双折线式多层卷绕钢丝绳失效行为及损伤机理研究
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摘要
钢丝绳的损伤与失效行为直接关系到钢丝绳使用的安全性、可靠性与技术经济性,长期以来一直是人们关注和研究的热点。随着起重货载单元的不断增加,在起重机械钢丝绳传动系统中,双折线式多层卷绕方式得到了越来越广泛的使用。在双折线式多层卷绕中,钢丝绳的失效行为表现、损伤机理及各使用条件对钢丝绳使用寿命的影响规律等问题,目前尚未有明确的研究结论,更没有试验论证依据。因此,本文采用理论分析与试验研究相结合的方法,对双折线式多层卷绕钢丝绳的失效行为与损伤机理进行研究,旨在掌握双折线式多层卷绕钢丝绳失效行为规律,并探索钢丝绳损伤机理。
钢丝绳的复杂构造决定了其损伤、失效行为与使用条件密切相关。论文通过对钢丝绳双折线式多层卷绕特征的研究,提出将钢丝绳在卷筒上的排列分为“金字塔”形、轴线交叉“X”形及“斜楔”式三种排列形式,并利用弹性接触理论分别对三种排列形式钢丝绳的接触力学行为进行了分析；在此基础上,采用定量与定性结合的分析方法,重点对双折线式多层卷绕过程中钢丝绳的磨损与弯曲疲劳损伤进行了理论分析。分析结果表明：钢丝绳卷绕过程的受力情况、磨损损伤程度与钢丝绳在卷筒上的卷绕位置及排列形式密切相关：钢丝绳反复弯曲工作时的弯曲直径D是影响弯曲疲劳损伤大小的主要因素。
钢丝绳损伤与失效问题的复杂性,使其研究方法一般建立在理论分析与试验研究相结合的基础上。因此,论文针对起重机械钢丝绳工作特点,在对比、总结国内外现有钢丝绳试验装置优、缺点的基础上,研究开发了能模拟起重机钢丝绳双折线式多层卷绕实际作业工况的多层卷绕钢丝绳-滑轮磨损试验装置。并利用此试验装置,选取润滑油脂性能、滑轮直径这两个因素为考察对象,进行两组双折线式多层卷绕钢丝绳失效对比试验。
钢丝绳的失效行为规律是其使用条件合理选配的重要依据。论文通过分析、对比不同性能润滑油脂与不同滑轮直径下两组钢丝绳失效试验结果,对双折线式多层卷绕钢丝绳失效形式、断丝分布与发展规律、钢丝绳磨损量变化特征及润滑油脂性能与滑轮直径对钢丝绳使用寿命的影响等进行了深入的研究。研究结果表明：双折线式多层卷绕钢丝绳的失效形式为外层丝断丝；断丝分布及钢丝绳磨损量变化与钢丝绳在卷筒中的卷绕位置密切相关；对于试验中选用的两种润滑油脂而言,润滑油脂性能对双折线式多层卷绕钢丝绳使用寿命无明显影响；滑轮-钢丝绳直径比则对钢丝绳使用寿命有显著影响。
双折线式多层卷绕钢丝绳的失效过程其实质为绳中断丝出现与发展的过程。论文通过对双折线式多层卷绕钢丝绳断丝部位及断丝断口进行形貌分析,分别探讨了钢丝绳外层丝与绳芯钢丝的断裂行为与断裂机理。分析结果表明：双折线式多层卷绕中,钢丝绳外层丝断裂主要是卷绕过程中钢丝受挤压产生的塑性变形、绳圈间摩擦滑动引起的磨损及疲劳累积损伤的共同作用结果,而绳芯钢丝断裂则是微动磨损损伤影响下的疲劳破坏。
The damage and the failure of wire rope is directly related to safety, reliability and technology economy of the use of wire rope which has been a focus of study attracts much attention these days. With the increasing of the units of the lifting load, the parallel grooved multi-layer winding is more and more widely used in the drive system of the lifting machinery. The problems such as the failure behaviors of the wire rope, damage mechanism and regulations that each condition influences the wire rope working life in the parallel grooved multi-layer winding, haven't a clear research conclusion and the basis of the test and argument. So in this paper, it combines theoretical analysis with experimental research to research the failure behavior and damage mechanism of the wire rope of the parallel grooved multi-layer winding in order to master the regulation of the failure behavior of the parallel grooved multi-layer winding and explore the damage mechanism of the wire rope.
The complexity of the wire rope structure determines that its damage and failure behaviors are closely related to the service conditions. Based on the study of wire rope parallel grooved multilayer winding characteristics, the wire rope on the drum are arranged into three forms,"Pyramid" form, axes intersection "X" shape and" wedge" from, and the contact mechanics behaviors of wire ropes under the three arrangement forms are analyzed in this paper. On this basis, focusing on theoretical analysis of the wear of wire rope during parallel grooved multilayer winding and bending fatigue damage by combining qualitative method with quantitative method. The results show that the force of wire rope winding process and the degree of wear in the rope are closely related to winding positions of wire ropes on wound roll and the arrangement form; bending diameter D during reverse bend of wire rope is the main influencing factor that determines the degree of fatigue damage.
The complexity of damage and failure of wire rope makes the research method based on combination of theories analysis and experimental study. Therefore, the paper research and develop the wear test device of multilayer winding wire rope and sheave that can simulate the real operation condition of parallel grooved multi-layer winding, based on comparison and summary on advantages and disadvantages of wire rope test device, according to the operating Features of steel wire rope for hoisting machinery. Besides, the two factors:performance of lubricant grease, diameter of sheaves are chose to be the objects of investigation by using the test device, comparison experiments on two groups of parallel grooved multi-layer winding wire rope and sheave failure is executed.
The regularity of failure of wire rope is the important basis for the proper selection and arrangement of service conditions. Failure form of multilayer winding wire rope, distribution and development discipline of broken wire, variation characteristics of wear in wire rope, the influence of performance of lubricant grease, diameter of sheaves on the life of wire rope and so on are researched profoundly by analyzing and comparing test results of the two groups of failure of wire rope on the different performance of lubricant grease and diameter of sheaves. The results indicate that the failure form of parallel grooved multi-layer winding wire rope is outer layer wire breaking; distribution of broken wire and variation of wear in wire rope correlate closely to the position where the wire rope lie in the drum; the performance of lubricant grease has no discernible effect on the life, but the diameter ratio of sheave and wire rope has significant effect on the life of wire rope.
Failure process of parallel grooved multi-layer winding wire rope is essentially the process of the emergence and development of the broken wire in wire rope. Broken wire position of parallel grooved multi-layer winding wire rope and fracture surface of broken wire are analyzed in this paper, fracture behaviors and fracture mechanisms of outer layer wire and rope core are discussed. The results revealed that fracture of outer layer wire is the result of a combination of plastic deformation caused by the extrusion of wires and wear caused by the extrusion of wire ropes during the parallel grooved multi-layer winding, and the fractured of wire in rope core is caused by fatigue failure under the influence of fretting wear.
钢丝绳的复杂构造决定了其损伤、失效行为与使用条件密切相关。论文通过对钢丝绳双折线式多层卷绕特征的研究,提出将钢丝绳在卷筒上的排列分为“金字塔”形、轴线交叉“X”形及“斜楔”式三种排列形式,并利用弹性接触理论分别对三种排列形式钢丝绳的接触力学行为进行了分析；在此基础上,采用定量与定性结合的分析方法,重点对双折线式多层卷绕过程中钢丝绳的磨损与弯曲疲劳损伤进行了理论分析。分析结果表明：钢丝绳卷绕过程的受力情况、磨损损伤程度与钢丝绳在卷筒上的卷绕位置及排列形式密切相关：钢丝绳反复弯曲工作时的弯曲直径D是影响弯曲疲劳损伤大小的主要因素。
钢丝绳损伤与失效问题的复杂性,使其研究方法一般建立在理论分析与试验研究相结合的基础上。因此,论文针对起重机械钢丝绳工作特点,在对比、总结国内外现有钢丝绳试验装置优、缺点的基础上,研究开发了能模拟起重机钢丝绳双折线式多层卷绕实际作业工况的多层卷绕钢丝绳-滑轮磨损试验装置。并利用此试验装置,选取润滑油脂性能、滑轮直径这两个因素为考察对象,进行两组双折线式多层卷绕钢丝绳失效对比试验。
钢丝绳的失效行为规律是其使用条件合理选配的重要依据。论文通过分析、对比不同性能润滑油脂与不同滑轮直径下两组钢丝绳失效试验结果,对双折线式多层卷绕钢丝绳失效形式、断丝分布与发展规律、钢丝绳磨损量变化特征及润滑油脂性能与滑轮直径对钢丝绳使用寿命的影响等进行了深入的研究。研究结果表明：双折线式多层卷绕钢丝绳的失效形式为外层丝断丝；断丝分布及钢丝绳磨损量变化与钢丝绳在卷筒中的卷绕位置密切相关；对于试验中选用的两种润滑油脂而言,润滑油脂性能对双折线式多层卷绕钢丝绳使用寿命无明显影响；滑轮-钢丝绳直径比则对钢丝绳使用寿命有显著影响。
双折线式多层卷绕钢丝绳的失效过程其实质为绳中断丝出现与发展的过程。论文通过对双折线式多层卷绕钢丝绳断丝部位及断丝断口进行形貌分析,分别探讨了钢丝绳外层丝与绳芯钢丝的断裂行为与断裂机理。分析结果表明：双折线式多层卷绕中,钢丝绳外层丝断裂主要是卷绕过程中钢丝受挤压产生的塑性变形、绳圈间摩擦滑动引起的磨损及疲劳累积损伤的共同作用结果,而绳芯钢丝断裂则是微动磨损损伤影响下的疲劳破坏。
The damage and the failure of wire rope is directly related to safety, reliability and technology economy of the use of wire rope which has been a focus of study attracts much attention these days. With the increasing of the units of the lifting load, the parallel grooved multi-layer winding is more and more widely used in the drive system of the lifting machinery. The problems such as the failure behaviors of the wire rope, damage mechanism and regulations that each condition influences the wire rope working life in the parallel grooved multi-layer winding, haven't a clear research conclusion and the basis of the test and argument. So in this paper, it combines theoretical analysis with experimental research to research the failure behavior and damage mechanism of the wire rope of the parallel grooved multi-layer winding in order to master the regulation of the failure behavior of the parallel grooved multi-layer winding and explore the damage mechanism of the wire rope.
The complexity of the wire rope structure determines that its damage and failure behaviors are closely related to the service conditions. Based on the study of wire rope parallel grooved multilayer winding characteristics, the wire rope on the drum are arranged into three forms,"Pyramid" form, axes intersection "X" shape and" wedge" from, and the contact mechanics behaviors of wire ropes under the three arrangement forms are analyzed in this paper. On this basis, focusing on theoretical analysis of the wear of wire rope during parallel grooved multilayer winding and bending fatigue damage by combining qualitative method with quantitative method. The results show that the force of wire rope winding process and the degree of wear in the rope are closely related to winding positions of wire ropes on wound roll and the arrangement form; bending diameter D during reverse bend of wire rope is the main influencing factor that determines the degree of fatigue damage.
The complexity of damage and failure of wire rope makes the research method based on combination of theories analysis and experimental study. Therefore, the paper research and develop the wear test device of multilayer winding wire rope and sheave that can simulate the real operation condition of parallel grooved multi-layer winding, based on comparison and summary on advantages and disadvantages of wire rope test device, according to the operating Features of steel wire rope for hoisting machinery. Besides, the two factors:performance of lubricant grease, diameter of sheaves are chose to be the objects of investigation by using the test device, comparison experiments on two groups of parallel grooved multi-layer winding wire rope and sheave failure is executed.
The regularity of failure of wire rope is the important basis for the proper selection and arrangement of service conditions. Failure form of multilayer winding wire rope, distribution and development discipline of broken wire, variation characteristics of wear in wire rope, the influence of performance of lubricant grease, diameter of sheaves on the life of wire rope and so on are researched profoundly by analyzing and comparing test results of the two groups of failure of wire rope on the different performance of lubricant grease and diameter of sheaves. The results indicate that the failure form of parallel grooved multi-layer winding wire rope is outer layer wire breaking; distribution of broken wire and variation of wear in wire rope correlate closely to the position where the wire rope lie in the drum; the performance of lubricant grease has no discernible effect on the life, but the diameter ratio of sheave and wire rope has significant effect on the life of wire rope.
Failure process of parallel grooved multi-layer winding wire rope is essentially the process of the emergence and development of the broken wire in wire rope. Broken wire position of parallel grooved multi-layer winding wire rope and fracture surface of broken wire are analyzed in this paper, fracture behaviors and fracture mechanisms of outer layer wire and rope core are discussed. The results revealed that fracture of outer layer wire is the result of a combination of plastic deformation caused by the extrusion of wires and wear caused by the extrusion of wire ropes during the parallel grooved multi-layer winding, and the fractured of wire in rope core is caused by fatigue failure under the influence of fretting wear.
引文
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