析转 8A 型转向架侧架的疲劳寿命.中国铁道科学,2002(4)
[33]徐倩,谢基龙,缪龙秀,郑明军,姜岩。基于单轴损伤的货车钩尾框多轴疲劳寿命分析.铁道学报,2002(1)
[34]虞丽娟,李元君,沈钢。机车构件疲劳寿命仿真分析.铁道学报,1998(3)
[35]董保童,施荣明,朱广荣。随机振动载荷作用下的结构疲劳寿命估算一飞机设计,2001(3)
[36]何泽夏,张继桐,辛发祥。液体火箭发动机结构动态疲劳分析方法初探.疲劳与断裂2000:第十届全国疲劳与断裂学术会议论文集,北京:气象出版社,2000
[37]赵少汴:常用累积损伤理论疲劳寿命估算精度的试验研究,[J]机械强度,Vol.22 No.3, 2000
[38]平安,王德俊,徐灏:疲劳载荷谱编制方法的统一,[J]机械工程学报,Vol.32 No.3,1996
[39]明平顺,王宇宁,张智勇:汽车路面载荷历程计数法的一种新思路,[J]武汉汽车工业大学学报,Vo1.21 No.l, 1999
[40]明平顺,张智勇,马前祖:汽车部件疲劳载荷谱的计算机统计处理,[J]武汉汽车工业大学学报,Vo1.19 No.2, 1997
[41]王德俊,平安,徐灏:疲劳载荷谱编制准则,[J]机械强度,Vol.l5 No.4, 1993
[42]齐中华:Miner 疲劳损伤累积假说在谱状载荷中的应用,[J]机械设计与制造,No.2,1997
[43]陈龙,刘星荣:改进雨流计数法在拖拉机零部件疲劳寿命估算中的应用,[J]江苏工学院学报,Vol.ll No.2, 1990
[44]周源泉,翁朝曦:威布尔分布可靠性下限的 F 一近似的更正,[J]强度与环境,Vol.1,1989
[45]张桂明,姚烈,李嘉等:探索疲劳损伤理论在汽车疲劳试验中的应用,[J]上海汽车
[46]刘义伦,张宏:Miner Rule 中损伤率对计算疲劳寿命的影响,[J]矿冶工程,Vo1.18 No.3, 1998
[47]聂 宏:Miner 公式和 Manson-Coffin 公式的能量基础,[J]航空学报,Vol.l5 No.5,1993
[48]姚卫星:Miner 理论的统计特性分析,[J]航空学报,Vol.16 No.5, 1995
[49]赵少汴,王忠保主编,疲劳设计,机械工业出版社,1992.5
[50]徐颧,疲劳强度。北京:高等教育出版社,1988
[2] 高镇同. 熊峻江. 疲劳可靠性. 北京航空航天大学出版社. 2000
[3] 刘惟辛. 机械可靠性设计. 清华大学出版社. 1995
[4] 张义民. 汽车零部件靠性设计. 北京理工大学出版社. 2000
[5] Peter J.Heyes‘林晓彬 泽.基于有限元的疲劳设计分析系统 MSC/FATIGUE,中国机械工程,1998,9(11):12—15.
[6] 林晓彬.一套完整的疲劳分析设计试验管理系统 nSoft.中国机械工程,1998,9(11):8—11
[7] 冯根宁,诸德培,林富甲.随机裁荷下的疲劳寿命的估算.机械科学与技术,1996,15(6):879—882
[8] 曾春华,邹十践编译.疲劳分析方法及应用.北京:国防工业出版社,1991.
[9] 徐滴编著.疲劳强度设计.北京:机械工丛出版社,1981.
[10] 吕文阁,谢里阳,徐 酒.及杂教行下的囊劳舞命估算,东北大学学报,1996,12(6):633—636
[11] 倪侃.随机变幅下疲劳强度可靠性分折.上海交通大学学报,1996,30(2):23-28
[12] Collins J A.Failure of Matenals in Mechamcal Design John Weily&Sons‘Inc.1981
[13] Jan M.Austen,林晓斌 译.工程中的一体化疲劳耐久管理,中国机拭工程,1998,9(11):3—11.
[14] 宋 云,陈全世,王宵锋.轻型电动车车身—车架的有限元结构分折及试验研究.汽车技术,1997(10):23 —27.
[15] 张维锋,戴冠军,刘万锋.汽车零部件动态应变场的模态分折法,汽车工程,1997,19(4):221-225.
[16] 石章俊,石若芳.发动机曲铀事曲疲劳强度的可靠性分析.汽车技术,1996(1):16-20
[17] 王志明,张卧波,张元毅。复杂载荷下曲轴疲劳强度的可靠性.汽车技术,1996(3):14—18
[18] 赵幼平,许可芳.有限元法在轻型车真空助力器壳体结构优化设计中的应用,汽车研究与开发,1997(1):12—17
[19]郦明,奥脱。布克斯鲍姆,哈茨·罗华克著.结构抗疲劳设计,机械工业出版社,1987:227-230
[20]吕澎民.随机载荷下机车车辆承载构件可靠性疲劳设计计算方法研究.西南交通大学博士学位论文,1995
[21]张立民.高速动力车客车转向架构架随机疲劳强度与寿命分析.西南交通大学博士学位论文,1996
[22]中宏伟.疲劳损伤概率模型及应用.铁道部科学研究院,1999
[23]安俊平.疲劳累积损伤统计理论及其应用.北京航空航大人学博士学位论文,1991
[24]廖敏.概率疲劳及概率断裂力学研究.西北_I 一业大学博十学位论文,1993
[25]丁丽娟 数值计算方法.北京:北京理工大学出版社,1997:112-116
[26]孙荣恒 随机过程及其应用.北京:清华人学出版社,2004:179-180
[27]倪振华 振动力学.西安:西安交通人学出版社,1989: 242, 84-85
[28]Fairbairn, W. Experiments to determine the effect of impact, vibratory action, and long continued changes of load on wrought iron girders. Philosophical Transactions of the Royal Society, London 154, 1864:311
[29]Gerber,H.Bestimmung der zulassigen Spannungen in Eisen-konstructionen. Zeitschrift des Bayerischen Architeckten and Ingenieur-Vereins 6, 1874:101 一110
[30]Goodman. J. Mechanics Applied to Engineering. London: Longmans Green
[31]王成国,孟广伟,原亮明,刘敬辉。新型高速客车构架的疲劳寿命数值仿真分析.中国铁道科学,2001(3)
[32]孟广伟,王成国,刘敬辉,原亮明。用虚拟疲劳样机技术分析转 8A 型转向架侧架的疲劳寿命.中国铁道科学,2002(4)
[33]徐倩,谢基龙,缪龙秀,郑明军,姜岩。基于单轴损伤的货车钩尾框多轴疲劳寿命分析.铁道学报,2002(1)
[34]虞丽娟,李元君,沈钢。机车构件疲劳寿命仿真分析.铁道学报,1998(3)
[35]董保童,施荣明,朱广荣。随机振动载荷作用下的结构疲劳寿命估算一飞机设计,2001(3)
[36]何泽夏,张继桐,辛发祥。液体火箭发动机结构动态疲劳分析方法初探.疲劳与断裂2000:第十届全国疲劳与断裂学术会议论文集,北京:气象出版社,2000
[37]赵少汴:常用累积损伤理论疲劳寿命估算精度的试验研究,[J]机械强度,Vol.22 No.3, 2000
[38]平安,王德俊,徐灏:疲劳载荷谱编制方法的统一,[J]机械工程学报,Vol.32 No.3,1996
[39]明平顺,王宇宁,张智勇:汽车路面载荷历程计数法的一种新思路,[J]武汉汽车工业大学学报,Vo1.21 No.l, 1999
[40]明平顺,张智勇,马前祖:汽车部件疲劳载荷谱的计算机统计处理,[J]武汉汽车工业大学学报,Vo1.19 No.2, 1997
[41]王德俊,平安,徐灏:疲劳载荷谱编制准则,[J]机械强度,Vol.l5 No.4, 1993
[42]齐中华:Miner 疲劳损伤累积假说在谱状载荷中的应用,[J]机械设计与制造,No.2,1997
[43]陈龙,刘星荣:改进雨流计数法在拖拉机零部件疲劳寿命估算中的应用,[J]江苏工学院学报,Vol.ll No.2, 1990
[44]周源泉,翁朝曦:威布尔分布可靠性下限的 F 一近似的更正,[J]强度与环境,Vol.1,1989
[45]张桂明,姚烈,李嘉等:探索疲劳损伤理论在汽车疲劳试验中的应用,[J]上海汽车
[46]刘义伦,张宏:Miner Rule 中损伤率对计算疲劳寿命的影响,[J]矿冶工程,Vo1.18 No.3, 1998
[47]聂 宏:Miner 公式和 Manson-Coffin 公式的能量基础,[J]航空学报,Vol.l5 No.5,1993
[48]姚卫星:Miner 理论的统计特性分析,[J]航空学报,Vol.16 No.5, 1995
[49]赵少汴,王忠保主编,疲劳设计,机械工业出版社,1992.5
[50]徐颧,疲劳强度。北京:高等教育出版社,1988