台架试验失效曲轴的原因分析与结构优化  

Cause analysis and structural improvement of failure crankshaft in bench test

作　　者：王旭阳 于晓东 吕世杰 于海波 林治军 宋春雨 WANG Xuyang;YU Xiaodong;LYU Shijie;YU Haibo;LIN Zhijun;SONG Chunyu(Tianrun Industrial Technology Co􀆰,Ltd􀆰,Weihai 264413,Shandong,China)

机构地区：[1]天润工业技术股份有限公司,山东威海264413

出　　处：《柴油机设计与制造》2022年第4期43-48,共6页Design and Manufacture of Diesel Engine

摘　　要：在曲轴开发初期,采用调质钢锻造的曲轴在800 h台架耐久试验中发生断裂失效。使用直读光谱仪、金相显微镜、ADCOLE轮廓仪、X射线衍射仪对该曲轴的失效原因进行了分析与研究,发现该调质钢曲轴的失效模式属于低应力高周断裂。针对调质钢曲轴的结构设计了2种改进方案,分别增加曲柄厚度和增大曲柄销沉割槽过渡圆角半径。采用有限元分析(FEA)仿真计算,进行了方案对比。仿真结果表明,增大曲柄销沉割槽过渡圆角半径可使得圆角危险区的应力最小。后期试验表明,采用该方案的曲轴设计满足800 h的台架耐久试验要求。In the early stage of crankshaft development,the crankshaft forged with quenched and tempered steel had fracture failure during the 800 h bench durability test.By means of direct reading spectrometer,metallographic microscope,profilometer and X⁃ray diffractometer,it is found that the fail⁃ure mode of the quenched steel crankshaft is low stress and high cycle fracture.According to the structure of quenched and tempered steel crankshaft,two improvement schemes are designed:increasing the thick⁃ness of the crank and the radius of the transition fillet of the crank pin sinking groove.The finite element analysis(FEA)simulation is used to compare the schemes.The simulation results show that increasing the transition fillet radius of the crank pin sinking groove can minimize the stress in the fillet danger zone.The late test shows that the crankshaft design using this scheme meets the requirements of 800 h bench durability test.

关 键 词：曲轴 圆角滚压 有限元分析 应力 台架试验 

分 类 号：TK403[动力工程及工程热物理—动力机械及工程]