一种基于低周疲劳特性的含缺陷车轴剩余寿命预测模型
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摘要
车轴几何约束和外部环境的特殊性,使得压装部、卸荷槽及过渡圆角易于形成缺陷或者微裂纹,该缺陷或微裂纹已成为高速列车运营的重大安全威胁。深入研究微裂纹的演变规律,准确预测含缺陷车轴的剩余强度和寿命,制定出合理、经济的无损检测周期,迫在眉睫。基于平面应力Ⅰ型裂纹尖端修正的RKE奇异场和循环塑性应变能准则,考虑应变硬化材料的小范围屈服行为,通过引入适用于正负应力比的裂纹闭合函数实现对裂纹闭合与近门槛区行为的模拟,提出一种基于材料低周疲劳特性的伤损车轴疲劳裂纹扩展寿命模型。结果表明,该模型的预测曲线与不同厚度标准试样得到的疲劳开裂数据吻合良好,可以用于承受典型旋转弯曲加载的铁路车轴的剩余寿命预测。
Serious fatigue damage or micro cracks may happen inside press-fits,relief groove,geometry transition and axle outer surface due to special geometry shape and environment,which imposes a major safety threat to the operation of high-speed trains.It is therefore,necessary to conduct detailed investigations on the evolution of fatigue cracks,which well predicts the fatigue crack growth and resulting service life and strength together with suitable and economic non-destructive testing cycle.Based on modeⅠfatigue cracking RKE singularity field and cyclic plastic strain energy failure criterion ahead of a growing crack tip,a novel low cycle fatigue behavior based fatigue cracking rate model was proposed in terms of plasticity-induced crack closure under small-scale yielding and plain stress conditions for variable loading ratios to realize the simulation of the closure and near threshold behavior of the crack.Results show that a very good agreement between the prediction curve of the model and experimental data is found on the fatigue cracking results from different specimens with varied thickness,thus providing aprobable theoretical residual life model of railway damaged axles subjected to typical rotating bending loads.
Serious fatigue damage or micro cracks may happen inside press-fits,relief groove,geometry transition and axle outer surface due to special geometry shape and environment,which imposes a major safety threat to the operation of high-speed trains.It is therefore,necessary to conduct detailed investigations on the evolution of fatigue cracks,which well predicts the fatigue crack growth and resulting service life and strength together with suitable and economic non-destructive testing cycle.Based on modeⅠfatigue cracking RKE singularity field and cyclic plastic strain energy failure criterion ahead of a growing crack tip,a novel low cycle fatigue behavior based fatigue cracking rate model was proposed in terms of plasticity-induced crack closure under small-scale yielding and plain stress conditions for variable loading ratios to realize the simulation of the closure and near threshold behavior of the crack.Results show that a very good agreement between the prediction curve of the model and experimental data is found on the fatigue cracking results from different specimens with varied thickness,thus providing aprobable theoretical residual life model of railway damaged axles subjected to typical rotating bending loads.
引文
[1]ZERBST U,VORMWALD M,ANDERSCH C,et al.The Development of a Damage Tolerance Concept for Railway Components and Its Demonstration for a Railway Axle[J].Engineer Fracture Mechanics,2005,72(2):209-239.
[2]MAKINO T,KATO T,HIRAKAWA K.Review of the Fatigue Damage Tolerance of High-speed Railway Axles in Japan[J].Engineer Fracture Mechanics,2011,78(5):810-825.
[3]周素霞,谢基龙,郑红霞.空心车轴不同形状比裂纹应力强度因子的仿真研究[J].铁道学报,2008,30(5):114-118.ZHOU Suxia,XIE Jilong,ZHENG Hongxia.The Finite Element Research of Stress Intensity Factors at Surface Crack Front of Hollow Axles[J].Journal of the China Railway Society,2008,30(5):114-118.
[4]BATHIAS C,PINEAU A.材料与结构的疲劳[M].吴圣川,李源,王清远,译.北京:国防工业出版社,2016.
[5]商跃进.车轴疲劳裂纹扩展寿命可靠性分析方法[J].兰州铁道学院学报(自然科学版),2003,22(5):44-46.SHANG Yuejin.Reliability Analysis Method for Fatigue Crack Grown Life of Axle[J].Journal of Lanzhou Railway University(Natural Sciences),2003,22(5):44-46.
[6]刘志明,孙守光,缪龙秀.车轴裂纹扩展寿命的分析与计算方法[J].中国铁道科学,2008,29(3):89-94.LIU Zhiming,SUN Shouguang,MIAO Longxiu.Analysis and Calculation Method of Axle Crack Growth Life[J].China Railway Science,2008,29(3):89-94.
[7]石凯凯,蔡力勋,包陈.预测疲劳裂纹扩展的多种理论预测模型[J].机械工程学报,2014,50(18):50-58.SHI Kaikai,CAI Lixun,BAO Chen.Various Theoretical Models Study of Prediction Fatigue Crack Growth[J].Journal of Mechanical Engineering,2014,50(18):50-58.
[8]杨冰,赵永翔.两种终加工工艺下LZ50车轴钢疲劳短裂纹扩展行为对比研究[J].铁道学报,2013,35(5):34-39.YANG Bing,ZHAO Yongxiang.Comparative Study on Short Fatigue Crack Growth Behavior of Axle Steel LZ50with Two Final Processing Methods[J].Journal of the China Railway Society,2013,35(5):34-39.
[9]RICE J R.Stresses Due to a Sharp Notch in a Work-hardening Elastic-plastic Material Loaded by Longitudinal Shear[J].Journal of Applied Mechanics,1967,34(2):287-298.
[10]ELLYIN F.Crack Growth Rate under Cyclic Loading and Effect of Different Singularity Fields[J].Engineer Fracture Mechanics,1986,25(4):463-473.
[11]RICE J R.The Mechanics of Crack Tip Deformation and Extension by Fatigue[C]//Symposium on Fatigue Crack Propagation.Philadelphia:ASTM STP,1967:247-309.
[12]ELBER W.Fatigue Crack Closure under Cyclic Tension[J].Engineer Fracture Mechanics,1970,2(1):37-45.
[13]MAIERHOFER J,PIPPAN R,GANSER H P.Modified NASGRO Equation for Physically Short Cracks[J].International Journal of Fatigue,2014,59:200-207.
[14]DOWLING NE.Mechanical Behaviour of Materials:Engineering Methods for Deformation,Fracture and Fatigue[M].New Jersey:Prentice Hall,1999.
[15]YUEN A,HOPKIN S W,LEVERANT G R,et al.Correlations Between Fracture Surface Appearance and Fracture Mechanics Parameters for StageⅡFatigue Crack Propagation in Ti-6AI-4V[J].Metallurgical Transactions,1974,5(8):1833-1842.
[16]WU S C,XU Z W,YU C,et al.A Physically Short Fatigue Crack Growth Approach Based on Low Cycle Fatigue Properties[J].International Journal of Fatigue,2017,103:185-195.
[17]DE CASTRO J T P,MEGGIOLARO M A,DE OLIVEIRA MIRANDA A C.Singular and Non-singular Approaches for Predicting Fatigue Crack Growth Behavior[J].International Journal of Fatigue,2005,27(10):1366-1388.
[18]MOWBRAY D F,KAISAND L R.Relationships Between Low-cycle Fatigue and Fatigue Crack Growth Rate Properties[J].Journal of Testing and Evaluation,1979,7(5):270-280.
[19]NOROOZI A H,GLINKA G,LAMBERT S.A Two Parameter Driving Force for Fatigue Crack Growth Analysis[J].International Journal of Fatigue,2005,27(10/11/12):1277-1296.
[20]GANSER H P,MAIERHOFER J,TICHY R,et al.Damage Tolerance of Railway Axles-the Issue of Transferability Revisited[J].Int.J.Fatigue,2016,86:52-57.
[21]SHI K K,CAI L X,QI S,et al.A Prediction Model for Fatigue Crack Growth using Effective Cyclic Plastic Zone and Low Cycle Fatigue Properties[J].Engineer Fracture Mechanics,2016,158:209-219.
[22]候卫星.车轴疲劳裂纹扩展的计算与分析[J].铁道学报,1993,15(2):8-15.HOU Weixing.Calculation and Analysis on the Expansion of Fatigue Cracks on Axle[J].Journal of the China Railway Society,1993,15(2):8-15.
[23]VARFOLOMEEV I,LUKE R,BURDACK M.Effect of Specimen Geometry on Fatigue Crack Growth Rates for the Railway Axle Material EA4T[J].Engineer Fracture Mechanics,2011,78(5):742-753.
[24]ZERBST U,SCHODEL M,BEIER H T H.Parameters Affecting the Damage Tolerance Behaviour of Railway Axles[J].Engineer Fracture Mechanics,2011,78(5):793-809.
[2]MAKINO T,KATO T,HIRAKAWA K.Review of the Fatigue Damage Tolerance of High-speed Railway Axles in Japan[J].Engineer Fracture Mechanics,2011,78(5):810-825.
[3]周素霞,谢基龙,郑红霞.空心车轴不同形状比裂纹应力强度因子的仿真研究[J].铁道学报,2008,30(5):114-118.ZHOU Suxia,XIE Jilong,ZHENG Hongxia.The Finite Element Research of Stress Intensity Factors at Surface Crack Front of Hollow Axles[J].Journal of the China Railway Society,2008,30(5):114-118.
[4]BATHIAS C,PINEAU A.材料与结构的疲劳[M].吴圣川,李源,王清远,译.北京:国防工业出版社,2016.
[5]商跃进.车轴疲劳裂纹扩展寿命可靠性分析方法[J].兰州铁道学院学报(自然科学版),2003,22(5):44-46.SHANG Yuejin.Reliability Analysis Method for Fatigue Crack Grown Life of Axle[J].Journal of Lanzhou Railway University(Natural Sciences),2003,22(5):44-46.
[6]刘志明,孙守光,缪龙秀.车轴裂纹扩展寿命的分析与计算方法[J].中国铁道科学,2008,29(3):89-94.LIU Zhiming,SUN Shouguang,MIAO Longxiu.Analysis and Calculation Method of Axle Crack Growth Life[J].China Railway Science,2008,29(3):89-94.
[7]石凯凯,蔡力勋,包陈.预测疲劳裂纹扩展的多种理论预测模型[J].机械工程学报,2014,50(18):50-58.SHI Kaikai,CAI Lixun,BAO Chen.Various Theoretical Models Study of Prediction Fatigue Crack Growth[J].Journal of Mechanical Engineering,2014,50(18):50-58.
[8]杨冰,赵永翔.两种终加工工艺下LZ50车轴钢疲劳短裂纹扩展行为对比研究[J].铁道学报,2013,35(5):34-39.YANG Bing,ZHAO Yongxiang.Comparative Study on Short Fatigue Crack Growth Behavior of Axle Steel LZ50with Two Final Processing Methods[J].Journal of the China Railway Society,2013,35(5):34-39.
[9]RICE J R.Stresses Due to a Sharp Notch in a Work-hardening Elastic-plastic Material Loaded by Longitudinal Shear[J].Journal of Applied Mechanics,1967,34(2):287-298.
[10]ELLYIN F.Crack Growth Rate under Cyclic Loading and Effect of Different Singularity Fields[J].Engineer Fracture Mechanics,1986,25(4):463-473.
[11]RICE J R.The Mechanics of Crack Tip Deformation and Extension by Fatigue[C]//Symposium on Fatigue Crack Propagation.Philadelphia:ASTM STP,1967:247-309.
[12]ELBER W.Fatigue Crack Closure under Cyclic Tension[J].Engineer Fracture Mechanics,1970,2(1):37-45.
[13]MAIERHOFER J,PIPPAN R,GANSER H P.Modified NASGRO Equation for Physically Short Cracks[J].International Journal of Fatigue,2014,59:200-207.
[14]DOWLING NE.Mechanical Behaviour of Materials:Engineering Methods for Deformation,Fracture and Fatigue[M].New Jersey:Prentice Hall,1999.
[15]YUEN A,HOPKIN S W,LEVERANT G R,et al.Correlations Between Fracture Surface Appearance and Fracture Mechanics Parameters for StageⅡFatigue Crack Propagation in Ti-6AI-4V[J].Metallurgical Transactions,1974,5(8):1833-1842.
[16]WU S C,XU Z W,YU C,et al.A Physically Short Fatigue Crack Growth Approach Based on Low Cycle Fatigue Properties[J].International Journal of Fatigue,2017,103:185-195.
[17]DE CASTRO J T P,MEGGIOLARO M A,DE OLIVEIRA MIRANDA A C.Singular and Non-singular Approaches for Predicting Fatigue Crack Growth Behavior[J].International Journal of Fatigue,2005,27(10):1366-1388.
[18]MOWBRAY D F,KAISAND L R.Relationships Between Low-cycle Fatigue and Fatigue Crack Growth Rate Properties[J].Journal of Testing and Evaluation,1979,7(5):270-280.
[19]NOROOZI A H,GLINKA G,LAMBERT S.A Two Parameter Driving Force for Fatigue Crack Growth Analysis[J].International Journal of Fatigue,2005,27(10/11/12):1277-1296.
[20]GANSER H P,MAIERHOFER J,TICHY R,et al.Damage Tolerance of Railway Axles-the Issue of Transferability Revisited[J].Int.J.Fatigue,2016,86:52-57.
[21]SHI K K,CAI L X,QI S,et al.A Prediction Model for Fatigue Crack Growth using Effective Cyclic Plastic Zone and Low Cycle Fatigue Properties[J].Engineer Fracture Mechanics,2016,158:209-219.
[22]候卫星.车轴疲劳裂纹扩展的计算与分析[J].铁道学报,1993,15(2):8-15.HOU Weixing.Calculation and Analysis on the Expansion of Fatigue Cracks on Axle[J].Journal of the China Railway Society,1993,15(2):8-15.
[23]VARFOLOMEEV I,LUKE R,BURDACK M.Effect of Specimen Geometry on Fatigue Crack Growth Rates for the Railway Axle Material EA4T[J].Engineer Fracture Mechanics,2011,78(5):742-753.
[24]ZERBST U,SCHODEL M,BEIER H T H.Parameters Affecting the Damage Tolerance Behaviour of Railway Axles[J].Engineer Fracture Mechanics,2011,78(5):793-809.