小家电中突跳式温控器的失效原因分析及改善策略

在小家电的使用中，突跳式温控器发生失效会导致电水壶，电饭煲等家电产品控温功能和过热保护功能产生失效。本文首先对突跳式温控器的结构和应用进行阐述，然后利用FMECA分析法对导致其失效的关键元件进行分析，从而得出突跳式温控器的失效机理，最后针对突跳式温控器的失效提出改善策略。     

JZC-1M/027-01继电器失效机理分析

通过对JZC-1M/027-01继电器进行失效分析,认为继电器失效原因是由于中簧片在焊接部位产生断裂,导致中簧片不能回弹,在继电器加电时中簧片与常开簧片接触,断电后不能复位,使中簧片与常开簧片为短路状态.断裂簧片脆性断裂的原因是簧片在焊接过程中曾经较长时间受到较高温度的作用,导致热影响区(断裂部位)晶粒长大,晶界变粗且弱化,在继电器工作过程中,由于该部位多次受到应力作用而产生脆性断裂.正常簧片在热影响区未发现类似现象.     

考虑热应力、热变形正交各向异性板的动特性及响应规律

该文开展了热环境下正交各向异性板固有特性和激励响应的研究,通过实验测试与数值计算,分析了其固有频率随温度的变化规律、模态交换或突跳现象、以及激励作用下响应受温度的影响。结果表明:温度引起的热应力与热变形会改变板的动态特性,但两者在热屈曲前后对板刚度的影响机制不同,导致固有频率随温度先降低后上升,且它们的微小变化会导致正交各向异性板的模态交换或突跳现象;激励作用下整体响应曲线随温度升高向低频漂移。     

冰箱压缩机电路控制保护器之关键技术“记忆金属元件设计应用”

通过探讨电冰箱压缩机电路控制保护器的工作机理,通过结合实践探讨关键记忆金属元件双金属片材料基础理论,包括双金属片的基本特性,如何工作,规格品种,标准试验方法,主要指标（曲率半径、挠性、热变形、弹性模量、机械力、温度力）,应力与温度关系,物理和机械性能（电阻率和电阻、硬度）,稳化热处理,耐腐蚀性及保护,特别是蠕变式园盘的热变形与温度力的组合、＂热变形与温度力＂和温度、直径、厚度的关系等规律,从而初步掌握电冰箱压缩机保护器设计与工艺编制中所需双金属片应用知识。     

风箱加热法测量热熔断体额定动作温度

一、概述 热熔断体是露置于超过设定温度下,经长时间后使电路断开、仅供一次性使用的元件.它是一种超温保护元件,在一个电气回路中接入一个(或数个)热熔断体,使之成为载流元件,当电路发生故障不能正常工作时,会产生大量的热,令回路本身温度不断上升,当温度接近热熔断体额定动作温度Tf时,热熔断体熔断,此时回路被切断,有效防止设备由于温升过高而导致绝缘失效引起触电及着火的危险,使人身和财产不受侵害.     

补偿器和探测器的研制CuZnAl系SMA的应用

用 CuZnAlSMA 作温度控制元件,研制出冷端温度补偿器和密封式定温探测器。SMA 温控元件的综合性能优于热双金属片和热敏电阻温控元件。上列两装置具有恒温温度稳定、精压高、工作可靠、结构简单、重量轻和成本低廉等优点。     

一款基于机械冰箱改良的电子温控器设计及运用

传统的机械式温控器它由一个感温管和气襄来感测冰箱内的温度;随着温度的高、低,气襄的伸张发生变化来推动机械杠杆使电触点发生改变;从而控制压缩是否工作来实现冰箱内的温度高、低。这种温控器灵敏度不高,温控器的性能会随时间的增长参数会发生漂移,导致冰箱制冷温度出现偏差。本文设计的电子温控器克服该弊端,使电冰箱温度控制更加智能、精确。     

基于B/S模式的弹药失效诊断评估系统研究

为了提高通用弹药产品可靠性评估的效率,实现产品失效及可靠性的系统化辅助分析评估,对通用弹药产品的失效过程进行研究,总结出产品的一般失效分析过程、失效诊断方法及弹药失效分析数据字典.在辅助分析系统中,提供了失效分析、可靠性评估、FMECA等模块.应用Java、JSP等语言,在B/S模式下进行设计开发,实现了对产品失效的过程分析及产品可靠性评估.优化可靠性统计分析的数学模型,改进评估参量算法,使评估工作效率提高30%以上,参数精度达到小数点后8位.     

圆柱基体热障涂层热冲击下失效的瞬态应力分析

用等离子喷涂方法在合金圆柱体上制备了热障涂层,并用水冷的方法进行了热冲击实验,试样的失效现象为轴向的开裂和剥落.利用有限元分析工具对热障涂层的热冲击进行模拟,通过对涂层内部应力随时间分布的分析发现:热冲击过程中陶瓷层表面的周向应力随着时间由拉转变为压,冷却初期陶瓷层的周向拉应力值较大,超过了陶瓷层的抗拉强度,因而淬冷初期的周向应力是导致轴向裂纹萌发的主要原因;陶瓷层与粘结层接触面上的径向拉应力与粘结层的氧化生长引起界面开裂;轴向裂纹和界面开裂共同导致陶瓷层的剥落.     

某余热锅炉集箱端盖断裂脱落原因分析

对某余热锅炉省煤器集箱端盖在运行24个月后发生整体断裂脱落事故进行了分析,通过对失效端盖进行宏观分析、化学成分分析、硬度测试、金相检验、扫描电镜以及能谱分析,找出了端盖断裂失效原因。结果表明:端盖失效性质为腐蚀疲劳断裂;端盖内的运行介质中含有具有腐蚀性的氯离子,在较高温度和应力作用下促使端盖内壁产生裂纹,并在集箱内温度波动造成的热疲劳应力作用下快速扩展最终导致端盖断裂脱落。     

Contact Fatigue Failure of a Tapered Roller Bearing Used in a Lorry Wheel

Tapered roller bearings, which are also known as angular-contact bearing, are suitable for supporting radial and axial loads. The more frequent types of defects in such bearings are caused by contact fatigue in these machine components, and this examination focuses on a contact fatigue failure in a tapered rolling bearing. The examination included visual inspection, microscopic analysis (optical and scanning electron microscope), and microhardness measurements. These measurements were conducted to help understand the failure mechanisms. Based on the results of visual examination and microstructure and fracture surface analysis, it was determined that the tapered roller bearing failed by contact fatigue that was caused by overloading of the bearing.     

Thermal and Mechanical Failure Analysis of a Two-Stroke Motocross Engine Piston

The failure analysis of an aluminum two-stroke single-cylinder 250 cc motocross engine piston with significant material cracking was performed using both computational and theoretical approaches revealing several contributing factors to the cracking. A main central crack in the piston skirt is the direct result of mechanical fatigue imposed by the contact loads exerted on the piston during cold-start situations. Two symmetric secondary cracks also observed on the piston skirt region are similarly caused by the resulting contact of the piston skirt against the engine cylinder wall. Although thermal fatigue is considered, theoretical calculations dismiss the likelihood that thermal stresses develop as a result of the piston-cylinder wall contact under normal operating conditions. However, under extreme temperatures due to cold start or altered air/fuel ratios, thermal fatigue plays a more likely role. A finite element analysis confirms the critical stress locations resulting from the contact of the piston skirt against the engine cylinder wall, and analyses of the fracture surfaces confirm the initiation and propagation of the fatigue cracks.     

加载循环数对2D针刺C/SiC复合材料疲劳剩余强度的影响

为研究陶瓷基复合材料的低周疲劳失效机理,通过试验和细观分析对其疲劳特性进行了探讨。研究了室温下加载循环数对2D针刺C/SiC复合材料拉-拉疲劳剩余强度的影响,并采用光学显微镜和扫描电子显微镜对该材料的断口形貌和微观结构进行了观察。结果表明:2D针刺C/SiC复合材料具有较好的抗疲劳特性,在85%极限拉伸强度(UTS)载荷下的循环数超过106;随着加载循环数的增加,剩余强度先增大然后下降。断口分析表明:纤维拔出长度随着加载循环数的增加而增加,说明在疲劳加载过程中,纤维/基体的界面结合强度降低,减缓了材料内部受力的不均匀性,提高了材料的承载能力,使2D针刺C/SiC复合材料出现了疲劳强化现象。      

Fretting fatigue failure mechanism of automotive shock absorber valve

Fretting fatigue is a complex mechanical failure phenomenon, in which two contact surfaces undergo a small relative oscillatory motion due to cyclic loading. This study proposes a methodology to analyze the fretting fatigue failure mechanism of automotive shock absorber valve by means of experimental and numerical approaches. A servo hydraulic test set-up is used to simulate fretting fatigue under real working conditions. Moreover, a 3-D finite element model is developed to analyze the contact status and stress distribution at contact interface between connected components, i.e. washer-disc contact. The experimental test results depict that fretting damage appears at contact interface between washer and disc, which causes the initial crack nucleation and advancing the crack up to the final fracture of valve disc. Stress field, obtained by numerical simulation, is used to monitor some fretting fatigue features such as the distribution of relative slip amplitude, contact pressure and different stress fields at contact interfaces. Eventually, the crack initiation site is estimated by monitoring variation of equivalent multiaxial damage stress at contact interface.     

Fatigue failure of steel links operating as chain components in a heavy duty draw bench

Steel links used as chain elements in draw benches are subjected to repetitive tensile stressing due to successive loading and un-loading conditions. In addition, friction caused by poor or improper lubrication can be very harmful, due to associated surface degradation and wear/corrosion related processes which play an important role to the integrity and performance of the machine components. Frequent in-service failures of chain links occurred in a copper tube draw bench have led to increased maintenance costs and machine downtime resulting in poor productivity indicators. Samples from fractured components, made of induction hardened structural steel, were brought for a failure analysis investigation. Failure analysis findings suggest strongly that the failure was accomplished by the operation of fatigue mechanism initiated at the inner-eye area of the link and followed by brittle overload fracture. Review of the service history (operating conditions, applied loads), in combination to the examination of a potential substitution of the material to a more fatigue resistant one are recommended as further fatigue damage preventive actions.     

Investigation of In-Flight Shutdown of Turboprop Engine Due to Electrical Discharge Damage

A turboprop training aircraft experienced an in-flight shutdown failure with complete seizure of its propeller. Disassembly of the mishap engine revealed that many of the engine components were severely damaged. The laboratory investigation of the failed engine components determined that mechanical failure of the driveshaft bearing in the gearbox was the principal contributing factor that led to in-flight complete seizure of the propeller shaft. Microscopic examination of the failed bearing remnants found electrical arc-induced pittings which played a role as crack initiation sites resulting in premature rolling contact fatigue cracking during continued engine operation. The investigation established clear evidence of electrical discharge damage (EDD) on engine components connecting from the starter-generator to the failed input driveshaft bearing. The evidence of EDD observed in multiple elements located along the electrical current path and the residual magnetism measurement suggested that the starter-generator is highly associated with the source of the EDD.     

变速箱双联齿和512齿轮失效分析

某型号变速箱在台架试验过程中,双联齿和与之啮合的512齿轮均发生失效事件。采用断口分析、金相检验、硬度测试以及化学成分分析等方法对失效件进行了检验。结果表明:由于双联齿和512齿轮的齿面存在严重的异常接触,加之双联齿的有效硬化层深度和心部硬度均低于技术要求,从而导致在台架试验过程中双联齿表面发生严重的接触疲劳剥落,与之啮合的512齿轮发生弯曲疲劳断齿。     

Failure analysis of components in compressor vane

The paper presents a failure analysis of components damaged in compressor vane. In order to investigate the damage mechanism and failure causes of components, macroscopic and microscopic observations, microstructural investigations, chemical analysis and hardness measurement have been performed. The results show that the damaged components are caused by fractured blades of 1st stage rotor. In all 1st stage rotor blades, 1^# blade is fractured firstly, and is troublemaker in this incident. The fracture mechanism of 1^# blade fractured from blade root is due to first order bending vibration fatigue damage. The microstructure, hardness and chemical compositions of 1^# blade fracture, all which coincide with technical requirements. The bad shot peening qualities in the surface near blade fracture have important influence on fatigue failure.     

吊车转盘连接螺栓断裂分析

吊车转盘后部的连接螺栓发生断裂,通过化学成分分析、宏观和微观检验等方法对断裂原因进行了分析。结果表明：螺栓为疲劳断裂,螺纹根部的细小裂纹是导致螺栓发生疲劳断裂的主要原因;螺栓松动后受到弯曲载荷是引起螺栓发生疲劳断裂的诱因。     

EH系统油动机螺栓断裂分析

采用宏、微观检验方法对电液压系统油动机的断裂螺栓进行了分析,确认螺栓机加工不当引起疲劳裂纹的萌生及扩展,加之螺栓受力不均匀加速了疲劳断裂过程,提出了预防螺栓疲劳开裂失效的防范措施及改进建议。