汽车发动机曲轴弯曲疲劳试验方法研究
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摘要
目的研究两种常用的疲劳试验加载原理对疲劳试验结果的影响,为曲轴选材、设计和制造的各阶段开展弯曲疲劳试验提供技术支持。方法在两种加载方式下采用同批次曲轴进行弯曲疲劳试验,利用成组法得到疲劳试验结果,针对试验加载原理和试验数据开展分析和讨论。结果电液伺服加载方法的试验精度更准确,而电磁谐振加载方法可以大幅度缩短试验周期。电液伺服加载和电磁谐振加载试验的疲劳极限分别为1140.4 N·m和1189.4 N·m。两种加载方法下,曲轴的失效情况均为连杆颈辊压槽处断裂。结论两种加载方法对曲轴弯矩的加载效果相同,试验结果的相对误差为4.3%。在曲轴的仲裁试验中或有争议的情况下使用,推荐使用电液伺服加载方法。在使用电磁谐振加载方法时须严格控制标定误差。曲轴连杆颈辊压槽是曲轴的薄弱环节,应严格控制辊压槽的机加工质量。
This paper aims to study the influence of two commonly used fatigue test loading principles on results of fatigue test, and to provide technical support for the bending fatigue test in each stage of crankshaft material selection, design and manufacture. By carrying out the bending fatigue test of the same batch crankshafts in two loading modes, the fatigue test results were obtained with the ancestor method. The loading principle and data of test were analyzed and discussed. The test results show that the accuracy of the electro-hydraulic servo loading method was more accurate; and the electromagnetic resonance loading method could shorten the test period greatly. The fatigue limit of the electro-hydraulic servo loading method test was 1140.4 N·m; and that of the electromagnetic resonance loading method test was 1189.4 N·m. Under the two loading methods, the failure of the crankshaft was fracture at the groove of the connecting rod neck roller. Therefore, the two loading methods have the same loading effect on crankshaft bending moment. The relative error of the test results is 4.3%. The electro-hydraulic servo loading method is recommended for use in the arbitration test of crankshaft or in controversial situations. The calibration error must be strictly controlled when using the electromagnetic resonance loading method. Crankshaft connecting rod groove is the weak link of crankshaft. The machining quality of the roller should be controlled strictly.
This paper aims to study the influence of two commonly used fatigue test loading principles on results of fatigue test, and to provide technical support for the bending fatigue test in each stage of crankshaft material selection, design and manufacture. By carrying out the bending fatigue test of the same batch crankshafts in two loading modes, the fatigue test results were obtained with the ancestor method. The loading principle and data of test were analyzed and discussed. The test results show that the accuracy of the electro-hydraulic servo loading method was more accurate; and the electromagnetic resonance loading method could shorten the test period greatly. The fatigue limit of the electro-hydraulic servo loading method test was 1140.4 N·m; and that of the electromagnetic resonance loading method test was 1189.4 N·m. Under the two loading methods, the failure of the crankshaft was fracture at the groove of the connecting rod neck roller. Therefore, the two loading methods have the same loading effect on crankshaft bending moment. The relative error of the test results is 4.3%. The electro-hydraulic servo loading method is recommended for use in the arbitration test of crankshaft or in controversial situations. The calibration error must be strictly controlled when using the electromagnetic resonance loading method. Crankshaft connecting rod groove is the weak link of crankshaft. The machining quality of the roller should be controlled strictly.
引文
[1]李海国,路俊峰.发动机曲轴材料及其发展[J].材料应用,2012(9):45-47.LI Hai-guo,LU Jun-feng.Material and Development of Engine Crankshaft[J].Material Application,2012(9):45-47.
[2]高广阔,刘景峰,辜祖勋.轿车发动机曲轴材料及工艺的研究[J].汽车工艺与材料,2005(6):3-9.GAO Guang-kuo,LIU Jing-feng,GU Zu-xun.Development of Car Engine Crankshaft Materials and Technology[J].Automobile Technology&Material,2005(6):3-9.
[3]郑真,张兵,赵剑.汽车发动机曲轴断裂分析[J].失效分析与预防,2016(6):261-264.ZHENG Zhen,ZHANG Bing,ZHAO Jian.Fracture Analysis of Car Engine Crankshaft[J].Failure Analysis and Prevention,2016(6):261-264.
[4]侯学勤,何玉怀,姜涛,等.内燃机曲轴疲劳断裂失效特征及原因探析[J].内燃机,2014(3):42-45.HOU Xue-qin,HE Yu-huai,JIANG Tao,et a1.Failure Characteristics and Causes Discussion on Fatigue Fracture of Internal Combustion Engine Crankshaft[J].Internal Combustion Engines,2014(3):42-45.
[5]丛建臣,邵诗波,慈惟红.曲轴扭转疲劳断裂分析[J].现代零部件,2010(10):77-78.CONG Jian-chen,SHAO Shi-bo,CI Wei-hong.Anaylsis of Torsional Fatigue Fracture of Crankshaft[J].Modern Components,2010(10):77-78.
[6]冯继军,郭文芳.汽车发动机曲轴常见的失效形式及原因分析[J].失效分析与预防,2006,1(2):7-12.FENG Ji-jun,GUO Wen-fang.Main Failure Forms and Analysis of Automobile Engine Crankshaft[J].Failure Analysis and Prevention,2006,1(2):7-12.
[7]王森林.发动机曲轴加工工艺方法[J].机械工程师,2014(4):189-190.WANG Sen-lin.Maching Technology of Engine Crankshaft[J].Mechanical Engineer,2014(4):189-190.
[8]邬杰,柳群,蒋国辉,等.曲轴强化工艺对疲劳极限的影响[J].汽车工艺与材料,2018(1):49-53.WU Jie,LIU Qun,JIANG Guo-hui,et al.Influence of Crankshaft Strengthening Process on Fatigue Limit[J].Automobile Technology&Material,2018(1):49-53.
[9]张小红,蒋国辉,章驰,等.提高曲轴疲劳极限的强化工艺探讨[J].热处理技术与装备,2017(6):27-31.ZHANG Xiao-hong,JIANG Guo-hui,ZHANG Chi,et a1.Discussion on Strengthening Process for Improving Fatigue Limit of Crankshaft[J].Heat Treatment Technology and Equipment,2017(6):27-31.
[10]周学勇,付长斌,许本允,等.标致雪铁龙集团曲轴疲劳强度测试的新方法[J].理化检验-物理分册,2012(48):579-582.ZHOU Xue-yong,FU Chang-bin,XU Ben-yun,et al.New Method of Fatigue Strength Testing of Crankshaft in PSA[J].Physical Testing and Chemical Analysis Part A:Physical Testing,2012(48):579-582.
[11]冯美斌,徐家炽,王小培.电动谐振式曲轴扭转疲劳试验装置的研制[J].汽车工程,1995(17):120-125.FENG Mei-bin,XU Jia-chi,WANG Xiao-pei.Electric Resonant Crankshaft Torsional Fatigue Testing Device Developed[J].Automotive Engineering,1995(2):120-125.
[12]周迅,俞小莉,李红珍,等.谐振加载式曲轴弯曲疲劳试验载荷标定方法的改进[J].内燃机工程,2007(1):43-45.ZHOU Xun,YU Xiao-li,LI Hong-zhen,et a1.Refinement on Load Calibration Technique of Resonant-loading Fatigue Test for Crankshaft[J].Chinese Internal Combustion Engine Engineering,2007(1):43-45.
[13]QC/T 637-2000,汽车发动机曲轴弯曲疲劳试验方法[S].QC/T 637-2000,Automobile Engine-CrankshaftsBending Fatigue Test Method[S].
[14]AVL R01N0030:1999,曲轴疲劳试验[S].AVL R01N0030:1999,Crankshaft fatigue test[S].
[15]GB/T 24176-2009,金属材料疲劳试验数据统计方案与分析方法[S].GB/T 24176-2009,Metallic Materials Fatigue Testing Statistical Planning and Analysis of Data[S].
[2]高广阔,刘景峰,辜祖勋.轿车发动机曲轴材料及工艺的研究[J].汽车工艺与材料,2005(6):3-9.GAO Guang-kuo,LIU Jing-feng,GU Zu-xun.Development of Car Engine Crankshaft Materials and Technology[J].Automobile Technology&Material,2005(6):3-9.
[3]郑真,张兵,赵剑.汽车发动机曲轴断裂分析[J].失效分析与预防,2016(6):261-264.ZHENG Zhen,ZHANG Bing,ZHAO Jian.Fracture Analysis of Car Engine Crankshaft[J].Failure Analysis and Prevention,2016(6):261-264.
[4]侯学勤,何玉怀,姜涛,等.内燃机曲轴疲劳断裂失效特征及原因探析[J].内燃机,2014(3):42-45.HOU Xue-qin,HE Yu-huai,JIANG Tao,et a1.Failure Characteristics and Causes Discussion on Fatigue Fracture of Internal Combustion Engine Crankshaft[J].Internal Combustion Engines,2014(3):42-45.
[5]丛建臣,邵诗波,慈惟红.曲轴扭转疲劳断裂分析[J].现代零部件,2010(10):77-78.CONG Jian-chen,SHAO Shi-bo,CI Wei-hong.Anaylsis of Torsional Fatigue Fracture of Crankshaft[J].Modern Components,2010(10):77-78.
[6]冯继军,郭文芳.汽车发动机曲轴常见的失效形式及原因分析[J].失效分析与预防,2006,1(2):7-12.FENG Ji-jun,GUO Wen-fang.Main Failure Forms and Analysis of Automobile Engine Crankshaft[J].Failure Analysis and Prevention,2006,1(2):7-12.
[7]王森林.发动机曲轴加工工艺方法[J].机械工程师,2014(4):189-190.WANG Sen-lin.Maching Technology of Engine Crankshaft[J].Mechanical Engineer,2014(4):189-190.
[8]邬杰,柳群,蒋国辉,等.曲轴强化工艺对疲劳极限的影响[J].汽车工艺与材料,2018(1):49-53.WU Jie,LIU Qun,JIANG Guo-hui,et al.Influence of Crankshaft Strengthening Process on Fatigue Limit[J].Automobile Technology&Material,2018(1):49-53.
[9]张小红,蒋国辉,章驰,等.提高曲轴疲劳极限的强化工艺探讨[J].热处理技术与装备,2017(6):27-31.ZHANG Xiao-hong,JIANG Guo-hui,ZHANG Chi,et a1.Discussion on Strengthening Process for Improving Fatigue Limit of Crankshaft[J].Heat Treatment Technology and Equipment,2017(6):27-31.
[10]周学勇,付长斌,许本允,等.标致雪铁龙集团曲轴疲劳强度测试的新方法[J].理化检验-物理分册,2012(48):579-582.ZHOU Xue-yong,FU Chang-bin,XU Ben-yun,et al.New Method of Fatigue Strength Testing of Crankshaft in PSA[J].Physical Testing and Chemical Analysis Part A:Physical Testing,2012(48):579-582.
[11]冯美斌,徐家炽,王小培.电动谐振式曲轴扭转疲劳试验装置的研制[J].汽车工程,1995(17):120-125.FENG Mei-bin,XU Jia-chi,WANG Xiao-pei.Electric Resonant Crankshaft Torsional Fatigue Testing Device Developed[J].Automotive Engineering,1995(2):120-125.
[12]周迅,俞小莉,李红珍,等.谐振加载式曲轴弯曲疲劳试验载荷标定方法的改进[J].内燃机工程,2007(1):43-45.ZHOU Xun,YU Xiao-li,LI Hong-zhen,et a1.Refinement on Load Calibration Technique of Resonant-loading Fatigue Test for Crankshaft[J].Chinese Internal Combustion Engine Engineering,2007(1):43-45.
[13]QC/T 637-2000,汽车发动机曲轴弯曲疲劳试验方法[S].QC/T 637-2000,Automobile Engine-CrankshaftsBending Fatigue Test Method[S].
[14]AVL R01N0030:1999,曲轴疲劳试验[S].AVL R01N0030:1999,Crankshaft fatigue test[S].
[15]GB/T 24176-2009,金属材料疲劳试验数据统计方案与分析方法[S].GB/T 24176-2009,Metallic Materials Fatigue Testing Statistical Planning and Analysis of Data[S].