FBG应变传感器的疲劳性能研究

将光纤布拉格光栅(FBG)应变传感器埋入树脂基复合材料内部,采用试验的方法研究了传感器的疲劳性能.FBG应变监测曲线变化规律符合复合材料层合板疲劳理论,经历106次循环载荷作用过程后,最大应变测量相对误差为1.11％,保持了良好的应变测试能力和较高的测量精度.实验证明:FBG能够实现对交变应变、应力的监测,具有良好的抗疲劳能力,为重要结构服役过程中的在线损伤监测、剩余寿命预报以及材料破坏失效的预警奠定了重要基础.     

缆索内置光纤光栅传感器胶接植入试验研究

为实现光纤光栅传感器胶接固定于桥梁缆索钢丝以监测缆索索力,利用胶接结构的剪切测试、钢丝疲劳测试和循环加卸载测试分别对光纤光栅传感器支座与钢丝间胶接结构的剪切性能、疲劳可靠性以及胶接光纤光栅传感器的测试性能进行评估.试验发现:光纤光栅传感器支座与桥梁缆索钢丝间的胶接结构具有较大的剪切载荷,且200万次疲劳载荷对其胶接结性能影响较小;胶接固定于钢丝上的光纤光栅传感器可测出钢丝加卸载的滞回效应,并每个循环加、卸载的波长和钢丝承载载荷关系呈线性且分别重合.结果表明:内置光纤光栅传感器的胶接固定结构具有良好的剪切力学性能和疲劳可靠性,可保证其光纤光栅传感器的测试具有良好的准确、稳定、可靠性.     

汽轮机汽缸蠕变-疲劳耦合寿命预测

为探索汽轮机汽缸裂纹产生的原因、带裂纹汽缸的剩余寿命、汽缸延寿等问题,开展蠕变和疲劳交互作用下的汽缸寿命预测。利用有限元计算汽缸在稳态和启停工况下的应力情况。基于蠕变 疲劳耦合理论进行裂纹萌生和扩展的寿命预测,从运行方式和汽缸结构2方面开展优化。研究结果表明：该中压内缸中分面法兰的拐角处存在较大的热应力集中,其寿命损伤大导致裂纹萌生。经过结构修复,机组寿命显著延长。     

基于有限元的方向舵分配机构延寿技术研究

某型方向舵分配机构延寿研究是飞机延寿研究的重要组成部分,方向舵分配机构延寿研究过程重点对壳体进行疲劳寿命估算。针对目前常用延寿方法的不足,提出了一种延寿综合决策方法,在分析产品延寿可行性、确定延寿目标和壳体为薄弱环节后,应用有限元分析及细节疲劳额定值(DFR)对壳体开展疲劳寿命估算。首先,通过有限元仿真,分析到寿方向舵分配机构壳体在额定工况下各主要功能管道的最大应力值,确定壳体是否满足静强度设计要求；其次,应用细节疲劳额定值(DFR)方法,对壳体疲劳寿命进行37.5万次(延寿目标值对应耐久试验循环次数)耐久试验循环校核；最后对壳体开展实验验证。实验结果表明,壳体未出现裂纹和其它机械损伤等现象,满足飞机的延寿使用需求,与仿真计算结果一致,验证了采用的延寿综合决策方法的正确性。     

飞机次结构振动测试系统的设计及应用

利用高性能的单片机MSP430F5418、C8051F340和虚拟仪器开发平台LabVIEW,设计了一个飞机次结构振动测试系统,它包括一个实时多通道数据采集模块和一个离线数据分析模块;将其应用在飞机次结构防振动疲劳中,配有独立电源,可直接自动采集并存储飞机飞行过程中次承力结构的振动环境数据.在飞机着陆后下载数据进行分析与处理;试验中示波器生成一组信号:频率分别为50Hz、100Hz、150Hz的正弦波、方波、三角波以及高斯噪声,幅值均为1V,将其叠加起来;通过测试系统采集分析,系统不仅能够真实地还原时间信号,而且清晰地得到了信号的频率50Hz、100Hz、150Hz;验证结果表明:采用所设计的系统可以获得飞机次结构在飞行中所受振源的频率或频率范围,使得所设计构件的固有频率与振源频率不同,从而有效地避免了由于振动疲劳引发的事故.     

基于Zencrack的岸边集装箱起重机圆管构件疲劳裂纹扩展分析

由于二维裂纹扩展模式不能非常全面地反映岸边集装箱起重机结构件的疲劳裂纹扩展行为,以岸边集装箱起重机圆管构件为研究对象,利用Zencrack三维裂纹分析软件,详细分析未穿透裂纹与穿透裂纹的裂纹扩展关系,以及初始裂纹大小和载荷幅值对未穿透裂纹的疲劳裂纹扩展寿命的影响,对岸边集装箱起重机结构的抗疲劳设计及裂纹管理具有一定的参考价值。     

橡胶材料疲劳断裂特性研究进展

由于橡胶材料的动态疲劳特性对保证橡胶制品使用时的安全性和可靠性具有重要意义,综述机械载荷、环境和橡胶配方等因素对橡胶材料疲劳寿命的影响,总结用疲劳裂纹萌生寿命法和基于断裂力学的疲劳裂纹扩展法预测橡胶材料动态疲劳寿命方法的优缺点,并展望这2种方法的发展趋势.     

基于FBG的新型加速度计研究

设计了一种新型的差动式光纤布拉格光栅(Fiber Bragg grating,FBG)加速度计,论述了其传感结构的设计原理、理论分析和有限元仿真。文中设计的主梁与微梁相结合的差动结构形式,克服了传统悬臂梁结构FBG加速度计存在的固有频率与灵敏度相互制约的矛盾,提高了固有频率和灵敏度。同时,为了解决单悬臂梁结构加速度计存在的温度补偿问题,设计了差动式光学检测系统,使该加速度计的灵敏度较传统单悬臂梁结构提高了一倍。理论分析结果表明,该加速度计灵敏度可达到52.7pm/gn,固有频率250Hz。实验结果表明,该结构提高了加速度计的灵敏度,有效解决了FBG加速度计应变和温度交叉敏感问题,实验结果与仿真数据具有很好的一致性。     

大功率柴油机连杆疲劳试验和数值模拟

对某型大功率柴油机连杆进行疲劳强度试验,观察连杆断口的微观形貌,分析连杆断裂的主要影响因素.试验结果表明:连杆杆身的残余压应力通常会使疲劳裂纹萌生在构件次表层,具有高平均应力水平的连杆小头对表层夹杂缺陷更加敏感.运用三维有限元数值计算方法和疲劳寿命预测理论,对连杆疲劳耐久性试验进行数值模拟.连杆疲劳试验与虚拟疲劳寿命预估结果的比较表明,基于材料S-N曲线的疲劳寿命预估方法在一定程度上能对疲劳试验中连杆破坏的薄弱部位和疲劳寿命进行模拟与预测.     

正交异性钢桥肋-桥面板焊缝裂纹的三维断裂力学分析

正交异性钢桥的肋-桥面板焊缝处的疲劳裂纹是典型的三维裂纹问题,但是现在普遍采用平面应变二维裂纹模型对其进行断裂力学分析.基于Schwartz-Neuman交替法建立正交异性钢桥肋-桥面板焊缝裂纹的局部三维断裂力学分析模型;评估焊缝处表面裂纹的形状和深度对应力强度因子的影响;采用Paris公式估算等应力幅下焊缝的疲劳寿命.计算结果表明:用平面应变二维裂纹模型进行正交异性钢桥的肋-面板焊缝的断裂力学分析会严重低估其疲劳寿命;采用三维断裂力学模型进行肋-桥面板焊缝裂纹的疲劳寿命分析十分必要.     

Influence of the frequency on fatigue of directly wafer-bonded silicon

Fatigue tests on directly wafer-bonded silicon samples were performed using pre-cracked Micro-Chevron samples applying cycling loading frequencies between 0.3 and 40 Hz. The experimental lifetime results were compared with a theoretical prediction using measured subcritical crack growth parameters under static loading conditions. The experimental investigations revealed that the number of cycles required to break the samples increased with frequency. In contrast, the corresponding time-to-failure values did not depend on frequency. Both the qualitative behavior and the quantitative life-time results agreed very well with a prediction based on a fracture mechanical model. Therefore, it could be concluded that fatigue behavior in the considered frequency range is solely controlled by stress corrosion in the bonded interface. Furthermore, the results demonstrate an available approach for life-time prediction of wafer-bonded micro-electro-mechanical systems components stressed by cycling loading.     

Fatigue-life estimation of functionally graded materials using XFEM

The present work deals with the fatigue crack growth simulation of alloy/ceramic functionally graded materials (FGMs) using extended finite element method (XFEM). Various cases of FGM containing multiple inhomogeneities/discontinuities along with either a major edge or a center crack are taken for the purpose of simulation. The fatigue life of the FGM plate is calculated using Paris law of fatigue crack growth under cyclic loading. The effect of multiple inhomogeneities/discontinuities (minor cracks, holes/voids, and inclusions) on the fatigue life of cracked FGM plate is studied in detail. These simulations show that the presence of inhomogeneities/discontinuities in the domain significantly influences the fatigue life of the components.     

A CAD-based on biological method for designing optimal fatigue life

This paper presents an innovative approach to shape optimisation of three-dimensional, damage-tolerant structures. In this approach, a new and simple method, which we termed Failure Analysis of Structures (FAST), is used to estimate the stress-intensity factor for cracks at a notch. The methodology and software used to automate damage-tolerance calculations are developed using computer-aided design and FAST codes. The worst crack locations are found by modeling many cracks along fractured critical edges of the structure by using FAST. This software is then used to evaluate damage-tolerance objective functions for optimisation algorithms. A particular stress-based biological growth method is employed to study the problem of optimisation with fatigue life as the design objective. This work confirms that a stress-optimised structure does not necessarily give the longest fatigue life by numerical examples.     

基于HHT的液压管路裂纹故障诊断方法研究

将HHT方法应用于液压管路裂纹的故障诊断,提出基于HHT的液压管路裂纹故障诊断方法,并以正常液压管路和有裂纹液压管路为例进行实验验证。首先进行EMD（经验模态分解法）振动信号分解。将EMD和HHT方法引入航空发动机液压管路裂纹的振动信号分析,某发动机液压管路的裂纹振动信号的分析结果表明,该方法能够克服傅里叶谱无法同时获得时域和频域信息的缺陷。同时边际谱能够比较真实客观地反映有裂纹液压管路的频率和幅值分布情况。此外由边际频谱图中可知,无裂纹液压管路、有裂纹液压管路振动信号的频率能量分别集中于25 Hz,有裂纹的整体系统刚度大于无裂纹的。据此,有裂纹的管路,其振动加大的现象得以由HHT方法明显呈现。     

基于无源RFID标签天线转向架表面裂纹检测研究

在高速列车长期、快速行驶中,其转向架金属结构会因疲劳、应力、环境等因素影响,产生金属裂纹。为了在高速列车中的转型架金属表面实现远距离无损检测并判断是否存在裂纹,设计了一种应用在超高频频段的微带贴片型射频识别（Radio Frequency Identification,RFID)抗金属标签,配合RFID芯片,标定RFID阅读器与标签天线的位置和其发射天线的功率,当金属表面存在裂纹时标签天线谐振频率会向低频移动,并产生影响导致RFID系统识别距离的改变,从而实现金属表面裂纹检测。使用高频结构仿真(High Frequency Structure Simulator,HFSS)软件对天线结构进行优化,使其与芯片阻抗匹配,模拟了天线在金属表面存在裂纹的情况。由仿真结果可以分析得出：设计的无线有芯片微带贴片型RFID转向架表面裂纹检测标签能够有效地实现远距离监测金属表面裂纹长度、方向的变化情况。     

Simulation of three-dimensional fatigue crack propagation using enriched finite elements

A three-dimensional methodology for simulation of fatigue crack propagation is presented. The method is leveraged by the use of enriched crack tip elements to compute the mixed-mode stress intensity factors. The crack growth model used and the crack propagation life calculation are also described. As examples, fatigue crack propagation of a mode-I surface crack and crack advancements of mixed-mode surface cracks are simulated. The predicted results showed excellent agreement with experimental data from the literature. Thus, it is concluded that the crack propagation method developed allows efficient and accurate simulation of three-dimensional fatigue crack propagation problems.     

Study of TBM cutterhead fatigue crack propagation life based on multi-degree of freedom coupling system dynamics

Cutterhead is the core component of TBM tunneling equipment, which endures strong, multi-point distributed impact loads when the TBM tunnels, owing to the extreme surrounding rock environment of high hardness, high temperature and high quartz content. For this reason, the cutterhead works in an extremely severe vibration environment, which leads to engineering fault by a large area crack damage before the service life. Hence, the study on life prediction of TBM cutterhead under the impact loads is a core part of cutterhead design. This paper combines with the technology of system dynamics, linear elastic fracture mechanics and cumulative theory of fatigue damage, for the first time, proposes a method of fatigue crack propagation life prediction for the large and complex structures. In this paper, the TBM cutterhead of an actual project is taken as an example, to predict the fatigue crack propagation life of cutterhead piece and analyze the influences of plate thicknesses on fatigue life, then a new improved scheme of cutterhead structure is presented. The results show that the fatigue crack propagation life of actual cutterhead is 26.6 km, which is able to meet the requirement of 20 km service life. Moreover, the upper cover plate thickness has the greatest influence on cutterhead fatigue crack propagation life, with the thickness increasing 10%, the life increases nearly by 1.24 times. Then, the other influencing factors are as follows: thickness of the main support plate, thickness of the annular support plate and thickness of the support plate, whereas the influence of the lower cover plate thickness on fatigue life is minimal. Furthermore, the plate thickness limit sizes meeting the life requirement are obtained, and a new structure modified scheme of cutterhead is proposed. Compared with the original scheme, the new cutterhead scheme meets the requirements of structural strength and service life with 8.08% weight decrease, which achieves life determination design and lightweight design. The proposed method of fatigue crack propagation life prediction is feasible in the design and application stage of TBM cutterhead, besides, it is flexible enough and can also be applied in damage strength assessment, dynamic parameters optimization and establishment of nondestructive inspection cycle for the other large and complex structure, and takes on stronger project value and generality.