钢丝的微动损伤行为及其微动疲劳寿命预测研究
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摘要
矿井提升过程中，提升钢丝绳内部股与股、丝与丝之间存在微动磨损和微动疲劳，将加速钢丝绳的疲劳断丝，导致钢丝绳承载能力的降低，影响了钢丝绳的使用可靠性以及煤矿的安全生产。因此，研究钢丝的微动损伤行为和微动疲劳寿命预测对延长钢丝绳服役寿命和提高钢丝绳的使用可靠性具有重要的意义。
本文以6×19+IWS钢丝绳为研究对象，通过静力学分析考察了矿井提升机上提容器始、末钢丝绳的承载状况及其受终端质量的影响。基于上提容器过程中钢丝绳张力的动力学模型建立了Simulink仿真模型，分析了最大提升速度、提升加（减）速度和终端质量对钢丝绳所受峰值张力和张力幅值的影响。仿真结果表明，在上提容器始、末阶段，过渡段钢丝绳张力的总范围分别为2102.1N～18762.1N和191.1N～16851.1N。在上提容器过程中，最大峰值张力、最大张力幅值、最小峰值张力和最小张力幅值的总变化范围分别为9793.3N～19896.9N、176N～4817.6N、1240N～19821.3N和39.5N～2366N。
依据钢丝绳静力学理论和接触力学知识，建立钢丝绳所受张力和张力幅值与钢丝微动疲劳参数间的数学关系模型并建立Simulink仿真模型，探讨了上提容器整个过程矿井提升参数对微动疲劳参数的影响。结果表明，在整个上提容器过程中，各微动疲劳参数的总范围几乎均随着矿井提升参数的增大而呈扩大或上升扩大的趋势，整个上提容器过程中绳内钢丝的拉力范围是1.5N～175.6N，相对位移范围是0.2μm～99.6μm，接触载荷的范围是0.2N～452.1N。
应用有限元法分析了6×19+IWS钢丝绳的应力和变形状况，运用精确的边界条件和子模型技术对受拉三层直股进行细致分析，探讨了摩擦系数和材料模型对应力分布和径向变形的影响。结果表明，钢丝表面的应力和变形均呈空间二次曲线状分布，钢丝绳轴向中间位置的截面上各应力均呈对称分布，直股和螺旋股中钢丝截面上的应力均分别沿径向向外降低，相邻螺旋股接触钢丝的变形差值最大。三层直股中，摩擦系数、材料模型和股轴向应变的变化均导致各丝的应力水平、相邻丝层钢丝接触区的应力突变和径向变形的不同。
运用三维赫兹接触理论分析了交叉角度和接触载荷对交叉接触钢丝的接触尺寸和最大接触应力的影响，建立了微动磨损过程中以不同角度交叉接触钢丝的磨损深度的演化模型以及磨损深度与微动参数间的关联模型。结果表明，不同的接触载荷和交叉角度会导致接触尺寸和最大接触应力的差异。比较钢丝交叉角度分别为90°和18°时不同微动参数下钢丝试样的微动磨损深度实验值和演化模型预测，发现两者吻合较好。
运用自制钢丝微动疲劳试验机开展了低周疲劳下钢丝的微动疲劳实验，探讨了微动振幅、应变幅值和接触载荷对钢丝微动疲劳行为的影响。结果表明，不同微动疲劳参数下实验过程中摩擦系数、微动运行区域、磨损机理、微动疲劳寿命以及裂纹萌生和扩展特性均有所差异，而这些微动疲劳行为要素是相互作用的。
采用有限元法研究了垂直交叉接触钢丝（无损伤和带磨损缺口）的微动疲劳行为，探讨了微动疲劳参数对微动运行区域和接触面应力分布的影响，运用多轴疲劳准则考察了微动疲劳初期疲劳钢丝微动面的裂纹萌生特性及其受微动参数的影响，运用线弹性断裂力学理论和幂函数拟合法建立了循环应力参数、接触载荷和微动振幅与钢丝微动疲劳寿命间的定量关系。结果表明，在两种情况下，不同微动疲劳参数均导致不同的微动运行区域、应力分布和接触边缘的应力突变。随着接触载荷和微动振幅的增大，疲劳钢丝接触面上裂纹萌生分别变得困难和容易，与应力分析结果一致。通过理论预测法和拟合法得到的寿命值与实验值吻合较好，验证了理论模型的正确性。
Fretting wear and fretting fatigue occurs among neighboring strands and among contactingwires in hoisting rope during lifting in coal mine, which accelerates the fatigue fracture of steelwires, thereby reduces the endurance strength of the rope, and thus affects the rope reliability andproduction safety in coal mine. Therefore, studies on fretting damage behavior and frettingfatigue life estimation of steel wires are significant to prolong the rope service life and toenhance the rope reliability.
6×19+IWS rope is taken as the objective of study in this thesis. Load-carrying conditionsof hoisting rope at the sheave tangent point at the start and end of a lifting cycle are explored bystatic analysis. Simulink simulation models are built based on dynamic models of the ropetension during the lifting cycle. The roles of maximum hoisting velocity, hoisting acceleration(deceleration), and terminal load on peak tensions and tension amplitudes of the rope during thelifting cycle are investigated. Simulation results show that overall ranges of the rope tensionvary from2102.1N to18762.1N and from191.1N to16851.1N at the start and end of thelifting cycle, respectively. During lifting, overall ranges of maximum peak tension, maximumtension amplitude, minimum peak tension and minimum tension amplitude are9793.3N-19896.9N,176N-4817.6N,1240N-19821.3N, and39.5N-2366N, respectively.
Mathematical relationships between tensions and tension amplitudes of the rope and frettingfatigue parameters of steel wires, and corresponding Simulink simulation models are establishedemploying the rope theory and contact mechanics. The effects of hoisting parameters onfretting fatigue parameters during the whole lifting cycle are discussed. Simulation resultsshow overall ranges of various fretting fatigue parameters almost all present the expanding orupward expanding trends with increasing hoisting parameters during the whole lifting cycle.Overall ranges of wire tension, contact load and relative displacement between wires changefrom1.5N to175.6N, from0.2N to452.1N and from0.2μm to99.6μm, respectively.
The stresses and deformations of6×19+IWS rope are explored employing the finite elementmethod. Detailed analysis of the three-layered strand under axial extension is carried out usingconcise boundary conditions and sub-modeling technique. Effects of friction of coefficient andmaterial model on stress distributions and radial deformations are analyzed. The results showthat stresses along wire surfaces and wire deformations both present distributions of quadraticcurves. Various stresses on the cross-section of rope in the axially middle location all exhibitsymmetric distributions. The stresses on cross-sections of the straight strand and spiral strandboth decrease along the radially outward direction, respectively. Neighboring spiral strands exhibit the largest difference in deformations of contacting wires. Variations of coefficient offriction, material model and strand axial extension strain all cause distinct stress levels of variouswires, abrupt changes of stress near contact zones of contacting wires of adjacent wire layers,and radial deformations.
Three-dimensional Hertzian contact theory is introduced to investigate the effects ofcrossing angle and contact load on the contact widths and maximum contact pressure. Theevolution of fretting wear depth of wires crossed at different angles during fretting wear and thecorrelation model between fretting wear depth and fretting parameters are established. Theresults demonstrate that different crossing angles and contact loads both cause distinct contactwidths and maximum contact pressure. Experimental values of wear depths of steel wirescrossed at angles of90°and18°in tests with different fretting parameters show good agreementwith corresponding predicted values, which validates the fretting wear evolution model.
The roles of fretting amplitude, strain amplitude and contact load on fretting fatiguebehaviors of steel wires in low cycle fatigue are investigated employing the homemade frettingfatigue test apparatus. The results show that different fretting fatigue parameters inducesdistinct coefficients of friction, fretting regimes, wear mechanisms, fretting fatigue lives, crackinitiation and propagation characteristics during the fretting fatigue tests. Those elements offretting fatigue behaviors interact with each other.
Fretting fatigue behaviors of perpendicularly crossed steel wires without damage and withwear gaps are studied using finite element method. The effects of fretting fatigue parameters onfretting regimes and stress distributions on contact surfaces are explored. Multiaxial fatiguecriteria are employed to investigate roles of fretting parameters on crack initiation characteristicson the tensile wire surface during the initial fretting stage. The linear elastic fracture mechanicsand method for a power function curve fitting are used to establish quantitative relationshipsbetween fretting fatigue lives of tensile wire and cyclic stress, contact load and fretting amplitude,respectively. The results show that different fretting fatigue parameters induce distinct frettingregimes, stress distributions and abrupt changes of stresses near trailing edges in two cases.Crack initiation on the contact surface of tensile wire becomes more difficult and easier withincreasing contact load and increasing fretting amplitude, respectively. Predicted fatigue livesare in good agreement with experimental values, which validates the theoretical model.
本文以6×19+IWS钢丝绳为研究对象，通过静力学分析考察了矿井提升机上提容器始、末钢丝绳的承载状况及其受终端质量的影响。基于上提容器过程中钢丝绳张力的动力学模型建立了Simulink仿真模型，分析了最大提升速度、提升加（减）速度和终端质量对钢丝绳所受峰值张力和张力幅值的影响。仿真结果表明，在上提容器始、末阶段，过渡段钢丝绳张力的总范围分别为2102.1N～18762.1N和191.1N～16851.1N。在上提容器过程中，最大峰值张力、最大张力幅值、最小峰值张力和最小张力幅值的总变化范围分别为9793.3N～19896.9N、176N～4817.6N、1240N～19821.3N和39.5N～2366N。
依据钢丝绳静力学理论和接触力学知识，建立钢丝绳所受张力和张力幅值与钢丝微动疲劳参数间的数学关系模型并建立Simulink仿真模型，探讨了上提容器整个过程矿井提升参数对微动疲劳参数的影响。结果表明，在整个上提容器过程中，各微动疲劳参数的总范围几乎均随着矿井提升参数的增大而呈扩大或上升扩大的趋势，整个上提容器过程中绳内钢丝的拉力范围是1.5N～175.6N，相对位移范围是0.2μm～99.6μm，接触载荷的范围是0.2N～452.1N。
应用有限元法分析了6×19+IWS钢丝绳的应力和变形状况，运用精确的边界条件和子模型技术对受拉三层直股进行细致分析，探讨了摩擦系数和材料模型对应力分布和径向变形的影响。结果表明，钢丝表面的应力和变形均呈空间二次曲线状分布，钢丝绳轴向中间位置的截面上各应力均呈对称分布，直股和螺旋股中钢丝截面上的应力均分别沿径向向外降低，相邻螺旋股接触钢丝的变形差值最大。三层直股中，摩擦系数、材料模型和股轴向应变的变化均导致各丝的应力水平、相邻丝层钢丝接触区的应力突变和径向变形的不同。
运用三维赫兹接触理论分析了交叉角度和接触载荷对交叉接触钢丝的接触尺寸和最大接触应力的影响，建立了微动磨损过程中以不同角度交叉接触钢丝的磨损深度的演化模型以及磨损深度与微动参数间的关联模型。结果表明，不同的接触载荷和交叉角度会导致接触尺寸和最大接触应力的差异。比较钢丝交叉角度分别为90°和18°时不同微动参数下钢丝试样的微动磨损深度实验值和演化模型预测，发现两者吻合较好。
运用自制钢丝微动疲劳试验机开展了低周疲劳下钢丝的微动疲劳实验，探讨了微动振幅、应变幅值和接触载荷对钢丝微动疲劳行为的影响。结果表明，不同微动疲劳参数下实验过程中摩擦系数、微动运行区域、磨损机理、微动疲劳寿命以及裂纹萌生和扩展特性均有所差异，而这些微动疲劳行为要素是相互作用的。
采用有限元法研究了垂直交叉接触钢丝（无损伤和带磨损缺口）的微动疲劳行为，探讨了微动疲劳参数对微动运行区域和接触面应力分布的影响，运用多轴疲劳准则考察了微动疲劳初期疲劳钢丝微动面的裂纹萌生特性及其受微动参数的影响，运用线弹性断裂力学理论和幂函数拟合法建立了循环应力参数、接触载荷和微动振幅与钢丝微动疲劳寿命间的定量关系。结果表明，在两种情况下，不同微动疲劳参数均导致不同的微动运行区域、应力分布和接触边缘的应力突变。随着接触载荷和微动振幅的增大，疲劳钢丝接触面上裂纹萌生分别变得困难和容易，与应力分析结果一致。通过理论预测法和拟合法得到的寿命值与实验值吻合较好，验证了理论模型的正确性。
Fretting wear and fretting fatigue occurs among neighboring strands and among contactingwires in hoisting rope during lifting in coal mine, which accelerates the fatigue fracture of steelwires, thereby reduces the endurance strength of the rope, and thus affects the rope reliability andproduction safety in coal mine. Therefore, studies on fretting damage behavior and frettingfatigue life estimation of steel wires are significant to prolong the rope service life and toenhance the rope reliability.
6×19+IWS rope is taken as the objective of study in this thesis. Load-carrying conditionsof hoisting rope at the sheave tangent point at the start and end of a lifting cycle are explored bystatic analysis. Simulink simulation models are built based on dynamic models of the ropetension during the lifting cycle. The roles of maximum hoisting velocity, hoisting acceleration(deceleration), and terminal load on peak tensions and tension amplitudes of the rope during thelifting cycle are investigated. Simulation results show that overall ranges of the rope tensionvary from2102.1N to18762.1N and from191.1N to16851.1N at the start and end of thelifting cycle, respectively. During lifting, overall ranges of maximum peak tension, maximumtension amplitude, minimum peak tension and minimum tension amplitude are9793.3N-19896.9N,176N-4817.6N,1240N-19821.3N, and39.5N-2366N, respectively.
Mathematical relationships between tensions and tension amplitudes of the rope and frettingfatigue parameters of steel wires, and corresponding Simulink simulation models are establishedemploying the rope theory and contact mechanics. The effects of hoisting parameters onfretting fatigue parameters during the whole lifting cycle are discussed. Simulation resultsshow overall ranges of various fretting fatigue parameters almost all present the expanding orupward expanding trends with increasing hoisting parameters during the whole lifting cycle.Overall ranges of wire tension, contact load and relative displacement between wires changefrom1.5N to175.6N, from0.2N to452.1N and from0.2μm to99.6μm, respectively.
The stresses and deformations of6×19+IWS rope are explored employing the finite elementmethod. Detailed analysis of the three-layered strand under axial extension is carried out usingconcise boundary conditions and sub-modeling technique. Effects of friction of coefficient andmaterial model on stress distributions and radial deformations are analyzed. The results showthat stresses along wire surfaces and wire deformations both present distributions of quadraticcurves. Various stresses on the cross-section of rope in the axially middle location all exhibitsymmetric distributions. The stresses on cross-sections of the straight strand and spiral strandboth decrease along the radially outward direction, respectively. Neighboring spiral strands exhibit the largest difference in deformations of contacting wires. Variations of coefficient offriction, material model and strand axial extension strain all cause distinct stress levels of variouswires, abrupt changes of stress near contact zones of contacting wires of adjacent wire layers,and radial deformations.
Three-dimensional Hertzian contact theory is introduced to investigate the effects ofcrossing angle and contact load on the contact widths and maximum contact pressure. Theevolution of fretting wear depth of wires crossed at different angles during fretting wear and thecorrelation model between fretting wear depth and fretting parameters are established. Theresults demonstrate that different crossing angles and contact loads both cause distinct contactwidths and maximum contact pressure. Experimental values of wear depths of steel wirescrossed at angles of90°and18°in tests with different fretting parameters show good agreementwith corresponding predicted values, which validates the fretting wear evolution model.
The roles of fretting amplitude, strain amplitude and contact load on fretting fatiguebehaviors of steel wires in low cycle fatigue are investigated employing the homemade frettingfatigue test apparatus. The results show that different fretting fatigue parameters inducesdistinct coefficients of friction, fretting regimes, wear mechanisms, fretting fatigue lives, crackinitiation and propagation characteristics during the fretting fatigue tests. Those elements offretting fatigue behaviors interact with each other.
Fretting fatigue behaviors of perpendicularly crossed steel wires without damage and withwear gaps are studied using finite element method. The effects of fretting fatigue parameters onfretting regimes and stress distributions on contact surfaces are explored. Multiaxial fatiguecriteria are employed to investigate roles of fretting parameters on crack initiation characteristicson the tensile wire surface during the initial fretting stage. The linear elastic fracture mechanicsand method for a power function curve fitting are used to establish quantitative relationshipsbetween fretting fatigue lives of tensile wire and cyclic stress, contact load and fretting amplitude,respectively. The results show that different fretting fatigue parameters induce distinct frettingregimes, stress distributions and abrupt changes of stresses near trailing edges in two cases.Crack initiation on the contact surface of tensile wire becomes more difficult and easier withincreasing contact load and increasing fretting amplitude, respectively. Predicted fatigue livesare in good agreement with experimental values, which validates the theoretical model.
引文
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