变速器机械封闭试验台自动化改造设计

变速器机械封闭疲劳寿命试验台由于结构简单,能耗小,成本低,因此应用广泛。随着企业人工成本的上升,对疲劳寿命试验系统提出了自动化需求。以现有的机械封闭式变速器疲劳寿命试验台为基础进行自动化改造,包括变频电气系统、液压加载系统、测控系统等,并设计开发了一套自动化程度较高的测控软件,可实现变速器试验过程中的试验流程设置、转速转矩自动控制、自动启停、自动采集存储试验数据等功能。疲劳寿命试验结果表明,该系统能具有较高的测控精度及自动化水平,具有广阔的应用前景。     

高速微粒轰击对微弧氧化铝合金疲劳性能的影响

以获取高性能微弧氧化陶瓷膜,且不降低基体铝合金的抗疲劳性能为目标,采用高速微粒轰击处理工艺和微弧氧化处理工艺制备了未处理、高速微粒轰击处理、微弧氧化处理、高速微粒轰击+微弧氧化处理复合处理4种状态的试样,通过疲劳试验机对其疲劳寿命进行了测试;同时,采用TEM和XRD残余应力测试仪等分析方法对试样的表层微观组织结构和残余应力进行了观察与测试。结果表明:加载载荷较高时,4种试样疲劳寿命基本相同,寿命较短;加载载荷较低时,微弧氧化处理铝合金的疲劳寿命明显低于未处理试样,高速微粒轰击处理导致的微观组织结构细化和形成的残余压应力可以有效抑制疲劳裂纹的萌生和扩展,使未处理和微弧氧化铝合金的疲劳寿命均得到有效提高,这2种高速颗粒轰击处理过的试样的疲劳寿命均高于未处理试样,这表明高速颗粒轰击强化处理可有效提高低应力水平时微弧氧化铝合金的疲劳寿命。     

Study on fibre laser spot welding of TRIP980 steel

A 980 MPa transformation induced plasticity (TRIP) steel was fibre laser spot welded by different Argon (Ar) shielding conditions, laser power (1000 up to 2500 W) and defocusing distances (?8 up to +8 mm). The surface appearance, cross-section macrostructure, microstructure, hardness, tensile shear properties and fatigue properties of laser spot welds were evaluated. The results showed that the welds with Ar shielding had larger weld appearance and bonding sizes, better tensile shear properties compared with the welds without Ar shielding. With the increase in laser power, the laser welding mode changed from conduction to keyhole, which improved the bonding size and mechanical properties. The bonding size and mechanical properties increased in the order of defocusing distances of +8, ?8, +4, ?4 and 0 mm. During the fatigue tests of laser spot weld, the fusion zone pullout and sheet transverse fracture failure modes were observed.     

液压加载式变速器疲劳试验台测控系统设计

变速器新产品在开发过程中,需要进行一定的载荷循环次加载疲劳寿命试验,以验证内部齿轮、轴、轴承、箱体等零部件以及整体系统的可靠性,液压加载式变速器疲劳寿命试验台是其中重要的试验设备。变速器疲劳寿命试验过程中,扭矩负载一般采用调节液压加载器中的压力进行控制,但温度、机械结构状态等因素会导致扭矩的波动,因此需要对液压加载器中的压力进行实时调节,确保试验扭矩的稳定性。通过试验扭矩PID控制方法和试验系统自动流程控制方法的研究,开发了一套可实现变速器疲劳试验所需的转速转矩自适应控制、试验流程自动控制、试验数据自动采集存储等功能为一体的自动化程度较高的测控系统。疲劳寿命试验结果表明,该测控系统可使液压加载式变速器疲劳寿命试验台具有较高的测控精度及自动化水平,具有广阔的应用前景。     

直升机主减速器用离合器自由轮表面铬碳相渗层 失效分析

直升机主减速器用离合器自由轮在使用过程中出现了表面渗层剥落失效问题,本研究采用体式显微镜观察、扫描电镜观察、金相分析、硬度分析、XRD分析等方法,对铬碳相渗层的剥落原因进行了分析。分析结果表明,渗层剥落的机理为接触疲劳剥落,渗层内部存在的显微孔洞在循环载荷的作用下产生的微裂纹扩展,是造成渗层剥落产生的主要原因,随着微裂纹的扩展,表面出现轻微剥落区域,剥落区域的出现造成了邻近区域的的应力集中,促进了剥落区域边缘贯穿裂纹的形成,加剧了剥落。同时,渗层的局部剥落,造成的承载区域减小,应力上升,促进了新剥落区域的产生,最终多个剥落区域扩展,形成贯穿性渗层剥落。     

Effect of fatigue loading-confining stress unloading rate on marble mechanical behaviors: An insight into fracture evolution analyses

Rocks in underground works usually experience rather complex stress disturbance. For this, their fracture mechanism is significantly different from rocks subjected to conventional triaxial compression conditions. The effects of stress disturbances on rock geomechanical behaviors under fatigue loading conditions and triaxial unloading conditions have been reported in previous studies. However, little is known about the dependence of the unloading rate on fatigue loading and confining stress unloading (FL-CSU) conditions that influence rock failure. In this paper, we aimed at investigating the fracture behaviors of marble under FL-CSU conditions using the post-test X-ray computed tomography (CT) scanning technique and the GCTS RTR 2000 rock mechanics system. Results show that damage accumulation at the fatigue stage can influence the final fracture behaviors of marble. The stored elastic energy for rock samples under FL-CSU tests is relatively larger compared to those under conventional triaxial tests, and the dissipated energy used to drive damage evolution and crack propagation is larger for FL-CSU tests. In FL-CSU tests, as the unloading rate increases, the dissipated energy grows and elastic energy reduces. CT scanning after the test reveals the impacts of the unloading rate on the crack pattern and a fracture degree index is therein defined in this context to represent the crack dimension. It shows that the crack pattern after FL-CSU tests depends on the unloading rate, and the fracture degree is in agreement with the analysis of both the energy dissipation and the amount of energy released. The effect of unloading rate on fracture evolution characteristics of marble is revealed by a series of FL-CSU tests.     

考虑温度影响的排气系统断裂原因仿真分析

针对某汽车排气系统在使用中发生断裂故障的现象,采用有限元方法,考虑实际工况中温度的影响,对排气系统进行热模态与热疲劳性能仿真分析。得出在高温载荷作用下,排气系统的模态频率有所下降,某阶模态频率下降至发动机激励频率附近。排气系统在高温使用工况下的疲劳寿命大幅下降,且疲劳寿命最小处与实际断裂位置相同。得出了高温环境对排气系统疲劳性能有重要影响,而结构中存在的共振现象进一步加剧了排气系统的疲劳失效,确定了排气系统断裂故障产生的主要原因。     

Estimating the system efficiency of the multifunctional hydrogen complex at nuclear power plants

The paper deals with the primary current frequency regulation in the energy system (ES) as well as the basic requirements for NPP power units (PUs) under the conditions of involvement into the primary regulation. According to these requirements, NPP operation is related to the unloading and corresponding decrease in efficiency. It has been shown in this connection that combining NPP with a hydrogen complex (HEC) allows excluding the inefficient unloading mode. This enables the steam turbine and reactor equipment to operate in the basic mode at nominal power level. Besides, the conditions for producing and storing hydrogen and oxygen during the day as well as additionally during the night-time of off-peak electrical load may be created, which allows using them for generating peak power.In the paper, the systemic economic benefit as a result of involving NPP combined with HEC into primary regulation of the current frequency in ES with allowance for expending resources for the main equipment has been estimated. In this regard, the paper gives grounds for cyclic loadings of HEC main equipment including metal tanks for storing hydrogen and oxygen, compressors, hydrogen-oxygen combustion chamber (HOCC) for hydrogen-steam superheating of the actuating medium in the NPP steam turbine cycle. Methodological grounds for evaluating the equipment endurance under cyclic loading with involving into the primary frequency regulation by the criterion of the fatigue crack growth rate are described. It has been shown that in terms of HEC equipment, the highest load intensity occurs in HOCC due to high thermal stresses.Also, the systemic economic benefit has been estimated, and the impact of the equipment deterioration under conditions of cyclic loading has been demonstrated. It is shown that when combining NPP PUs with HEC, the efficiency of primary regulation may significantly depend on such factors as the cost of equipment exposed to cyclic loads, the frequency and intensity of cyclic loads, and the relation between the peak electricity tariff and the cost price of electric energy produced by NPP.It has been shown on the basis of novel methods for estimating the efficiency of involving NPP with HEC into the primary frequency regulation with allowance for damage to the equipment, that the use of HEC may provide a considerable economic benefit, as compared to the version of NPP unloading when involving directly into frequency regulation.     

Modeling extreme loads acting on steering components using driving events

Forces during steering events, such as curves and maneuvers, cause large stresses on steering components. In this paper, we formulate a model for the lateral loads causing fatigue damage of the steering components. Steering events are identified using a Hidden Markov model on the CAN (Controller Area Network) bus data. The CAN data is available on all vehicles, thus the model is applicable across many types of vehicles. To identify the events, the observation from CAN data is modeled by a multivariate generalized Laplace (GAL) distribution. An explicit formula for the expected fatigue damage is given. Results are validated using measured lateral acceleration.     

Fatigue performance of Friction Stir Welded Ti–6Al–4V subjected to various post weld heat treatment temperatures

The purpose of this study was to evaluate a variety of post weld heat treatment temperatures on the fatigue performance of Friction Stir Welded Ti–6Al–4V joints in order to identify an optimal post weld heat treatment condition. Microstructure, microhardness and tensile properties were also evaluated for each heat treatment condition to provide additional insight into the fatigue results obtained. Four heat treatment temperatures were evaluated, 760, 816, 871 and 927 °C. In general, it was found that that hardness and strength decreased with heat treatment temperature, but ductility and fatigue performance improved. It is recommended that a high heat treatment temperature be used on Ti FSW’s to obtain the best combination of strength, ductility and fatigue performance.