多轴随机振动下制动器防尘罩失效分析与优化  

Failure Analysis and Optimization of Dust Cover of Brake Disc Under Multi-axis Random Vibration

作　　者：赵礼辉[1,2,3] 施玉东 翁硕 张东东 朱江峰[4] 杨万杰 ZHAO Lihui;SHI Yudong;WENG Shuo;ZHANG Dongdong;ZHU Jiangfeng;YANG Wanjie(School of Mechanical Engineering,University of Shanghai for Science and Technology Shanghai,200093,China;CMIF Key Laboratory for Strength and Reliability Evaluation of Automotive Structures Shanghai,200093,China;Public Technology Platform for Reliability Evaluation of New Energy Vehicles in Shanghai Shanghai,200093,China;Technology Center,Sushi Testing Group Suzhou,215000,China;Technology Center,Yihe Axle Co.,Ltd.Zhucheng,262200,China)

机构地区：[1]上海理工大学机械工程学院,上海200093 [2]机械工业汽车底盘机械零部件强度与可靠性评价重点实验室,上海200093 [3]上海市新能源汽车可靠性评价公共技术服务平台,上海200093 [4]苏州苏试试验集团公司技术中心,苏州215000 [5]义和车桥有限公司技术中心,诸城262200

出　　处：《振动．测试与诊断》2023年第6期1176-1182,1247,共8页Journal of Vibration,Measurement & Diagnosis

基　　金：国家自然科学基金资助项目(51705322)。

摘　　要：针对某型商用车制动器防尘罩提前失效的问题,采用基于实测载荷谱的数值仿真与试验验证相结合的方法,准确识别了失效原因,并提出寿命提升的优化改进方案。首先,分析防尘罩失效部位断口的微观形貌,确定失效机理;其次,结合防尘罩结构的模态分析与基于实测道路载荷谱的随机振动应力响应分析,识别结构失效原因;然后,考虑随机载荷多轴耦合特性,通过分析失效主导载荷,制定单轴高加速试验载荷谱,通过加速试验验证仿真分析结果的准确性;最后,通过形状优化给出防尘罩的寿命提升方案,并采用数值仿真进行了验证。结果表明:基于实测载荷谱的数值仿真与主导载荷下的高加速试验对防尘罩结构的失效分析吻合度良好,并与耐久试验结果一致,形状优化后的防尘罩寿命提升显著。该方法可为实际工况下多轴随机振动载荷作用的结构失效分析与优化提供参考依据。Aiming at the premature failure of a certain type of commercial vehicle brake dust cover,the combination of numerical simulation and experimental verification based on the measured load spectrum is used to identify the failure cause accurately,and an optimization and improvement scheme for life improvement is proposed.Firstly,the micro-morphology of the failure part of the dust cover is analyzed to determine the failure mechanism.Then combined with modal analysis of dust cover structure and random vibration stress response analysis based on measured road load spectrum,the failure cause of structure is identified.Considering the multi-axis coupling characteristics of random loads,the single-axis high acceleration test load spectrum is developed by analyzing the failure dominant load,and the accuracy of simulation analysis results is verified by acceleration test.Finally,the life improvement scheme of dust cover is given by shape optimization,and verified by numerical simulation.The results show that the numerical simulation based on the measured load spectrum is in good agreement with the failure analysis of the dust cover structure by the high acceleration test under the dominant load,and is consistent with the durability test results.The service life of dust cover after shape optimization is significantly improved.This method can provide a reference for structural failure analysis and optimization under multi-axis random vibration load.

关 键 词：失效分析 随机振动 高加速试验 形状优化 

分 类 号：TH122[机械工程—机械设计及理论] TH114