机体关键部位机械疲劳分析方法研究
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摘要
我国汽车产量逐年增长并已居世界第一,发动机的可靠性是汽车技术水平的重要指标之一,对提高产品的竞争力有重要意义。目前在车用发动机技术领域,燃烧强化与结构轻量化是两大主流趋势,这对于发动机主承力结构的设计提出了挑战。
本文以发动机机体为研究对象,采用疲劳仿真方法结合试验验证手段,重点针对机体疲劳关键部位研究了载荷和结构因素的影响,并结合分析案例实施了结构改进设计。
论文的主要工作和结论如下：
1.以495机体为例,采用S-N曲线法,进行某运行工况下的疲劳寿命仿真,获得了机体的疲劳关键部位,包括中隔板和上机体两个区域。
2.以中隔板为重点考察部位,采用数值仿真方法对比分析了运行工况下与现有疲劳试验载荷加载方式下中隔板的疲劳寿命分布,说明了疲劳试验载荷加载方法的合理性；对比分析了集中载荷、分布载荷两种载荷形式对中隔板疲劳寿命的影响,结果表明,对于中隔板而言,两种载荷影响的差异可以忽略。
3.在上述研究及参考国外机体疲劳试验设备的基础上,开发了机体疲劳试验系统,系统能够实现两种加载方式。
4.进行了机体疲劳试验,并与机体疲劳仿真计算结果进行了对比,结果表明,在中隔板处,试验失效位置与仿真得到的疲劳薄弱位置基本一致。针对试验发现的主轴承螺栓孔断裂问题进行了螺纹联接结构疲劳仿真,获得了疲劳薄弱位置,且与试验结果一致。对比计算了螺纹联接局部结构改变对螺纹孔疲劳寿命的影响,结果表明螺纹啮合区末端对应的机体壁面加厚是提高疲劳寿命的有效方法,改进设计后的试验结果验证了分析结果。
China is a country with the highest automobile products in the world. The reliability of automobile is one of the most important performances to the level of technology. It has a significant impact on the product competitiveness. Strengthened combustion and lightweight structures are2main trends in vehicle engine technology. It puts forward the new challenge to the design for main loaded structures in engine.
This thesis conducted the study on mechanical fatigue of cylinder block. The influence of loads and structures to fatigue lives in key parts of cylinder block is studied by simulation and fatigue test. The improving design of structure is conducted according to simulation and test results.
Contents of this thesis can be briefly listed as:
1. The fatigue life distribution of495diesel cylinder block under a working condition is simulated and obtains the key parts including bulkhead and upper part of cylinder block.
2. The fatigue lives of bulkhead under fatigue test load and operation load are simulated, The results show that the existing fatigue test load is valid; The fatigue lives of cylinder block under the two means of applying loads in fatigue test are simulated and compared, the results show that in bulkhead area the influence by different applying load means can be ignored.
3. The cylinder block fatigue test rig are developed on the basis of above study and reference of test rig in foreign country. Two different loads can be applied on the test rig.
4. The cylinder block fatigue tests are conducted on the developed test rig. The test results are compared with the simulation results. The weak positions in bulkhead are almost the same with the positions that fracture occurred during tests. The fatigue lives of bolt hole area are simulated after fatigue crack occurred in this area. The fatigue weak position obtained by simulation is same as position where crack occurred in fatigue tests. Then the fatigue lives are simulated and compared after design change near thread engage area. The results showed that increasing thickness near the last engage thread is a valid method. It is verified by the tests results after improving design.
本文以发动机机体为研究对象,采用疲劳仿真方法结合试验验证手段,重点针对机体疲劳关键部位研究了载荷和结构因素的影响,并结合分析案例实施了结构改进设计。
论文的主要工作和结论如下：
1.以495机体为例,采用S-N曲线法,进行某运行工况下的疲劳寿命仿真,获得了机体的疲劳关键部位,包括中隔板和上机体两个区域。
2.以中隔板为重点考察部位,采用数值仿真方法对比分析了运行工况下与现有疲劳试验载荷加载方式下中隔板的疲劳寿命分布,说明了疲劳试验载荷加载方法的合理性；对比分析了集中载荷、分布载荷两种载荷形式对中隔板疲劳寿命的影响,结果表明,对于中隔板而言,两种载荷影响的差异可以忽略。
3.在上述研究及参考国外机体疲劳试验设备的基础上,开发了机体疲劳试验系统,系统能够实现两种加载方式。
4.进行了机体疲劳试验,并与机体疲劳仿真计算结果进行了对比,结果表明,在中隔板处,试验失效位置与仿真得到的疲劳薄弱位置基本一致。针对试验发现的主轴承螺栓孔断裂问题进行了螺纹联接结构疲劳仿真,获得了疲劳薄弱位置,且与试验结果一致。对比计算了螺纹联接局部结构改变对螺纹孔疲劳寿命的影响,结果表明螺纹啮合区末端对应的机体壁面加厚是提高疲劳寿命的有效方法,改进设计后的试验结果验证了分析结果。
China is a country with the highest automobile products in the world. The reliability of automobile is one of the most important performances to the level of technology. It has a significant impact on the product competitiveness. Strengthened combustion and lightweight structures are2main trends in vehicle engine technology. It puts forward the new challenge to the design for main loaded structures in engine.
This thesis conducted the study on mechanical fatigue of cylinder block. The influence of loads and structures to fatigue lives in key parts of cylinder block is studied by simulation and fatigue test. The improving design of structure is conducted according to simulation and test results.
Contents of this thesis can be briefly listed as:
1. The fatigue life distribution of495diesel cylinder block under a working condition is simulated and obtains the key parts including bulkhead and upper part of cylinder block.
2. The fatigue lives of bulkhead under fatigue test load and operation load are simulated, The results show that the existing fatigue test load is valid; The fatigue lives of cylinder block under the two means of applying loads in fatigue test are simulated and compared, the results show that in bulkhead area the influence by different applying load means can be ignored.
3. The cylinder block fatigue test rig are developed on the basis of above study and reference of test rig in foreign country. Two different loads can be applied on the test rig.
4. The cylinder block fatigue tests are conducted on the developed test rig. The test results are compared with the simulation results. The weak positions in bulkhead are almost the same with the positions that fracture occurred during tests. The fatigue lives of bolt hole area are simulated after fatigue crack occurred in this area. The fatigue weak position obtained by simulation is same as position where crack occurred in fatigue tests. Then the fatigue lives are simulated and compared after design change near thread engage area. The results showed that increasing thickness near the last engage thread is a valid method. It is verified by the tests results after improving design.
引文
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