大型超静定回转窑支承系统等强度调窑优化研究

回转窑运行中由于轴线偏移,支承载荷分配严重不均,托轮轴疲劳断裂现象频繁,对它运行轴线的合理调整是防止托轮轴疲劳断裂的关键。通过对回转窑托轮轴进行力学分析,导出支承系统疲劳强度与轴线的关系;以轴线调整量为优化变量,托轮轴安全系数最大值与最小值之差最小为目标函数建立优化模型;结合现场实例进行支承系统等强度优化调整研究,得出了一些有益的结论。为回转窑的维护与调整提供理论依据,对现场生产有重要的指导意义。     

大型多支承回转窑支承结构的接触有限元分析

回转窑是冶金、水泥、耐火材料生产中的关键设备,它是一种重载、大扭矩、多支点、静不定运行系统。回转窑运行中由于轴线偏差,支承载荷分配严重不均,导致支承部件因接触应力过大而产生压溃、剥落和点蚀等现象。从支承载荷分配与轴线偏差的线性关系出发,根据赫兹接触理论,得出了支承结构接触力与轴线偏差的关系式;采用有限元方法对某档支承结构的接触问题进行分析,得到了接触区域情况及各部件的变形应力规律。分析结论与实际生产一致,为回转窑最佳运行状态的调整提供有效的理论依据。     

大型多支承回转窑托轮偏斜接触有限元分析

针对回转窑托轮偏斜对接触区应力分布的影响,运用赫兹接触理论,推导出托轮与滚圈最大接触应力比与托轮偏斜角的关系;采用有限元方法计算某支承结构托轮平行与呈最大偏斜角时的接触问题,得到支承部件接触应力和等效应力应变分布情况,并得出滚圈和托轮的危险易损部位;为回转窑的轴向调控提供了有效的理论依据。     

各种平均应力下高周疲劳极限间的定量关系

疲劳极限是材料工程应用中的一个重要特性参数,但它并不是材料常数。在不同循环载荷作用下,材料会有不同的疲劳极限值。疲劳极限值很大程度上依赖于循环载荷中的平均应力或最大应力幅值,两者之间的关系是材料自身固有的特性关系。因为在接近疲劳极限的低循环应力幅下,S-N曲线受疲劳极限控制,所以在工程应用中对其定量关系有迫切的需求,但现有的经典经验关系只能对其进行非常粗略的估算,不能满足工程应用中有关寿命设计的需要。现状是只能通过大量的实验,得出其实验关系。该文提出了一种函数形式的关系式,该关系式可以足够精确地描述各种材料的疲劳极限和平均应力之间的关系,且只包含三个材料常数。只要这三个材料疲劳特性常数被事先确定,则任意疲劳载荷下的疲劳极限值,都可由该关系式估计得到,因此可以作为材料本身固有的疲劳强度的状态关系式使用。     

回转窑托轮轴轴端断裂原因分析及其修复环节的分析

为了满足当下水泥生产的需要，展开回转窑托轮轴断裂故障的避免是必要的，本文就事故处理措施展开分析，进行实际情况的掌握，保证回转窑托轮轴轴端断裂情况的避免，这需要进行详细的总结及其分析，保证其断裂原因的分析，进行修复模块的有效开展。     

铝合金焊接接头的疲劳性能

在轴向应力加载情况下,铝合金的对接、搭接和T型接头以及在反复弯曲(簿板材料)加载情况下的对接接头的研究表明,疲劳强度主要受其几何物特性的影响。相对于载荷轴线的应力集中程度和对称性都有助于按下述次序减少所研究的接头的轴向应力疲劳强度。     

考虑裂纹效应的弹性板振动分析模型

针对含裂纹板的动力学问题,提出了一种耦合裂纹效应的弹性板动力学建模方法。该方法依据变形等效原则用虚拟外部载荷代替裂纹作用,并通过力学平衡原理建立了耦合裂纹项的弹性板运动方程,且基于Rice和Levy应力关系式推导出裂纹项表达式;在此基础上,结合Galerkin法和Berger经验,把含裂纹弹性板振动系统简化成一单自由度非线性振动模型进行动力学特性分析。通过算例探讨了裂纹尺度、阻尼以及激励力位置对弹性板振动特性的影响。结论表明,裂纹尺度和板尺寸对振动非线性作用明显,动应力幅值受阻尼与激励力位置的控制。     

液压模块挂车刚柔耦合动态响应特性及摆臂疲劳分析

为了研究重型液压模块挂车动态响应特性及其摆臂疲劳强度的问题,基于有限元分析方法与刚柔多体动力学理论,建立挂车刚柔耦合多体动力学模型,以路面不平度作为仿真的激励信号,结合振动试验验证模型的准确性。对挂车在不同的运行工况下,进行动态响应仿真分析。将多体动力学仿真结果作为有限元分析的动载荷,计算获得疲劳分析所需要的应力时间历程,运用局部应力应变法对摆臂进行疲劳寿命预测。计算结果表明,摆臂应力集中部位出现在已发生断裂的断面位置及应力水平已进入塑性状态。挂车在B级、C级与D级路面下的运行,危险点的疲劳寿命均大于挂车使用年限。而在正弦形凹凸路面冲击下,危险点的疲劳寿命随正弦形幅值与车速增加而明显减短。根据仿真计算结果,可提出适用的运行工况以提高挂车运行安全性与运输效率。     

基于三点法的回转窑轴线在线测量系统

论述了一种基于三点法的大型回转窑轴线在线测量新方法,该方法不仅能够测得回转窑筒体回转中心的动态变化情况,同时还可以测取轮带和托轮的直径以及它们的变形情况。应用该方法,设计研制了一种新型大型回转窑运行轴线动态测量系统,由基于ATmega128单片机的下位机数据采集系统和基于PC机的上位机数据分析处理系统共同构成,通过USB口实现上下位机的通信。该系统具有结构简单、安装使用方便、测量精度高等特点。     

一种基于三轴与单轴随机振动最大应力等效的载荷裁剪方法

为了避免三轴振动试验对产品造成过试验问题,现以单轴振动试验标准为基准,进行基于三轴振动与单轴依次振动最大响应应力等效的三轴载荷谱裁剪。首先对线性系统在随机振动下激励与响应均方根值的关系进行推导,将单轴振动时的最大等效应力与三轴振动时的最大等效应力的比值n作为三轴振动载荷谱均方根值的裁剪系数,裁剪保持载荷谱扫频范围、拐点频率值以及载荷谱斜线段的斜率N不变,根据梯形谱均方根值计算公式反推出梯形载荷谱直线段谱值,进而得到满足三轴与单轴随机振动最大应力等效的三轴载荷谱。通过对某典型舱段结构进行三轴载荷谱的裁剪,并将载荷谱裁剪后的三轴振动应力响应与载荷谱裁剪前的单轴振动应力响应进行对比,验证了方法的有效性与准确性。     

Environmental effects on fracture resistant and biaxial fatigue design of aircraft structures

This paper discusses the two interrelated fields of crack initiation and crack propagation by presenting analytical techniques for calculating fatigue damage in biaxially stressed structures along with determining safe inspection intervals for contained crack growth.The equivalent stress concept is used to derive a set of uniaxial stresses that produce the same amount of fatigue damage as the biaxial stress exposure. The distortion energy concept serves as the basis for combining alternating principal stresses by translating the uniaxial SN curves for zero mean stress into a family of concentric ellipses. The major axis bisects the principal stress axes for isotropic materials with invariant directional fatigue performance. The intercept of these ellipses with the maximum alternating principal stress axis defines the equivalent alternating stress at various cyclic lives.Empirical procedures are given for treating problems with varying principal stress directions and areas with directional dependent fatigue performance.The Goodman diagram relates alternating stresses and mean stresses at any constant cyclic life. If two uniaxial Goodman diagrams are constructed on each reference axis, a three-dimensional body can be visualized which intercepts the zero alternating stress plane in a shape identical to that described by the applicable static load criterion. The equivalent mean stress concept is based on the existence of a similarly shaped closed surface at any value of alternating stress. The intercept of this surface boundary with the maximum mean stress axis is the equivalent mean stress.Crack growth rates and residual strength of structure are important items since it is necessary to consider the possible existence of cracks. Static failsafety consists of contained crack growth for reasonable lengths of time and back-up structure providing alternate load paths. The stress intensity factor $\text{K}$, reflecting the distribution of stress in cracked structure, is the basis for computing crack growth. Baseline crack growth data for several material toughnesses and environmental exposures is required for fracture analysis. The method employed consists of calculating stress intensities for various crack lengths in the structure, these primarily being a function of geometry and applied stress distribution. The crack growth curves are constructed by integrating the baseline data for the appropriate corrosive exposure with additional factors applied to allow for scatter in growth rates and load magnitudes.     

Fatigue life estimation of adhesive bonded shaft joints

Fatigue tests and analytical investigation of adhesive bonded shaft joints were conducted to propose the estimation method of fatigue strength. Two kinds of adhesive bonded joints were studied: one, shaft joints connected with adhesive coupling, the other, adhesive joints of thin wall tubes to obtain standard fatigue strength. Both pulsating tensile and torsional fatigue tests were conducted with each adhesive joint. Furthermore, the stress distributions under tensile and torsional load conditions were analyzed by finite element method. Based on the analytically computed maximum normal shear stress in the adhesive layer, fatigue strength of the shaft joints was tandardized and compared with that of adhesive joints of thin wall tubes. As a result, it is confirmed that the maximum normal and shear stresses are key parameters for estimating fatigue strength under pulsating tensile and forsional load conditions, respectively. Furthermore, this study indicates an improved method of estimating fatigue strength by using tapered coupling order to reduce the stress concentration at the end of the adhesive layer.     

考虑加载速度影响的沥青混合料疲劳方程

为了建立沥青混合料强度与疲劳行为之间的联系,通过不同加载速率下的沥青混合料直接拉伸强度试验,揭示了强度随加载速率的幂函数变化规律;基于不同加载速率下的强度值,得到了与疲劳加载速率对应的沥青混合料疲劳真实应力比;通过疲劳试验,创建了基于名义应力比和真实应力比的沥青混合料疲劳方程,基于名义应力比的疲劳方程后延后与横坐标的交点远比1 大,不具有后延性,而基于真实应力比的疲劳方程可以后延到疲劳寿命为1 的强度破坏点,统一了强度破坏与疲劳破坏行为;据此推导了沥青路面抗拉强度结构系数计算新方法;研究结果可为我国公路沥青路面设计规范的修订提供理论依据.     

Load distribution in the axial direction in a spline coupling

A finite element model has been made of a spline coupling between a shaft and a sleeve. The stress concentration factor is calculated and compared to analytical calculations. An analytical model for the load distribution in the axial direction and the torque transfer between shaft and sleeve is presented and compared to finite element results. Methods to uniform the load distribution and thereby decrease the stress concentration factor are tested with the analytical model. The induction hardened shafts with splines are fatigue tested and the lives are presented. The residual stress on the shaft surface is measured. The analytical model shows that the best way uniform the load is to vary the thickness of the spline tooth in the axial direction. Different shapes and sizes of the tooth thickness variation are also investigated. It is probably possible to extend the fatigue life at least two times for this spline, by uniforming the load distribution.     

Investigation on the failure of the gear shaft connected to extruder

In respect to the fracture of the gear shaft of an extruder, the torque on the shaft replaced the fractured one is measured under typical work conditions. The fatigue and material mechanics properties of the fractured shaft are obtained by tensile and fatigue test. Based on the analysis of cyclic fatigue load and the stress of gear shaft, the reason of the shaft fracture is discussed. The analysis indicates that when the extruder is running, high mean stress occurs in the gear shaft, the failure of the gear shaft was caused by fatigue and material strength degradation. Finally, suggestions are given to guide the future operating of the extruder to prevent the gear shaft from fracture.     

汽车发动机曲轴断裂分析

某6缸发动机曲轴在运行8910km时，第六曲拐颈断裂。对断裂曲轴进行了断口观察、化学成分复验、基体硬度和显微组织检验。结果表明，曲轴的拐颈断裂为扭转疲劳断裂，断裂疲劳源位于油道孔与倒圆角曲面交接处，此处的切削加工刀痕及金属损伤形成应力集中且处于最大主应力面上，因而引发扭转疲劳断裂。     

基于分形理论的人工挖孔嵌岩桩承载特性分析

嵌岩长桩的承载性能主要取决于桩-岩接触面的剪切强度。基于岩体结构面强度的研究方法,引入分形维数描述的两相接触介质粗糙表面的抗剪强度公式,建立了以分维数表示的嵌岩桩侧摩阻力传递模型,求得了弹性条件下的桩侧摩阻力及桩身轴力的解析式。基于所获得的解答,深入地探讨了分形维数D对桩侧摩阻力?、桩身轴力P及桩端荷载分担比Pb/Pd的影响规律。研究表明:同等条件下一定范围内粗糙分维值D越大,桩侧摩阻力在桩身上部分布越集中,荷载传递深度越小,桩端荷载分担比Pb/Pd也越小;长径比l/d越小,桩端荷载分担比越大,反之越小。工程算例对比分析表明:理论计算与实测结果吻合较好,对嵌岩桩设计有一定参考价值。     

EURAXLES – A global approach for design,production and maintenance of railway axles: WP1 – Advances in fatigue load analysis and reliability assessment of railway axles

The work presented in this paper was led within the collaborative project “Euraxles” of the FP7 program of the European Commission. It aimed at developing processes and methods that contribute to the minimization of the risk of fatigue failure of railway axles in service. This paper focuses on the development of a method to assess the reliability of axles according to fatigue damage. The proposed approach is mainly based on the stress strength interference analysis (SSIA) and the fatigue‐equivalent‐load (FEL) methods. It aims at calculating the axles’ probability of fatigue failure, by characterizing the variability of real in‐service loads and the scatter of the axles fatigue strength, and at evaluating more accurately the actual design margins. First of all, the main lines of the stress strength interference analysis method are recalled. This method aims at evaluating the in‐service reliability of components for their design or their homologation. It is used in many industries for various applications (mechanical components or systems, electronic elements, etc.). In the second part, the fatigue load analysis method that is proposed for railway axles is described. It starts with a post‐processing of an axle load measurement: from a time signal of forces applied to both wheels fitted on the axle, fatigue cycles of bending moment applied to the axle are identified and transformed into a cyclic equivalent load, the M_eq, which is a measurement of the severity of the initial variable load. Then, virtual but realistic load spectra are generated, thanks to a classification operation followed by a random draw of elementary load data that considers the operation and maintenance conditions of the axle. All the spectra are then analysed thanks to the fatigue‐equivalent‐load method in order to build the distribution of in‐service load severities that gives a picture of the stress to which the axles are submitted. In the third and last part of the paper, the methods are applied to real data of “Société nationale des chemins de fer français” (SNCF), the French national railway operator. Sensitivity analyses are performed in order to quantify the effect on the M_eq of variations of parameters and to verify the convergence and robustness of the process. Finally, results obtained for a passenger coach are given. The comparison between the distribution of load severities and the normative load, defined as according to european standards EN13103, shows that, for the studied axle, the normative load is very conservative. Using the axles fatigue limits identified on full‐scale tests, a stress strength interference analysis is performed to calculate the probability of failure of the axle.