汽车后驱动桥断裂失效分析

汽车后驱动桥由多个零件焊接而成,在行驶约790000 km时该零件发生断裂。通过宏观分析、显微组织分析、化学成分分析以及断口形貌分析后认为,该零件断裂性质为疲劳断裂,主要原因为被焊接的两个零件尺寸差异较大,局部形成应力集中,再加上焊接热影响区存在焊接应力和魏氏体组织,并在汽车行进中不断受到颠簸和震动造成该区域产生裂纹源,进而在运行一定时间后发生疲劳断裂。     

汽车螺栓断裂失效分析

对汽车上某一连接发动机和车身的高强度级别螺栓在使用过程中发生的断裂进行了分析.结果表明,螺栓的化学成分和金相组织均正常,其断裂为多源疲劳断裂.经对螺栓使用过程中的受力情况分析,认为螺栓断裂主要是由于该螺栓在安装时预紧力不足或汽车在运行过程中,发动机自身振动和汽车行进中颠簸而使螺栓产生了松动,从而受到交变载荷而在应力集中最为严重的螺纹根部发生疲劳断裂.     

压力机偏心齿轮主轴断裂分析

采用扫描电镜及光学显微镜对压力机偏心齿轮主轴断口进行了系统的分析。确定了主轴断裂属于疲劳断裂,并具有低周疲劳断裂的特征。找出了齿轮主轴断裂的主要原因－主轴油孔处的奕力集中以及超负荷运行造成轴的工作应力过大引起断裂。     

某风电机组行星齿轮断齿原因

某风电机组行星齿轮在运行约2a后发生断齿.采用化学成分分析、宏观观察、断口分析、金相检验、扫描电镜及能谱分析等方法,分析了该齿轮断齿的原因.结果表明:该行星齿轮原材料中存在大量聚集的夹杂物,在齿轮服役过程中,夹杂物附近易产生应力集中,从而在该处萌生裂纹,齿轮表面烧伤加速裂纹扩展,最终导致齿轮发生疲劳断裂.     

某工程机械传动系统用主轴断裂原因分析

某工程机械传动系统用主轴的正常使用周期为0.5a(年),但是在使用70d(天)后就发生了断裂。通过宏观分析、化学成分分析、金相检验、硬度测试、微观分析及能谱分析等方法,对主轴的断裂原因进行了分析。结果表明:该主轴的断裂模式为疲劳断裂,主轴和轴套的偏磨使得主轴表面磨损严重,磨损造成的温度升高超过奥氏体化温度,冷却后形成了局部未回火马氏体的白亮区。白亮区周围的回火区域萌生的裂纹成为疲劳源,在主轴高速旋转过程中裂纹扩展直至发生疲劳断裂。     

40CrNiMo钢主轴断裂原因分析

40CrNiMo钢主轴在使用过程中发生断裂。采用宏观观察、化学成分分析、硬度测试及显微组织分析等方法,分析了该40CrNiMo钢主轴断裂的原因。结果表明:主轴的倒角曲率半径偏小且材料中存在氮化物,使应力集中程度严重,导致裂纹源产生;粗大的晶粒降低了主轴的解理断裂强度,使疲劳扩展速率加大,最终导致主轴发生早期疲劳断裂。最后根据主轴失效原因提出了改进措施。     

摩托车主轴断裂失效分析

摩托车主轴在渗碳淬火热处理后校直时发生断裂,采用化学成分分析、金相检验、硬度测试及断口宏、微观分析等方法对断裂主轴进行了分析。结果表明：因为该主轴棒料冷挤压加工成形后轴表面附近区域产生的大量塑性变形已经达到了临界变形量,而主轴坯件冷锻后未按技术要求进行正火处理,使渗碳淬火热处理的原始组织不符合要求,从而导致主轴在渗碳加热过程中轴边缘区域发生再结晶转变,形成了极粗大的等轴晶粒区域,该区域经淬火和低温回火后形成了脆性大、硬度偏高的极粗大的回火板条马氏体组织,最终使得主轴在校直时的过高外力作用下发生脆性断裂。     

变速箱第二轴断裂原因分析

变速箱第二轴在总装时发生批量断裂，断裂部位均在轴端螺纹收尾根部。采用化学成分分析、金相检验以及断口宏、微观分析等方法，对该轴的断裂原因进行分析。结果表明，该零件在热处理过程中，因超音频回火工艺控制不当，以及机加工缺陷引起的应力集中是导致断裂的主要原因。提出了改进措施。     

柴油机连杆盖及连杆螺栓断裂分析

采用化学分析,金相检验及力学性能测定方法对汽车柴油机在运行中发生的连杆盖及上、下螺栓的早期断裂进行了分析。结果表明,连杆盖首先发生疲劳断裂,随后导致连杆螺栓的断裂,而这种断裂既与应力有关,又与零件的加工工艺有关。     

采煤机齿轮横断分析

采用断口分析、金相检验、硬度测试和化学分析方法对服役仅3天便发生断裂的齿轮进行失效分析.结果表明断口上的明显缩松、枝晶组织是断裂源,而金相组织中粗大马氏体、铁素体、珠光体又使材料强度和塑性降低,在热处理淬火过程中在热应力作用下发生断裂.     

变速箱二轴的断裂分析

汽车变速箱二轴在工作中发生多起断裂事故。采用金相检验、扫描电镜和化学成分分析等手段，对断裂变速箱二轴进行了检验分析。结果表明，轴的断口具有明显的疲劳特征，疲劳源位于二轴花键槽根部。由于渗碳淬火工艺不当，在二轴花键槽根部的组织中产生了网状碳化物和粗大的针状马氏体，在外力作用下形成沿晶显微裂纹并扩展，是导致二轴疲劳断裂的主要原因。     

客车直拉杆断裂分析

通过宏观检验、化学成分分析、断口分析以及金相检验,对客车直拉杆断裂的原因进行了分析。结果表明:直拉杆的146°弯处在使用前存在微裂纹,在客车行驶过程中该直拉杆受交变应力的作用,微裂纹以疲劳的方式扩展,当扩展到一定程度,剩余截面不能承受外力作用时发生断裂。     

Determination of large deformation and fracture behaviour of starch gels from conventional and wire cutting experiments

Large deformation and fracture properties of two types of starch gels were investigated through uniaxial compression, single edge-notched bend (SENB) and wire cutting experiments. Tests were performed at various loading rates and for various starch/powder concentrations (%w/w). It was found that starch gels exhibit rate independent stress–strain behaviour but show rate-dependent fracture behaviour, i.e. stress–strain curves at three loading rates are similar but fracture stress and fracture strain increase with increasing strain rate. This is rather unusual and interesting behaviour. SENB and wire cutting experiments also revealed rate-dependent fracture behaviour and that the true fracture toughness (G _c) values increase with loading/cutting speeds and starch powder concentration. In addition, the G _c values from wire cutting and SENB tests were in reasonable agreement. The wire cutting process was also studied numerically using finite element techniques. A non-linear elastic constitutive relationship based on Ogden was used to model the starch gels and a frictionless condition was assumed at the wire–starch gel contact interface. A fracture criterion based on maximum principal strain was assumed for the prediction of the steady state cutting force.     

Dynamic fracture of bovine bone

True clinical fracture of bones in bovine, race horses or humans occur predominantly during impact loading (e.g. car accidents, falls or physical violence). Although static fracture tests provide an estimate of fracture toughness or R-curve behavior in bones, the static toughness values may be ill suited for predicting failure under dynamic loading conditions due to the visco-elastic response of bone (i.e. strain rate dependent properties). Despite decades of the study on deformation rate dependency of bone properties such as compression and fracture toughness, high-quality dynamic fracture data remain limited. Preliminary tests (compression and fracture toughness) have been conducted on dry and wet bovine bone under both static and dynamic loading conditions. While compression tests have been conducted with loading direction parallel and perpendicular to the bone axis (longitudinal and transverse, respectively), fracture tests were performed only in the transverse direction. The strain rate in compression tests varied between 10^− 3 and 10³ s^− 1, and the stress intensity rate varied between ∼10^− 3 and 10⁵ MPa√m/s. While low strain rate tests were conducted on conventional mechanical testing machines, high strain rate experiments were conducted on a split-Hopkinson bar under compression and a novel three-point bend configuration. The fracture morphology and the extent of damage of bone in each case were characterized using SEM, and an attempt is made to relate these to the rate dependent fracture toughness of the bone. It is believed that such understanding is crucial for mechanistic interpretation of bone fracture phenomenon and eventually for predicting bone failure reliably.     

悬臂施工连续梁桥顶板预应力束平弯段径向力效应

平面杆系模型无法考虑预应力束平弯效应的影响,三维实体模型的建立又过于复杂。针对此问题,该文以悬臂施工连续箱梁顶板为研究对象,推导了顶板中轴线处平弯束径向力效应引起的拉应力的弹性力学解。基于拉应力最大值往往是设计控制点,提出了等效宽度的概念,对弹性力学解进行进一步简化。最后,借助ANSYS软件进行算例验证。结果表明,随着平弯半径的增大,曲率逐渐减小,级数解推导过程中由平弯束“以直代曲”造成的误差逐渐减小,增加修正项以考虑平弯束斜率改变的影响后,数值解与公式解趋于一致,即简化后的公式是行之有效的。     

尼龙-6 合金的分散形态和破坏机理

利用低真空扫描电镜和高真空扫描电镜及偏光显微镜对尼龙-6/热塑性聚酰胺弹性体合金的分散形态和破坏形貌观察照相, 结果表明: (1) 在三轴应力作用下, 尼龙-6 合金试样U 型缺口前部塑性区域由微细程度和密度均不等的银纹组成, 银纹结构是空洞, 空洞是TPA E 粒子的变形和破坏所致, 空洞的变形加剧母体尼龙-6 的颈缩化; (2)尼龙-6 合金因塑性区域内的空洞化和空洞的变形及空洞之间区域的颈缩和纤维化, 有效地吸收了破坏能量, 使塑性约束得到缓解, 促进了平面应变状态向平面应力状态转变, 最终呈半韧性或韧性破坏; (3) 低真空扫描电镜观察照相既能反映TPA E 粒子的变形程度, 又能反映分散相粒子的破坏过程和空洞大小。     

Numerical investigation on stable crack growth in plane stress

Large deformation finite element analysis has been carried out to investigate the stress-strain fields ahead of a growing crack for compact tension (a/W=0.5) and three-point bend (a/W=0.1 and 0.5) specimens under plane stress condition. The crack growth is controlled by the experimental J-integral resistance curves measured by Sun et al. The results indicate that the distributions of opening stress, equivalent stress and equivalent strain ahead of a growing crack are not sensitive to specimen geometry. For both stationary and growing cracks, similar distributions of opening stress and triaxiality can be found along the ligament. During stable crack growth, the crack- tip opening displacement (CTOD) resistance curve and the cohesive fracture energy in the fracture process zone are independent of specimen geometry and may be suitable criteria for characterizing stable crack growth in plane stress. This revised version was published online in August 2006 with corrections to the Cover Date.     

Fatigue behaviour of ribbon-reinforced composites

The fatigue behaviour of aluminium-based composites reinforced with high-strength steel ribbons has been examined. In the directions both parallel (longitudinal composites) and perpendicular (transverse composites) to the principal ribbon axis the development of the fatigue deformation is controlled by the matrix. The steel-matrix bond does not deteriorate during the initial stages of fatigue. The fatigue limit at 10⁷ cycles was arbitrarily defined in the case of the longitudinal composites as corresponding to approximately the half-destruction of the composite. In this way the limit for a composite with a volume fraction,V _r of 0.25 was around 25% of the fracture strength while with aV _r of 0.34, the limit was raised to about 33% of the fracture strength. The use of an alloy matrix increases the fatigue strength of the composite. The fatigue mechanism in both longitudinal and transverse composites initially involves matrix cracking; this leads to steel-aluminium or aluminium-aluminium debonding parallel to the principal stress axis in specimens fabricated from pre-coated steel ribbons, followed by ribbon fracture. In specimens fabricated by simply rolling together the steel ribbons and aluminium foils, little debonding is evident. The debonding results in a high fracture resistance.     

高强钢低匹配焊接接头应用性能研究

本文采用低匹配焊条材料焊接了高强度钢材,对其焊接接头硬度、强度、抗弯性能、韧性和抗爆性能进行了综合试验研究,研究结果表明,对于屈服强度高达1,000 MPa的钢,其低匹配焊接接头如果采用常规焊缝余高控制工艺,将出现以下不利状况:(1)无余高焊缝金属承受横向拉应力,在母材及HAZ拘束下首先屈服时,发生低延性破坏;(2)有余高焊接接头在弯曲应力及弯曲、拉伸复合作用下,焊接接头易出现焊缝首先塑变破裂的低应力失效现象。其根本原因为焊接接头软质焊缝区塑性变形抗力的不足。此类破坏发生时,钢板尚未充分塑性变形,从承受应力水平和吸收能量能力来看,这将导致焊接接头系统的服役能力大为降低,因此提高低匹配焊接接头焊缝区塑性变形抗力变得极为重要。利用第三强度理论分析了低匹配焊接接头变形特点,并进行了此类接头焊缝余高的特殊设计,获得和传统等强匹配等效的焊接接头,即在服役状态下,确保焊缝金属不先于母材发生塑变集中而失效。     

Microstructural aspects of tensile deformation of high density polyethylene

Abstract

The paper describes tensile flow behaviour and related microstructural aspects of injection moulded polyethylene. The flow stress increased with increase in strain rate indicating that the tensile flow behaviour is sensitive to strain rate. Also, the yield stress exhibited a linear relationship with strain rate and followed the thermal activation concept with the activation volume consistent with the thickness of the lamellar crystallite. The behaviour of mechanically induced surface damage on polyethylene was studied by SEM. At low strain rates, the deformation process was characterised by features that looked like deformation bands. With increase in strain rate and strain, the deformation bands developed into a distinct array of crazes and grew inwards, followed by tearing. Also, with increasing strain rate the crazes multiplied and secondary crazes were generated that were at an angle to the tensile axis. The examination of the morphology of the fracture surface of polyethylene at various strain rates provided an insight into the mode of fracture process. At low strain rates polyethylene exhibited a ductile type of fracture with extreme fibrillation and, at intermediate strain rates, crazing - tearing was the predominant mode of fracture at the edges, while fibrillar failure occurred in the mid-thickness of the fractured surface. But, at higher strain rates the percentage of fibrillation was relatively small in comparison to lower strain rates. The different modes of deformation processes can be represented in the form of mechanical deformation - strain diagrams, which provide a broad perspective of the deformation processes operating in the different regimes.