基于混合损伤准则的火车轴楔横轧芯部损伤建模与分析

doi:10.3901/JME.2025.12.141

机械工程学报 ›› 2025, Vol. 61 ›› Issue (12): 141-152.doi: 10.3901/JME.2025.12.141

• 材料科学与工程 • 上一篇

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基于混合损伤准则的火车轴楔横轧芯部损伤建模与分析

林龙飞^1,2, 王宝雨³, 郭威³, 彭文飞¹, 吴晓成¹, 黄明辉¹

1. 宁波大学机械工程与力学学院宁波 315211;
2. 宁波工程学院机械与汽车工程学院宁波 315211;
3. 北京科技大学机械工程学院北京 100083

收稿日期:2024-07-15 修回日期:2024-12-31 发布日期:2025-08-07
作者简介:林龙飞(通信作者)，男，1991年出生，博士，助理研究员。主要研究方向为大型轴锻件成形、金属材料性能调控。E-mail：colin0910@foxmail.com
基金资助:
国家科技部重点研发计划资助项目(2018YFB1307900)。

Modeling and Analysis of Central Damage of Cross Wedge Rolling Railway Axles Based on Hybrid Damage Criterion

LIN Longfei^1,2, WANG Baoyu³, GUO Wei³, PENG Wenfei¹, WU Xiaocheng¹, HUANG Minghui¹

1. Faculty of Mechanical Engineering and Mechanics, Ningbo University, Ningbo 315211;
2. College of Mechanical and Automotive Engineering, Ningbo University of Technology, Ningbo 315211;
3. School of Mechanical Engineering, University of Science and Technology Beijing 100083

Received:2024-07-15 Revised:2024-12-31 Published:2025-08-07

摘要/Abstract

摘要： 因楔横轧存在芯部裂纹趋势，采用试验与仿真相结合方式对比分析了有裂纹、无裂纹情况下轧件各向应力、应力三轴度、材料温度的分布情况，揭示了主导芯部损伤的关键因素。考虑非等温复杂应力状态对楔横轧芯部损伤的作用机制，提出了耦合第一主应力、最大剪应力、平均应力、应力三轴度与变形温度的新型混合损伤准则，预测了不同工艺参数下的芯部损伤值。基于回归分析求解了芯部损伤与工艺参数的数学方程，建立了判别芯部裂纹条件的临界工艺参数窗口。结果表明：芯部材料在成形过程中受到横向拉应力和轴向拉应力，且芯部温度明显高于外层，从而芯部最容易产生裂纹缺陷；准则预测结果符合楔横轧芯部损伤大于外层的特点，其损伤分布云图也与轧件实际疏松形貌一致，相对预测精度为1.004%；在一定范围内，楔横轧芯部损伤随着成形角增大而减小，随展宽角增大而增大，随断面收缩率增大先增大后减小。研究结果为楔横轧轴类件降低损伤提供了预测准则和参数优化方法。

关键词: 楔横轧, 火车轴, 芯部损伤, 混合损伤准则, 参数优化

Abstract: Due to the trend of central cracks in cross wedge rolling (CWR), the distributions of stress state, stress triaxiality, and temperature under conditions with and without cracks are analyzed by combining of experiments and finite element (FE) simulations, and the main factors for central damage are analyzed. A hybrid damage criterion coupling the first principal stress, maximum shear stress, average stress, stress triaxiality and deformation temperature is proposed by comprehensively considering the influential mechanism of CWR damage behavior under non isothermal and complex stress, then the central damage under different CWR parameters is predicted. The mathematical equation between central damage and CWR parameters is described by regression analysis methods, and a critical parameter window for identifying the conditions of central cracks is established. The results show that, the central material is subject to tangential and axial tensile stress, and the temperature of center material is higher than that of outer layer, so the central material is most prone to cracks. The prediction of the new criterion is consistent with the characteristic that the central damage is greater than that of the outer layer, and its damage distribution is also consistent with the actual cracking morphology of the rolled piece with a relative prediction accuracy of 1.004%. In a certain rang, the central damage decreases with the increase of forming angle, increases with the increase of spreading angle, and first increases and then decreases with the increase of reduction area. The results provide a prediction criterion and a parameter optimization method for reducing damage in cross wedge rolling shafts.

Key words: cross wedge rolling, railway shafts, central damage, hybrid damage criterion, parameter optimization

中图分类号:

TG336

林龙飞, 王宝雨, 郭威, 彭文飞, 吴晓成, 黄明辉. 基于混合损伤准则的火车轴楔横轧芯部损伤建模与分析[J]. 机械工程学报, 2025, 61(12): 141-152.

LIN Longfei, WANG Baoyu, GUO Wei, PENG Wenfei, WU Xiaocheng, HUANG Minghui. Modeling and Analysis of Central Damage of Cross Wedge Rolling Railway Axles Based on Hybrid Damage Criterion[J]. Journal of Mechanical Engineering, 2025, 61(12): 141-152.

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基于混合损伤准则的火车轴楔横轧芯部损伤建模与分析

Modeling and Analysis of Central Damage of Cross Wedge Rolling Railway Axles Based on Hybrid Damage Criterion

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