发动机机体疲劳可靠性模拟试验基础问题研究
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摘要
疲劳可靠性是汽车关键零部件的重要性能指标之一,也是我国汽车产品设计技术与国际先进水平的主要差距所在。本文以CAE仿真分析方法和强化疲劳试验技术为手段,对发动机机体疲劳特性进行了深入研究,主要研究内容如下：
1)基于有限元分析方法,对发动机机体疲劳模拟试验系统进行CAE仿真分析,建立了较为完备的试验模型,研究了疲劳试验中加载轴类型(半轴、全轴)及轴瓦装配参数(间隙、过盈量)对发动机机体相应部位的应力特性的影响。研究发现,与全轴传递方式相比,半轴传递作用下的轴瓦接触压力、主轴承座应力及轴承孔变形等均较大。应力随轴瓦装配过盈量增大而增大,而轴瓦间隙对应力的影响作用相对复杂。
2)为实现发动机机体疲劳试验系统中裂纹发生诊断的自动化、智能化,通过经典时序分析方法对试验过程中采集的动态应变信号进行AR模型参数估计,时序模型中残差方差特征量对裂纹发生非常敏感,应变时序信号的微小变化便可使模型残差方差发生突变,因此,利用时间序列的残差方差可定性地诊断裂纹的发生。基于CAE仿真分析,对机体进行裂纹预制,并采用“应变相对变化量”方法对裂纹进行定位分析,通过损伤指标可以对裂纹的发生位置进行识别。损伤位置指标利用了各点应变的相关性,具有定位精度高的特性,论文采用对机体预制裂纹的方法进行了验证,通过计算可知定位误差约为2.25%。
3)由于发动机机体的几何结构复杂,即使在简单载荷的作用下,结构复杂的部位仍然呈现多轴应力状态,如凸轮轴孔与主油道孔贯穿部位。这些部位需采用多轴疲劳损伤模型进行疲劳寿命预测。论文在现行的应用于标准缺口试件的多轴疲劳损伤模型的基础上,以临界平面内的剪切应变与正应变的非线性组合作为损伤控制参量,提出了一种新的基于临界平面的多轴疲劳损伤模型,并通过试验验证了该损伤模型的正确性。
4)针对发动机机体生产成本较高,试验周期较长等特点,采用小样本试件对机体疲劳极限进行预测,以最小二乘法反推寿命为1000次的载荷为低周疲劳载荷点,将其应用于SAFL方法中对疲劳极限值进行预测,分别采用Gauss分布和Weibull分布进行疲劳可靠性统计。通过对多组疲劳试验数据的回归分析可知,Gauss分布统计的母体样本均值和方差与Weibull分布统计的差别甚微,但是试验数据的质量直接影响拟合的精度。
5)采用标准裂纹和缺口构件对机体凸轮轴孔部位应力场进行等效,将断裂力学概念引入到机体疲劳极限预测中,通过疲劳试验结果与标准裂纹的对比将疲劳试验的结果与标准裂纹的对比,计算材料的疲劳裂纹扩展的门槛值,通过应力强度因子门槛值对相同材料、相同生产工艺的其它构件的疲劳极限载荷进行预测。
Fatigue reliability is one of the most important performances of critical automobile parts, and it is the principal element that restricts our automobile industry to achieve international level. In the paper fatigue properties of engine-block were lucubrated by means of CAE (Computer Aided Engineering) and strengthened fatigue test. The main contents are as follows:
1) Simulation experiment system was modeled based on FE (Finite Element) analysis, and the relationship between shaft style (half-shaft, whole-shaft), assembly parameters of bearing (clearance, interference) and stress of engine-block was studied. The results show that compared with acting by half-shaft, the contact pressure of bearing, stress of main bearing wall and deformation of bearing hole acting by whole-shaft are greater.. Stress with the bearing assembly interference increases, but relationship between bearing clearance and stress is relatively complex.
2) In order to realize automation and intelligentialize for fatigue crack diagnosis of engine-block fatigue test system, classical time-series analysis was applied to dynamic strain data acquired in fatigue test, and parameters of AR model were estimated. Residual variance of AR model is very sensitive to occurrence of crack, and the sbutle difference of strain lead to abrupt change of residual variance of AR model. Residual variance of AR model can diagnose the occurence of crack qualitatively in engine-block fatigue test. Engine-block with prefabricated crack was modeled by FE, and relative variation of strain was analysed, and damage index was applied to diagnose the position of crack. Damage index made full use of the relationship between all strain points, so it has high-accuracy for diagnosing position of crack, and position error is approximately2.25%.
3) Engine-block has complex geometry, and thouth it was acted by simple load, the stress status can take on multiaxiality. For example, the position of intercrossing between camshaft hole and main oil hole is that. Fatigue life of these positons should be estimated by multiaxial fatigue damage model. On the basis of popular multiaxial damge model which had applied to the standard notched specimens generally, a new multiaxial damage model was proposed based on cirtial plane, which was made by nolinear combination of shear and normal strain on critical plane. Finally, the new damage model was verified by experiment.
4) Considering high costs and large test period for the engine-block, a small number of specimens were used to predict fatigue limit of the engine-block. The load of low cycle life was estimated using least-squares method from test data. Fatigue limit was estimated by SAFL which was modified by load of low cycle life. Fatigue reliability was studied using Gauss and Weibull distribution respectively. The result of regression analysis on fatigue test data shows that mean and variance estimated by Gauss distribution were little different from that estimated by Weibull distribution, But the quality of test data affects fitting accuracy directly.
5) Model of crack and notch was built by stress field of crack equivalent to camshaft hole, and fracture mechanics was applied to prediction of fagitue limit of engine-block. The threshold of stress intensity factor was estimated by comparing between test datum and crack model. Fatigue limit of other components with the same material, the same production process were estimated by threshold of stress intensity factor and the stress status.
1)基于有限元分析方法,对发动机机体疲劳模拟试验系统进行CAE仿真分析,建立了较为完备的试验模型,研究了疲劳试验中加载轴类型(半轴、全轴)及轴瓦装配参数(间隙、过盈量)对发动机机体相应部位的应力特性的影响。研究发现,与全轴传递方式相比,半轴传递作用下的轴瓦接触压力、主轴承座应力及轴承孔变形等均较大。应力随轴瓦装配过盈量增大而增大,而轴瓦间隙对应力的影响作用相对复杂。
2)为实现发动机机体疲劳试验系统中裂纹发生诊断的自动化、智能化,通过经典时序分析方法对试验过程中采集的动态应变信号进行AR模型参数估计,时序模型中残差方差特征量对裂纹发生非常敏感,应变时序信号的微小变化便可使模型残差方差发生突变,因此,利用时间序列的残差方差可定性地诊断裂纹的发生。基于CAE仿真分析,对机体进行裂纹预制,并采用“应变相对变化量”方法对裂纹进行定位分析,通过损伤指标可以对裂纹的发生位置进行识别。损伤位置指标利用了各点应变的相关性,具有定位精度高的特性,论文采用对机体预制裂纹的方法进行了验证,通过计算可知定位误差约为2.25%。
3)由于发动机机体的几何结构复杂,即使在简单载荷的作用下,结构复杂的部位仍然呈现多轴应力状态,如凸轮轴孔与主油道孔贯穿部位。这些部位需采用多轴疲劳损伤模型进行疲劳寿命预测。论文在现行的应用于标准缺口试件的多轴疲劳损伤模型的基础上,以临界平面内的剪切应变与正应变的非线性组合作为损伤控制参量,提出了一种新的基于临界平面的多轴疲劳损伤模型,并通过试验验证了该损伤模型的正确性。
4)针对发动机机体生产成本较高,试验周期较长等特点,采用小样本试件对机体疲劳极限进行预测,以最小二乘法反推寿命为1000次的载荷为低周疲劳载荷点,将其应用于SAFL方法中对疲劳极限值进行预测,分别采用Gauss分布和Weibull分布进行疲劳可靠性统计。通过对多组疲劳试验数据的回归分析可知,Gauss分布统计的母体样本均值和方差与Weibull分布统计的差别甚微,但是试验数据的质量直接影响拟合的精度。
5)采用标准裂纹和缺口构件对机体凸轮轴孔部位应力场进行等效,将断裂力学概念引入到机体疲劳极限预测中,通过疲劳试验结果与标准裂纹的对比将疲劳试验的结果与标准裂纹的对比,计算材料的疲劳裂纹扩展的门槛值,通过应力强度因子门槛值对相同材料、相同生产工艺的其它构件的疲劳极限载荷进行预测。
Fatigue reliability is one of the most important performances of critical automobile parts, and it is the principal element that restricts our automobile industry to achieve international level. In the paper fatigue properties of engine-block were lucubrated by means of CAE (Computer Aided Engineering) and strengthened fatigue test. The main contents are as follows:
1) Simulation experiment system was modeled based on FE (Finite Element) analysis, and the relationship between shaft style (half-shaft, whole-shaft), assembly parameters of bearing (clearance, interference) and stress of engine-block was studied. The results show that compared with acting by half-shaft, the contact pressure of bearing, stress of main bearing wall and deformation of bearing hole acting by whole-shaft are greater.. Stress with the bearing assembly interference increases, but relationship between bearing clearance and stress is relatively complex.
2) In order to realize automation and intelligentialize for fatigue crack diagnosis of engine-block fatigue test system, classical time-series analysis was applied to dynamic strain data acquired in fatigue test, and parameters of AR model were estimated. Residual variance of AR model is very sensitive to occurrence of crack, and the sbutle difference of strain lead to abrupt change of residual variance of AR model. Residual variance of AR model can diagnose the occurence of crack qualitatively in engine-block fatigue test. Engine-block with prefabricated crack was modeled by FE, and relative variation of strain was analysed, and damage index was applied to diagnose the position of crack. Damage index made full use of the relationship between all strain points, so it has high-accuracy for diagnosing position of crack, and position error is approximately2.25%.
3) Engine-block has complex geometry, and thouth it was acted by simple load, the stress status can take on multiaxiality. For example, the position of intercrossing between camshaft hole and main oil hole is that. Fatigue life of these positons should be estimated by multiaxial fatigue damage model. On the basis of popular multiaxial damge model which had applied to the standard notched specimens generally, a new multiaxial damage model was proposed based on cirtial plane, which was made by nolinear combination of shear and normal strain on critical plane. Finally, the new damage model was verified by experiment.
4) Considering high costs and large test period for the engine-block, a small number of specimens were used to predict fatigue limit of the engine-block. The load of low cycle life was estimated using least-squares method from test data. Fatigue limit was estimated by SAFL which was modified by load of low cycle life. Fatigue reliability was studied using Gauss and Weibull distribution respectively. The result of regression analysis on fatigue test data shows that mean and variance estimated by Gauss distribution were little different from that estimated by Weibull distribution, But the quality of test data affects fitting accuracy directly.
5) Model of crack and notch was built by stress field of crack equivalent to camshaft hole, and fracture mechanics was applied to prediction of fagitue limit of engine-block. The threshold of stress intensity factor was estimated by comparing between test datum and crack model. Fatigue limit of other components with the same material, the same production process were estimated by threshold of stress intensity factor and the stress status.
引文
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