汽车发动机曲轴疲劳性能分析研究

目的汽车发动机曲轴在疲劳实验的过程中,经常会出现非正常疲劳裂纹,裂纹从轴颈末端的油孔槽开始起源,造成曲轴轴颈的扭转强度达不到要求。有必要对汽车发动机曲轴的疲劳性能进行研究。方法通过疲劳、拉伸、金相实验以及疲劳断口SEM手段,对曲轴疲劳试样进行了分析。结果汽车曲轴疲劳实验在循环基数为1×107次下,弯矩的疲劳极限为607.5 Nm;曲轴轴颈的中部所受到的疲劳极限压力为96.7 MPa;该40Cr曲轴断口为典型的韧窝和台阶混合断裂。结论曲轴的钻油孔在轴颈内壁造成的应力集中,比较容易产生缺陷;曲轴轴颈在交变应力的作用下,很容易产生疲劳裂纹并扩展,导致曲轴的早期断裂。     

汽车发动机曲轴弯曲疲劳试验方法研究

目的研究两种常用的疲劳试验加载原理对疲劳试验结果的影响,为曲轴选材、设计和制造的各阶段开展弯曲疲劳试验提供技术支持。方法在两种加载方式下采用同批次曲轴进行弯曲疲劳试验,利用成组法得到疲劳试验结果,针对试验加载原理和试验数据开展分析和讨论。结果电液伺服加载方法的试验精度更准确,而电磁谐振加载方法可以大幅度缩短试验周期。电液伺服加载和电磁谐振加载试验的疲劳极限分别为1140.4 N·m和1189.4 N·m。两种加载方法下,曲轴的失效情况均为连杆颈辊压槽处断裂。结论两种加载方法对曲轴弯矩的加载效果相同,试验结果的相对误差为4.3%。在曲轴的仲裁试验中或有争议的情况下使用,推荐使用电液伺服加载方法。在使用电磁谐振加载方法时须严格控制标定误差。曲轴连杆颈辊压槽是曲轴的薄弱环节,应严格控制辊压槽的机加工质量。     

Ti/TiN/Zr/ZrN多层膜对钛合金疲劳性能的影响

采用真空阴极电弧沉积技术在TC11钛合金基体上沉积约10μm厚的Ti/Ti N/Zr/Zr N多层膜,通过对比镀膜前后试样的屈服强度、抗拉强度、疲劳强度、疲劳寿命,以及断口形貌,研究沉积Ti/Ti N/Zr/Zr N多层膜对基体疲劳性能的影响,探讨疲劳断裂机理。结果表明:多层膜对TC11钛合金基体材料的屈服强度和抗拉强度影响不大,但由于膜层硬而脆而降低了基体材料的收缩率和延伸率;多层膜提高基体材料的疲劳极限;低应力下,裂纹源在多层膜表面萌生,并向内部扩展,在多层结构的膜层界面处受到阻碍,发生偏转,从而提高基体疲劳寿命;高应力下,膜层容易破裂,裂纹源增多,降低基体疲劳寿命;应力水平在520 MPa到650 MPa范围内,疲劳寿命增量从+40.82%降到-36.88%。     

基于热红外成像技术的300M钢疲劳极限测定

对经过热处理和未经过热处理的超高强度300M钢在室温下的常规疲劳性能进行了研究,用红外成像仪测量了疲劳试验过程中合金表面的温度变化;根据疲劳试验过程中温度-应力关系及试样表面温度分布差异,确定疲劳断裂位置和疲劳极限。结果表明:根据试件表面温度变化可以预测疲劳断裂位置;以此法确定的热处理300M钢疲劳极限为833MPa,与常规疲劳试验测得的疲劳极限吻合较好;加载初期300M钢升温到一定温度后形成平稳段,在断裂前温度快速升高。     

航空零件孔内表面挤压强化对疲劳强度的影响

一、前言 在航空零件上,孔的内表面加工质量好坏对零件的使用性能影响很大,尤其对零件的疲劳性能影响更大。飞机和发动机的带孔零件,在使用中大多数是在孔的内表面上或在孔的两端尖角部位产生疲劳源。在交变载荷的作用下,疲劳源进而发展成疲劳裂纹,最后导致灾难性的疲劳破坏。因此,提高孔内壁的疲劳强度是航空制造者的重要任务之一。 孔内壁挤压强化是提高疲劳强度行之有效的好方法。内孔挤压强化是用与孔的形状相同的挤压棒,推过或拉过孔,使之达到一定的尺寸精度、表面光洁度和在内表面产生强烈的塑性变形层,此变形层叫做冷作硬化层或挤压强化层。在强化层内产生与基体有区别的组织结构和应力状态,从而提高孔内壁的疲劳强度。本     

45Cr4NiMoV钢支承辊锻件表面感应淬火后的残余应力分布

采用机械剥层和电解剥层相结合的剥层工艺,利用X射线应力分析仪研究了支承辊锻件表面中频感应淬火后的残余应力沿横截面的分布规律。结果表明:180mm的45Cr4NiMoV钢支承辊表面中频感应淬火后表层为压应力,压应力层深约30mm,从表往里逐渐由压应力转变为拉应力,拉应力峰值出现在距表面约60mm处,不在支承辊锻件的中心部位。通过对支承辊锻件表面感应淬火后残余应力沿横截面分布规律的研究,可为生产特大型支承辊锻件制定合理的生产工艺方案提供可靠的试验依据。     

16Mn结构钢超高周疲劳性能研究

采用超声疲劳试验技术对16Mn结构钢超高周疲劳性能进行了研究，并用扫描电镜对疲劳断口进行了分析。结果显示16Mn结构钢在10^5-10^10周次范围内的S—N曲线呈阶梯型下降趋势，在10^6-10^8周次出现平台，平台对应应力幅约为220MPa．在平台应力以下，10^8周次以上超高周范围16Mn结构钢仍然发生疲劳断裂，不存在传统意义的疲劳极限。16Mn结构钢疲劳断口分析结果表明高周和超高周断裂试样的裂纹源主要从试件表面和次表面缺陷处萌生。10^7周次下超高周疲劳试样强度比常规试样疲劳强度低。     

油缸活塞杆断裂失效分析

经过高频淬火的活塞杆在使用中发生了早期断裂,通过断口的宏观微观分析、化学成分分析、显微硬度分析及显微组织分析,对活塞杆的早期断裂原因进行了分析。结果表明:活塞杆断裂属于疲劳断裂,表面没有感应淬硬层降低了活塞杆的抗疲劳性能;次表面微裂纹的存在造成了应力集中,从而形成了疲劳源;活塞杆未进行调质处理,心部硬度和强度偏低加速了活塞杆的断裂。     

发动机曲轴早期疲劳开裂失效分析

针对某型号发动机曲轴疲劳试验未达到规定载荷累计循环次数,早期疲劳开裂的问题,采用化学成分分析、力学性能测试、断口分析、金相检验和表面氮化层检验等方法对其进行了失效分析。结果表明:该曲轴为疲劳开裂,曲轴过渡圆角处的高应力区存在大尺寸硬质非金属夹杂物是导致曲轴过早疲劳开裂的主要原因;另曲轴过渡圆角处加工质量差,使得该处应力集中加剧,也是致使该曲轴过早疲劳开裂的重要因素。     

小子样测定叶片S-N曲线试验方法研究

根据试验要求,对叶片在样本较少情况下测定其疲劳极限σ-1和S-N曲线。通过振动疲劳试验的方法进行研究,试验采用升降法选择所施加振动应力的水平,采用异方差回归分析方法进行疲劳试验数据的分析。最后获得叶片材料的均值S-N曲线和置信度为95%、可靠度为99.9%的P-S-N曲线,并得到各自曲线上的疲劳极限σ-1。此方法保证试验的顺利进行并且具有较高的可靠性,对于小样本测定材料的S-N曲线具有较好的实用价值。     

On the assessment of fatigue life of marine diesel engine crankshafts

The fatigue strength and its correct assessment play an important role in design and maintenance of marine crankshafts to obtain operational safety and reliability. Crankshafts are under alternating bending on crankpins and rotating bending combined with torsion on main journals, which mostly are responsible for fatigue failure. The commercial management success substantially depends on the main engine in service and of its design crankshaft, in particular. The crankshaft design strictly follows the rules of classification societies. The present study provides an overview on the assessment of fatigue life of marine engine crankshafts and its maintenance taking into account the design improving in the last decades, considering that accurate estimation of fatigue life is very important to ensure safety of components and its reliability. An example of a semi-built crankshaft failure is also presented and the probable root case of damage, and at the end some final remarks are presented.     

Effect of hich-temperature thermomechanical treatment on mechanical properties of 45KhNMFA steel in torsion

High-temperature thermomechanical treatment involving deformation in torsion ensures a substantially larger increase in the fatigue limit of steel carrying pulse torsion loads than the ordinary quench-hardening treatment. Rapid electrical resistance heating for quenching also has a beneficial effect on the fatigue strength. Oriented strain hardening of specimens subjected to a high-temperature thermomechanical treatment produces an additional increase in their fatigue strength in torsion.     

Failure Analysis of a Vehicle Engine Crankshaft

An investigation of a damaged crankshaft from a horizontal, six-cylinder, in-line diesel engine of a public bus was conducted after several failure cases were reported by the bus company. All crankshafts were made from forged and nitrided steel. Each crankshaft was sent for grinding, after a life of approximately 300,000 km of service, as requested by the engine manufacturer. After grinding and assembling in the engine, some crankshafts lasted barely 15,000 km before serious fractures took place. Few other crankshafts demonstrated higher lives. Several vital components were damaged as a result of crankshaft failures. It was then decided to send the crankshafts for laboratory investigation to determine the cause of failure. The depth of the nitrided layer near fracture locations in the crankshaft, particularly at the fillet region where cracks were initiated, was determined by scanning electron microscope (SEM) equipped with electron-dispersive X-ray analysis (EDAX). Microhardness gradient through the nitrided layer close to fracture, surface hardness, and macrohardness at the journals were all measured. Fractographic analysis indicated that fatigue was the dominant mechanism of failure of the crankshaft. The partial absence of the nitrided layer in the fillet region, due to over-grinding, caused a decrease in the fatigue strength which, in turn, led to crack initiation and propagation, and eventually premature fracture. Signs of crankshaft misalignment during installation were also suspected as a possible cause of failure. In order to prevent fillet fatigue failure, final grinding should be done carefully and the grinding amount must be controlled to avoid substantial removal of the nitrided layer. Crankshaft alignment during assembly and proper bearing selection should be done carefully.     

Truck Diesel Engine Crankshaft Failure Analysis

A diesel engine crankshaft fractured in service after 76010 km of operation. The fracture took place on the first crankpin, and the fracture surface has a 45° inclination with respect to the axial. The results indicate that fatigue is the dominant failure mechanism of the crankshaft. It was observed that the fatigue crack initiated at the fillet region of the first crankpin-web. This crankpin is the one among the six crankpins which bear operational load. Absence of the induction hardening case in the fillet region decreased the fatigue strength and led to fatigue initiation and propagation in the weakened region. Although hard-rolling process was conducted in the fillet region, the depth of hard-rolling layer was insufficient to produce the desired residual compressive stress in the fillet region, and therefore the fillet could not offer resistance to the applied load. In addition, the presence of network-like ferrite in the microstructure facilitated the fatigue crack to be initiated and propagated.     

Berechnung der Schwingfestigkeit festgewalzter Kurbelwellen

Predicting the fatigue strength of fillet-rolled crankshafts Since three years Darmstadt University of Technology uses finite element method for simulation of fillet rolling process. Now, together with Daimler-Benz AG, a fracture mechanics based concept has been successfully applied predicting the fatigue strength of fillet-rolled crankshafts. For these parts conventional assessment of fatigue behaviour shows several disadvantages. The new concept reduces time and costs for development and design. It consists of three parts:

• calculation of residual stresses induced by fillet rolling and affected by crankshaft and roller geometry, rolling load and work hardening data of material
• simulation of residual stress redistribution due to cyclic load
• assessment of fatigue cracks starting from notch root and propagating under compressive residual stresses by means of linearelastic fracture mechanics.

     

Effect of prior treatment on the low cycle fatigue behaviour of aluminium alloy RR58 at 423K

The effect of the quenching medium and of varying the microstructure on low cycle fatigue behaviour of aluminium alloy RR58 has been investigated at 423K. It is observed that fatigue resistance is significantly impaired if, following solutionizing, the alloy is quenched in water instead of in oil. Thermal as well as thermomechanical treatments were employed to produce different microstructures. The overaged microstructure displayed the highest fatigue life. It is shown with the help of fractographic observations that differences in fatigue resistance due to differences in severity in quenching or in microstructure arise mainly due to the influence of these variables on crack initiation and early crack propagation. It has also been demonstrated that as the rate of hardening or softening is increased, cyclic strength coefficient K′ and fatigue hardening exponent n′ increase; the fatigue ductility coefficient ?′_f decreases as a result of varying microstructures, and the fatigue resistance at 423K of the alloy is lowered. When compared with the behaviour at ambient temperature, the test temperature of 423K has been found to have no significant effect on the fatigue life/strain plot.     

曲轴材料48MnV钢及其具有3Cr13电弧喷涂涂层的疲劳行为

汽车发动机再制造中,采用电弧喷涂技术修复曲轴具有一定的潜在应用价值,本文对曲轴材料48MnV钢及其具有3Cr13电弧喷涂涂层的疲劳行为进行了研究。选用标准48MnV钢材料及其具有不同厚度涂层的试样进行拉伸和疲劳试验,计算了其疲劳极限并加以分析比较,同时对断口做了分析。发现基体材料为48MnV钢,具有3Cr13电弧喷涂层的试样在轴向载荷下的疲劳性能有相当程度的降低。涂层越厚,疲劳性能越差,疲劳极限越低。疲劳性能降低的主要原因是涂层的结合强度较小,以及喷砂时残留的铝氧化物引起疲劳裂纹萌生。     

Effects of residual stresses on fatigue resistance in torsion with bending in the presence of stress concentrations

Fatigue-test results are given for torsion with bending in cylindrical steel 45 specimens having small semicircular profile notches and with and without residual stresses. The effects of hardening on the fatigue resistance are evaluated from a residual-stress criterion. The test data for the unhardened and hardened specimens are closely described by the equation of an ellipse, which enables one to express the margin coefficient in torsion with bending with allowance for the residual stresses.Translated from Problemy Prochnosti, No. 12, pp. 37–40, December, 1992.     

Investigation of the effectiveness of electromechanical hardening of metallized crankshafts of car engines

The article describes the results of an investigation of the feasibility of using an electromechanical surface treatment as a means of hardening automobile engine crankshafts reconditioned by high-frequency induction metallizing. Metallographic examination of the metal structure, determination of residual stresses in the connecting rod journals and fatigue tests on actual parts established that electromechanical hardening ensures a high endurance of crankshafts reconditioned by high-frequency metallization.