表面强化车轴裂纹扩展及剩余寿命预测方法研究

doi:10.3901/JME.2023.14.043

摘要/Abstract

摘要： 为了研究表面强化车轴的裂纹扩展行为，提出了基于裂纹扩展行为表征与探伤概率结合的剩余寿命预测方法。首先，基于线弹性有限元裂纹扩展方法，考虑车轴表面残余应力及裂纹扩展闭合效应，开展了表面强化车轴疲劳裂纹扩展行为研究；然后，研究了服役载荷对裂纹缺陷演化的影响，探索了不同初始深长比裂纹的扩展剩余寿命；最后，将剩余寿命曲线与无损检测检出概率结合，提出了基于裂纹检出状态的阶梯检修周期策略。分析结果表明：残余压应力对深度小于4 mm裂纹的扩展有显著抑制作用，基于NASGRO方程估算了不同初始深长比的裂纹扩展剩余寿命区间为10.5万～18.8万km，初始缺陷深长比越小，剩余寿命越短；基于动态的阶梯周期探伤策略实现了0.056 1%～0.007 84%的累积探伤失效概率用于指导维修周期优化。研究方法和结果为含缺陷表面强化车轴的剩余寿命评价及服役安全性运营维护提供有益参考。

关键词: 表面强化车轴, 疲劳裂纹扩展, 残余应力, 剩余寿命, 检修周期

Abstract: In order to study the crack growth behavior of surface-strengthened axles, a remaining life prediction method based on the combination of crack propagation behavior characterization and flaw detection probability was proposed. Firstly, based on the linear elastic finite element crack propagation method, considering the residual stress on the axle surface and the crack growth closure effect, the fatigue crack growth behavior of the surface strengthened axle was studied. Then, the influence of service load on the evolution of crack defects was studied, and the remaining life of crack growth with different initial depth-to-length ratios was explored. Finally, combining the remaining life curve with the detection probability of non-destructive testing, a stepped maintenance cycle strategy based on the crack detection status is proposed. The analysis results show that the residual compressive stress has a significant inhibitory effect on the growth of cracks with a depth of less than 4 mm. Based on the NASGRO equation, the remaining life interval of crack propagation with different initial depth-to-length ratios is estimated to be 105 000-188 000 km. The smaller the initial defect depth-length ratio, the shorter the remaining life. The dynamic step cycle flaw detection strategy achieves a cumulative flaw detection failure probability of 0.056 1%-0.007 84%, which is used to guide the maintenance cycle optimization. The research methods and results provide a useful reference for the remaining life assessment and service safety operation and maintenance of the surface-enhanced axle with defects.

Key words: surface strengthened axle, fatigue crack growth, residual stress, remaining life, repair cycle

中图分类号:

TH117

王超, 杨冰, 朱涛, 肖守讷, 阳光武, 范晓达. 表面强化车轴裂纹扩展及剩余寿命预测方法研究[J]. 机械工程学报, 2023, 59(14): 43-53.

WANG Chao, YANG Bing, ZHU Tao, XIAO Shoune, YANG Guangwu, FAN Xiaoda. Research on Crack Propagation and Remaining Life Prediction Method of Surface Strengthened Axle[J]. Journal of Mechanical Engineering, 2023, 59(14): 43-53.

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