Research on Crack Propagation and Remaining Life Prediction Method of Surface Strengthened Axle

doi:10.3901/JME.2023.14.043

Abstract

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

CLC Number:

TH117

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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