活塞疲劳失效的力学分析
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摘要
本文应用断裂力学的理论,结合试验,在数值模拟的基础上,对硅铝合金活塞机械疲劳可靠性问题展开了研究。
1.活塞销孔疲劳试验。利用活塞销孔机械疲劳试验机装置进行的试验表明,活塞顶部及内腔承受的交变液压,在销孔内侧上端处产生很大的棱缘负荷,导致销孔开裂,
2.活塞有限元分析。计算了活塞在热应力场、机械应力场以及热-力耦合应力场中的应力应变值。研究表明:在活塞销孔内侧上端出现了应力集中,裂纹开启于此处。分析结果与试验相吻合。通过对活塞实体模型加载交变的机械载荷,采用隐式算法(Newmark法)进行了活塞的瞬态动力学分析,得到了活塞销孔危险部位的循环应力幅值。
3.形状几何因子表达式。本文采用“自上而下”的子结构模型法施加裂纹体,计算了裂纹尖端的应力强度因子,计算值与应力强度因子手册中给出的理论值非常吻合,最大误差不超过6%。分析可知,热载荷对裂纹尖端的应力场起很小的作用,而起决定作用的是机械载荷。因此,忽略热载荷的影响,利用最小二乘法,拟合出了活塞在机械应力场中的形状几何因子的表达式。
4.基于线弹性断裂理论,分析出活塞裂纹属于Ⅰ型裂纹,开启于销孔内侧上端应力集中处,属于孔边角裂纹;经过交变载荷长时间的加载,裂纹会继续扩展到内腔处,成为表面裂纹,最后断裂失效;在Paris疲劳寿命经验公式的基础上,给出了修正的疲劳寿命估算公式。估算结果表明,活塞疲劳寿命与试验值吻合。
This work employs the theory of fracture mechanics, combines the experiment, on the basis of numerical simulation, have launched research to the fatigue reliability and safety problem of silicon aluminium alloy piston.
1. The mechanical fatigue experiment. Utilizing piston of machinery fatigue testing machine, this work executes fatigue test. The result indicates that the great tensile stress generates at the upper end of the piston pin seat.
2. The finite element analysis of piston. This work calculates piston's thermal stress field, mechanical stress field and coupling stress field. The calculation results indicate that the great tensile stress generates at the upper end of the piston pin seat. Via analyzing the dynamics under the transient loading, the circulatory stress of the crack tip is computed, and the critical crack length is calculated.
3. The expression of the piston shape geometry factor. Using the sub-structure model method, this work exerts the crack body to compute the stress intensity factor for different crack depths. The calculation results are extremely tallied with the academic values offered by the handbook; the limiting error is less than 6%. Thereby the expression of the shape geometry factor is obtained by curve fitting.
4. Based on the theory of rupture, the crack is considered to be type I, and the crack location and expansion direction also have been confirmed. The special crack is separated into two sections, one is the horny crack at the aperture and the other is the surface crack at the lumen. In order to calculate the exact data, a modificatory Paris formula is available to prognosticate the fatigue life-span of the piston.
1.活塞销孔疲劳试验。利用活塞销孔机械疲劳试验机装置进行的试验表明,活塞顶部及内腔承受的交变液压,在销孔内侧上端处产生很大的棱缘负荷,导致销孔开裂,
2.活塞有限元分析。计算了活塞在热应力场、机械应力场以及热-力耦合应力场中的应力应变值。研究表明:在活塞销孔内侧上端出现了应力集中,裂纹开启于此处。分析结果与试验相吻合。通过对活塞实体模型加载交变的机械载荷,采用隐式算法(Newmark法)进行了活塞的瞬态动力学分析,得到了活塞销孔危险部位的循环应力幅值。
3.形状几何因子表达式。本文采用“自上而下”的子结构模型法施加裂纹体,计算了裂纹尖端的应力强度因子,计算值与应力强度因子手册中给出的理论值非常吻合,最大误差不超过6%。分析可知,热载荷对裂纹尖端的应力场起很小的作用,而起决定作用的是机械载荷。因此,忽略热载荷的影响,利用最小二乘法,拟合出了活塞在机械应力场中的形状几何因子的表达式。
4.基于线弹性断裂理论,分析出活塞裂纹属于Ⅰ型裂纹,开启于销孔内侧上端应力集中处,属于孔边角裂纹;经过交变载荷长时间的加载,裂纹会继续扩展到内腔处,成为表面裂纹,最后断裂失效;在Paris疲劳寿命经验公式的基础上,给出了修正的疲劳寿命估算公式。估算结果表明,活塞疲劳寿命与试验值吻合。
This work employs the theory of fracture mechanics, combines the experiment, on the basis of numerical simulation, have launched research to the fatigue reliability and safety problem of silicon aluminium alloy piston.
1. The mechanical fatigue experiment. Utilizing piston of machinery fatigue testing machine, this work executes fatigue test. The result indicates that the great tensile stress generates at the upper end of the piston pin seat.
2. The finite element analysis of piston. This work calculates piston's thermal stress field, mechanical stress field and coupling stress field. The calculation results indicate that the great tensile stress generates at the upper end of the piston pin seat. Via analyzing the dynamics under the transient loading, the circulatory stress of the crack tip is computed, and the critical crack length is calculated.
3. The expression of the piston shape geometry factor. Using the sub-structure model method, this work exerts the crack body to compute the stress intensity factor for different crack depths. The calculation results are extremely tallied with the academic values offered by the handbook; the limiting error is less than 6%. Thereby the expression of the shape geometry factor is obtained by curve fitting.
4. Based on the theory of rupture, the crack is considered to be type I, and the crack location and expansion direction also have been confirmed. The special crack is separated into two sections, one is the horny crack at the aperture and the other is the surface crack at the lumen. In order to calculate the exact data, a modificatory Paris formula is available to prognosticate the fatigue life-span of the piston.
引文
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[6]白敏丽,丁铁新,吕继组.活塞组-气缸套耦合热模拟[J].发动机学报,2005,23(2):168-175.
[7]聂建军,杜发荣,袁峰,等.柴油机活塞和连杆运动的有限元分析[J].拖拉机与农用运输车,2002,(6):23-24.
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[9]佟景伟,李林安,李鸿琦,等.在温度和机械载荷作用下活塞应力与变形的三维有限元分析[J].发动机学报,1995,13(2):124-131.
[10]李兵,胡欲立,姚倡峰.活塞在温度和机械载荷作用下的应力和变形的有限元分析[J].机械科学与技术,2002,21(2):223-223,227.
[11]李爱民.三维弹性接触问题的数值模拟技术及其应用研究[D].西北工业大学,2004.
[12]姜成.结构瞬态动力响应及其灵敏度分析的精细积分法[D].大连理工大学,2000.
[13]张卫正.发动机受热件热疲劳试验与寿命预测[D].北京:北京理工大学,2002.
[14]王忠渝.活塞的传热和热强度研究[D].重庆:重庆大学,2002.
[15]门秀花.发动机活塞组有限元分析[D].山东:山东理工大学,2006.
[16]戴旭东,王义亮,袁小阳,等.多缸发动机缸体瞬态动力分析[J].发动机学报,2003,21(3):277-282.
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[18]雷基林.增压柴油机活塞三维有限元分析及其温度场试验研究[D].昆明:昆明理工大学,2003.
[19]任长春.大功率机车组合活塞失效分析及其温度场有限元模拟[D].南京:东南大学, 2005.
[20]陈欣.运用可靠性设计原理进行活塞寿命分析[J].铁道技术监督,2006,(8):9-11.
[21]陶莉莉.中重型汽车发动机活塞的设计研究[J].内燃机与动力装置.2006,(3):19-22.
[22]高观,译.汽车柴油机用的高负荷铝活塞[J].国外内燃机,1975,(6):13-21.
[23]Whitacre J P,Trainer H G.Piston Pin Bore Treatments for High Performance Diesel Engines[C].SAE Paper 860160,1986.
[24]张雪,译.保证发动机主要零部件可靠性的设计技术[J].国外内燃机,1988,(5):2-4.
[25]林祖鑫,译.内燃机油冷活塞的热裂问题[J].国外内燃机,1983,(3):1-5.
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