CN109614721A - Component of machine defect under fatigue load effect checks and accepts stage division - Google Patents
Component of machine defect under fatigue load effect checks and accepts stage division Download PDFInfo
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Abstract
The present invention relates to the component of machine defects under a kind of effect of fatigue load to check and accept stage division, the specific steps are that: data analysis is carried out non-destructive testing to component of machine, determine defect type and maximum boundary size, and regularization processing and damage phenetic analysis are carried out to defect, fatigue life prediction is carried out on the numerical simulation analysis that component of machine fatigue life influences by defect, obtain the relational expression of fatigue life and flaw size, and carry out verification test, finally, defect is carried out according to the life requirements of component of machine and checks and accepts classification, its defect is instructed to check and accept.Acceptance method of the invention can be common to component of machine, and defect examination classification work is effectively performed in energy science, improve acceptance quality, the quality and safety of Support Equipment.
Description
Technical field
The present invention relates to component of machine defects to check and accept stage division, specifically, being related to a kind of general fatigue load work
Component of machine defect under checks and accepts stage division.
Background technique
Due to many in raw material, manufacture and use, industrial equipment and engineering structure are in production and military service process
In would generally generate many defects, and the presence of defect often causes equipment fault that major disaster safety accident even occurs
Root, especially for the component of machine for bearing long-life of fatigue load, Reusability, Fatigue Failures are had become
Restrict the critical bottleneck of industrial equipment quality.Currently, industrial circle mainly uses lossless detection method to carry out the quality of Support Equipment
And safety, the defect how will test are classified and are checked and accepted always one of engineering staff's concern.Currently, by
In the reasons such as structure loaded condition is complicated, defect kind is various, experimentation cost is high, the defect for entire engineering structure is caused to be tested
Contracture grade is extremely difficult.
With being substantially improved for the development of non-destructive testing technology, especially detectability and detection sensitivity, so that defect
High-precision detection and precise quantitative are achieved, in addition improved day by day for the theoretical method of flaw evaluation, so that for machinery
The defect of components is checked and accepted classification work and be can be realized.It is classified currently, being checked and accepted for component of machine there is no complete defect
Method, the existing defect estimation method that can refer to is mainly with for based on pressure vessel or typical welding structure, such as ASME boiler
Pressure vessel code Section III twisting cohesion records R6 [the R6 Assessment of the integrity of I volumes of appendix A of G and X, Britain
Of structures containing defects, Procedure R6-Revision], the API579 in the U.S.
Recommended practice for fitness-for-service.Washington,D.C.American
Petroleum Institution, 2000, the CVDA-1984 Defect Assessment of Pressure Vessels specification of China, Britain BS 7910:
1999:(incorporating Amendment No.1)Guide on methods for assessing the
acceptability of flaws in metallic structures.British Standards Institution,
London, the methods of 2000..These methods give the method for some defect estimations mainly for specific structure or technique,
Generally it is difficult in the assessment for directly applying to other service conditions or structure, its requirement for checking and accepting classification can not be provided, removes this
Except, for newly-designed structure or components, what designer was more concerned about is inspection of quality requirement, and these methods provide more
Defects assessment figure or Assessment Curves etc. are similar conclusive as a result, there is no pass through a large amount of verification experimental verification, side for new construction
The applicability of method is unknown.Through document and patent retrieval, at present both at home and abroad not yet for the examination point of component of machine defect
The universal method of grade.
Summary of the invention
In view of the deficiencies of the prior art, the present invention provides the component of machine defect under the general Fatigue Load of one kind
Stage division is checked and accepted, firstly, carrying out non-destructive testing data analysis to component of machine, determines defect type and maximum boundary ruler
It is very little, and regularization processing and damage phenetic analysis, the number influenced by defect on component of machine fatigue life are carried out to defect
It is worth sunykatuib analysis and carries out fatigue life prediction, obtains the relational expression of fatigue life and flaw size, and carry out verification test, most
Eventually, defect is carried out according to the life requirements of component of machine and checks and accepts classification, instruct its inspection of quality.
The present invention is implemented as follows:
A kind of lower component of machine defect examination stage division of fatigue load effect comprising following steps:
S1, the defect type for determining component of machine and maximum boundary size:
Component of machine is carried out non-destructive testing, Non-destructive Testing Data is analyzed, determines its existing defect type
With maximum boundary size；
S2, mischief ruleization processing are characterized with damage:
Classify according to the geometrical characteristic of defect, the defect with planar disfigurement feature be characterized as crackle by rule,
Characterization crack size is L, the defect with volume defect feature is characterized as spherical or elliposoidal defect by rule, characterization is spherical
Or elliposoidal is having a size of D；
S3, the component of machine fatigue life prediction containing defect:
S31, the finite element model for establishing component of machine simultaneously carry out finite element analysis computation, analyze mechanical under service load
The stress and deformation behaviour of components；
S32, be characterized as crackle planar disfigurement crack propagation life expression formula are as follows:
Wherein: a is half crack length, and N is stress-number of cycles, i.e. fatigue life, and C and m are material constant, and Δ K is to answer
Power intensity factor amplitude, Δ K=Kmax-Kmin；KmaxFor the stress intensity factor of alternating load maximum value calculation, KminFor alternating download
The stress intensity factor that lotus minimum value calculates；
S33, using step S31 component of machine stress characteristics and material fracture toughness KIC, determine component of machine
Allow existing maximum crack size aL, relational expression are as follows:
Wherein: aLTo allow existing maximum crack size, KICFor material fracture toughness, f is that crack size and component are several
What function, σ are stress；
S34, the characterization size L based on planar disfigurement, calculate it using step S32 and extend to maximum allowable crack size aL
The Life Cycle number N neededL, that is, the service life is extended,
S35, for volume defect, the S-N curve of bond material calculates fatigue life, and the fitting of the S-N curve of material is closed
It is formula are as follows:
Sm′N=C '
In formula, S is stress, and N is Life Cycle number, and m ' and C ' are material constant；
S36, the characterization dimension D based on volume defect establish the component of machine finite element analysis mould comprising volume defect
Type calculates stress distribution and deformation around defect, calculates different defect rulers using the S-N curve matching relational expression of step S35
Very little fatigue life cycles times ND, i.e. fatigue life；
S4, mechanical component lifetime and planar disfigurement size L, volume defect are established respectively using the prediction result of step S3
Functional relation between dimension D:
NL=f (L), ND=g (D)
The verification test of S5, mechanical component lifetime containing defect:
Carry out the mechanical component lifetime containing defect verification test, specific test method using the first test method,
Second of test method or the first test method and second of two kinds of test method of combination:
The first test method are as follows: according to the stress characteristics of component of machine key position, design simulation testpieces, simulation
The geometry and stress characteristics at the position, carry out the verification test of simulation test piece, are respectively L for size containing planar disfigurement1,
L2,…LnThe n simulation test piece of (n >=1) obtains its fatigue life cycles number for extending to maximum allowable crack size point
It is notFor containing volume defect having a size of D1,D2,…DmThe m simulation test piece of (m >=1), is obtained
Obtaining its fatigue life cycles number is
Second of test method are as follows: directly carry out the mechanical component lifetime containing defect with component of machine to be checked and accepted and try
It tests, for containing planar disfigurement having a size of L1,L2,…LnThe n simulation test piece of (n >=1) obtains it and extends to maximum allowable split
The fatigue life cycles number of line size is respectivelyFor containing volume defect having a size of D1,D2,…
DmThe m simulation test piece of (m >=1), obtaining its fatigue life cycles number is
S6, formula N is utilizedL=f (L) Calculation Plane flaw size is respectively L1,L2,…LnThe n simulation test piece of (n >=1)
The fatigue life cycles times N for extending to maximum allowable crack sizeLi=f (Li), utilize formula ND=g (D), which is calculated, contains volume
Flaw size is D1,D2,…DmThe fatigue life cycles times N of the m simulation test piece of (m >=1)Di=g (Di), utilize step
The test result of S5 calculates dispersion degree EL、ED:
S7, defect check and accept classification:
If dispersion degree EL、EDMeet respectively: EL≤ P, ED≤ Q, wherein P, Q are respectively planar disfigurement dispersion degree threshold value and body
Product defect dispersion degree threshold value, then be divided into M grades for defect according to the life requirements of component of machine:
The first order: mechanical component lifetime N1, utilize formula NL=f (L) and ND=g (D) calculates the flaw size allowed
L1、D1, planar disfigurement is 0~L1And volume defect is 0~D1Component of machine be divided into the first order；The second level: zero mechanical
The part service life is N2, utilize formula NL=f (L) and NDIt is L that=g (D), which calculates the flaw size allowed,2、D2, planar disfigurement is 0~L2And
Volume defect is 0~D2Component of machine be divided into the second level；And so on, M grades, mechanical component lifetime NM, utilize
Formula NL=f (L) and NDIt is L that=g (D), which calculates the flaw size allowed,M、DM, planar disfigurement is 0~LMAnd volume defect is 0~DM
Component of machine be divided into M grades；Wherein, L1> L2> L3。
Preferably, the method for the non-destructive testing is one of ray, ultrasound, vortex, magnetic powder and infiltration or a variety of.
Preferably, in step S2 by with the defect of planar disfigurement feature carry out regularization when foundation principle include etc.
Stress intensity factor.
Preferably, in step S2, the specific of regularization processing is carried out according to planar disfigurement and with volume defect two types
Method are as follows:
Planar disfigurement: the defect by planar disfigurement rule process includes crackle, incomplete fusion and incomplete penetration defect etc., and plane lacks
It falls into and is equivalent to crackle and is characterized, equivalent crack characterizes size L by height of defect boundary rectangle and long determination；
For burying type defect, if actual measurement maximum length of the defect along surface is l, the actual measurement maximum itself of through-thickness
Height is h, and the shortest distance of defect to outer surface is respectively p1 and p2, and p1≤p2, then makees at regularization in the following way
Reason:
A) as p1≤p2 < 0.4h, rule turns to the penetrated crack of 2a=l+2h；
B) as p1 < 0.4h≤p2, rule turns to the surface half-ellipse crack of a=h+p1,2c=l；
C) as 0.4h≤p1≤p2: as h < l, the ellipse that rule turns to 2c=l, 2a=h buries crackle；As h >=l
When, the ellipse that rule turns to 2c=l, 2a=h buries crackle；
Volume defect: include stomata, slag inclusion and pit by the defect that volume defect regularization is handled, volume type is lacked
It falls into, is characterized as spherical or elliposoidal defect.
Preferably, in step S4, functional relation is established by exponential function or Polynomial curve-fit.
Preferably, the simulation test piece of the first test method of step S5 is by manufacturing artificial defect or directly from containing
It is cut on the component of machine of defect.
Preferably, if dispersion degree E > P or ED> Q, the then Life Prediction Model in amendment step S3 and step S4 again
Functional relation, until EL≤ P and ED≤Q。
Compared with prior art, the invention has the following advantages:
Component of machine defect under fatigue load effect of the invention checks and accepts stage division and is common to component of machine, energy
Science effectively carries out the universal method that defect checks and accepts classification and a kind of product quality is checked and accepted to component of machine, and guidance produces
Product design；Meanwhile the present invention can control providing method and tool, existing defect for the non-destructive testing of engineering goods, quality
Acceptance criteria and stage division general range are wider, above lack applicability verifying in the application of specific object, the present invention is also one
Kind is directed to the non-destructive testing inspection of quality evaluation method of component of machine, can instruct for nondestructive testing personnel providing method, and
And reception time is saved, and it is time saving and energy saving, improve acceptance quality, the quality and safety of Support Equipment.
Detailed description of the invention
Fig. 1 is the flow chart of the component of machine defect examination stage division under fatigue load of the invention；
Fig. 2 is to bury type flaw size schematic diagram according to planar disfigurement progress regularization processing；
Fig. 3 is blemish surface, sub-surface and interior location schematic diagram；
Fig. 4 is aluminium alloy cylindrical body mischief rule schematic diagram；
Fig. 5 is aluminium alloy cylindrical body stress calculating results；
Fig. 6 is the finite element model of defect containing porous；
Fig. 7 is the stress distribution of typical stomata part；
Fig. 8 is weld seam S-N curve；
Fig. 9 is simulation test piece size when carrying out the verification test of the mechanical component lifetime containing defect.
Specific embodiment
Below with reference to the attached drawing exemplary embodiment that the present invention will be described in detail, feature and aspect of performance.It is identical in attached drawing
Appended drawing reference indicate element functionally identical or similar.Although the various aspects of embodiment are shown in the attached drawings, remove
It non-specifically points out, it is not necessary to attached drawing drawn to scale.
As shown in Figure 1, the component of machine defect under a kind of fatigue load effect checks and accepts stage division comprising following step
It is rapid:
S1, the defect type for determining component of machine and maximum boundary size:
Component of machine is carried out non-destructive testing, lossless detection method is selected according to the characteristics of component of machine, is
One of ray, ultrasound, vortex, magnetic powder and infiltration are a variety of, analyze Non-destructive Testing Data, determine that it is existing scarce
Fall into type and maximum boundary size；
S2, mischief ruleization processing are characterized with damage:
Classify according to the geometrical characteristic of defect, the defect with planar disfigurement feature be characterized as crackle by rule,
Characterization crack size is L, the defect with volume defect feature is characterized as spherical or elliposoidal defect by rule, characterization is spherical
Or elliposoidal is having a size of D；
Regularization processing is carried out according to planar disfigurement and with volume defect two types method particularly includes:
Planar disfigurement: the defect by planar disfigurement rule process includes crackle, incomplete fusion and incomplete penetration defect etc., and plane lacks
Fall into and be equivalent to crackle and characterized, equivalent crack characterize size according to specific defect situation by height of defect boundary rectangle and it is long really
It is fixed.
For burying type defect, as shown in Fig. 2, if actual measurement maximum length of the defect along surface is l, the reality of through-thickness
Surveying maximum oneself height is h, and the shortest distance of defect to outer surface is respectively p1 and p2, and p1≤p2, then in the following way
Make regularization processing:
A) as p1≤p2 < 0.4h, rule turns to the penetrated crack of 2a=l+2h；
B) as p1 < 0.4h≤p2, rule turns to the surface half-ellipse crack of a=h+p1,2c=l；
C) as 0.4h≤p1≤p2: as h < l, the ellipse that rule turns to 2c=l, 2a=h buries crackle；As h >=l
When, the ellipse that rule turns to 2c=l, 2a=h buries crackle；
Volume defect: include stomata, slag inclusion and pit by the defect that volume defect regularization is handled, volume type is lacked
It falls into, is characterized as spherical or elliposoidal defect；As shown in figure 3, defect 2 and defect 3 are positioned at surface location, that is, as -1 ﹤ d/r
Defect corresponding position when ﹤ 1, defect 1 and defect 4 illustrate the extreme position of surface district defect；Defect 5 is located at sub-surface position
It sets, i.e. defect corresponding position when 1≤d/r≤2, defect 4 and defect 6 then represent the extreme position in sub-surface region；Defect 7
It is internal flaw, the position of defect when corresponding to d/r ﹥ 2 with defect 8；
For different defects, different regularization processing methods may be selected.
S3, the component of machine fatigue life prediction containing defect:
S31, the finite element model for establishing component of machine simultaneously carry out finite element analysis computation, analyze mechanical under service load
The stress and deformation behaviour of components；
S32, be characterized as crackle planar disfigurement crack propagation life expression formula are as follows:
Wherein: a is half crack length, and N is stress-number of cycles, i.e. fatigue life, and C and m are material constant, and Δ K is to answer
Power intensity factor amplitude, Δ K=Kmax-Kmin；KmaxFor the stress intensity factor of alternating load maximum value calculation, KminFor alternating download
The stress intensity factor that lotus minimum value calculates；
S33, using step S31 component of machine stress characteristics and material fracture toughness KIC, determine component of machine
Allow existing maximum crack size aL, relational expression are as follows:
Wherein: aLTo allow existing maximum crack size, KICFor material fracture toughness, f is that crack size and component are several
What function, σ are stress；
S34, the characterization size L based on planar disfigurement, calculate it using step S32 and extend to maximum allowable crack size aL
The Life Cycle number N neededL, that is, the service life is extended, expression formula is
Planar disfigurement size should cover the flaw size boundary of component of machine.
S35, for volume defect, the S-N curve of bond material calculates fatigue life, and the fitting of the S-N curve of material is closed
It is formula are as follows:
Sm′N=C '
In formula, S is stress, and N is Life Cycle number, and m ' and C ' are material constant；
S36, the characterization dimension D based on volume defect establish the component of machine finite element analysis mould comprising volume defect
Type calculates stress distribution and deformation around defect, calculates different defect rulers using the S-N curve matching relational expression of step S35
Very little fatigue life cycles times ND；Volume defect size should cover the flaw size boundary of component of machine.
S4, mechanical component lifetime and planar disfigurement size L, volume defect are established respectively using the prediction result of step S3
Functional relation between dimension D:
NL=f (L), ND=g (D)
The verification test of S5, mechanical component lifetime containing defect:
Carry out the mechanical component lifetime containing defect verification test, specific test method using the first test method,
Second of test method or the first test method and second of two kinds of test method of combination:
The first test method are as follows: according to the stress characteristics of component of machine key position, design simulation testpieces, simulation
The geometry and stress characteristics at the position, carry out the verification test of simulation test piece, are respectively L for size containing planar disfigurement1,
L2,…LnThe n simulation test piece of (n >=1) obtains its fatigue life cycles number for extending to maximum allowable crack size point
It is notFor containing volume defect having a size of D1,D2,…DmThe m simulation test piece of (m >=1), is obtained
Obtaining its fatigue life cycles number is
Second of test method are as follows: directly carry out the mechanical component lifetime containing defect with component of machine to be checked and accepted and try
It tests, for containing planar disfigurement having a size of L1,L2,…LnThe n simulation test piece of (n >=1) obtains it and extends to maximum allowable split
The fatigue life cycles number of line size is respectivelyFor containing volume defect having a size of D1,D2,…
DmThe m simulation test piece of (m >=1), obtaining its fatigue life cycles number is
S6, formula N is utilizedL=f (L) Calculation Plane flaw size is respectively L1,L2,…LnThe n simulation test piece of (n >=1)
Extension service life NLi=f (Li), utilize formula ND=g (D) is calculated containing volume defect having a size of D1,D2,…DmThe m mould of (m >=1)
The fatigue life N of quasi- testpiecesDi=g (Di), using the test result of step S5, calculate dispersion degree EL、ED:
S7, defect check and accept classification:
If dispersion degree EL、EDMeet respectively: EL≤ P, ED≤ Q, wherein P, Q are respectively planar disfigurement dispersion degree threshold value and body
Product defect dispersion degree threshold value, then be divided into M grades for defect according to the life requirements of component of machine:
The first order: mechanical component lifetime N1, utilize formula NL=f (L) and ND=g (D) calculates the flaw size allowed
L1、D1, planar disfigurement is 0~L1And volume defect is 0~D1Component of machine be divided into the first order；The second level: zero mechanical
The part service life is N2, utilize formula NL=f (L) and NDIt is L that=g (D), which calculates the flaw size allowed,2、D2, planar disfigurement is 0~L2And
Volume defect is 0~D2Component of machine be divided into the second level；And so on, M grades, mechanical component lifetime NM, utilize
Formula NL=f (L) and NDIt is L that=g (D), which calculates the flaw size allowed,M、DM, planar disfigurement is 0~LMAnd volume defect is 0~DM
Component of machine be divided into M grades；Wherein, L1> L2> L3。
If dispersion degree E > P or ED> Q, then the function of the Life Prediction Model in amendment step S3 and step S4 close again
It is formula, until EL≤ P and ED≤Q。
Preferably, the method for non-destructive testing is one of ray, ultrasound, vortex, magnetic powder and infiltration or a variety of.
Preferably, in step S2 by with the defect of planar disfigurement feature carry out regularization when foundation principle include etc.
Stress intensity factor.
Preferably, in step S4, functional relation is established by exponential function or Polynomial curve-fit.Below with one
It is illustrated for the examination classification of aluminium alloy cylindrical body:
Certain aluminium alloy cylindrical body is made of inner cylinder and exterior skin, is wherein added between inner cylinder and exterior skin by welding procedure
Work forms, and carries out an acceptance inspection classification to its weld seam, and specific steps include:
S1, the defect type for determining component of machine and maximum boundary size:
Aluminium alloy cylindrical body weld seam is detected using ultrasonic phase array, testing result shows that defect mainly includes incomplete fusion
With two kinds of defects of stomata, wherein incomplete fusion defect length is less than 10mm, and gas hole defect diameter is no more than 2.8mm.
S2, mischief ruleization processing are characterized with damage:
When defect is analyzed by planar disfigurement, as shown in figure 4, groove width W1=18mm, root of notch width is W2, slope
Mouthful angle is 70 °, flaw height h, and defect top is P2 away from barrel outer surface distance, defect distance from bottom cylinder inner surface away from
From for P1, defect center position is D away from barrel outer surface distance.Cylinder wall thickness is B, and circumferentially length is l to defect.
For incomplete fusion defect, as p1≤p2 < 0.4h, rule turns to the penetrated crack of 2a=l+2h.
For gas hole defect, characterized according to its practical detecting size with spherical porosity.
S3, the component of machine fatigue life prediction containing defect:
S31, aluminium alloy cylindrical body stress finite element analysis: aluminium alloy cylindrical body is by portions such as inner cylinder, exterior skin, clump weight and hoops
Part composition, wherein inner cylinder is main bearing carrier, and exterior skin is connect with inner cylinder by welding manner, and inner cylinder, exterior skin are respectively by 2
Duan Zucheng, totally 4 weld seams.Front and back respectively has 2 sections of counterweight cylinder, the gravity that simulation practical structures generate.Commissure stress calculating results
As shown in Figure 5；
S32, the incomplete fusion defect for being characterized as crackle expand using the crackle that Method of Fracture Mechanics carries out component of machine
Service life calculating is opened up, for the stress intensity factor calculation formula of the plate shell (the wide 2W of plate, the long 2L of plate) of the penetrated crack containing 2a are as follows:
Based on the above calculation formula, stress intensity factor variation range delta K.
Then using formula (1) counting crack length with the variation of Life Cycle number, wherein C=5.13 × 10-9, m=3.91.
S33, stress characteristics and material fracture toughness K using component of machineIC, utilize formulaIt determines mechanical
Components allow existing maximum crack size aL=112mm.
S34, the characterization crack size L based on planar disfigurement, utilize formulaCalculate separately difference
Life Cycle times N needed for defect characterization crack size extends to maximum allowable crack sizeL, i.e. crack propagation life is shown in Table
1。
The extension service life of the different flaw sizes of table 1
S35, for volume defect, the S-N curve of bond material calculates fatigue life, and the fitting of the S-N curve of material is closed
It is formula are as follows:
Sm′N=C '
In formula, S is stress, and N is Life Cycle number, and m ' and C ' are material constant；
The S-N curve of material is as shown in figure 8, fitting obtains C '=2.03 × 1010, m '=2.32.
S36, the characterization dimension D based on volume defect establish the component of machine finite element analysis mould comprising volume defect
Type is calculated stress distribution and deformation around defect, the tired longevity of different flaw sizes is calculated using S-N curve matching relational expression
Order recurring number ND, typical volume flaw size should cover the flaw size boundary of component of machine.
For porous defect, with reference to detection defective data, calculate separately flaw size be 1.0mm, 1.5mm, 2.0mm,
The ball-type stomata of 2.5mm, 2.8mm take 1/8 cylinder welded seam area to establish finite element model, such as to simplify FEM calculation scale
Shown in Fig. 6.Material parameter selects base material parameter when calculating, and the plane of symmetry applies symmetrical boundary condition, the tensile stress that cylinder is born
Local defect for 160MPa, computation model is as shown in Figure 6.
The stress around stomata, maximum stress 266MPa, 282MPa, 348MPa, 362MPa and 377MPa is calculated.
The stress distribution of typical stomata part is as shown in Figure 7.Using the S-N curve of material, calculating separately remanent fatigue life is
48058、41967、25765、23213、21398。
S4, mechanical component lifetime and planar disfigurement size L, volume defect are established respectively using the prediction result of step S3
Functional relation between dimension D:
NL=f (L)=39140L-0.989
ND=g (D)=- 15900D+63246
The verification test of S5, mechanical component lifetime containing defect:
According to the stress characteristics of component of machine key position, design simulation testpieces is simulated the geometry at the position and is answered
Power feature carries out the verification test of the simulation test piece containing different flaw sizes, and testpieces is directly cut from aluminium alloy cylindrical body,
Test result is given in Table 2.The size of simulation test piece is as shown in Figure 9.
2 verification test result of table
S6, formula N is utilizedL=f (L)=39140L-0.989The extension service life N of planar disfigurement in computational chart 2Li, utilize formula ND=
Fatigue life N containing volume flaw in g (D)=- 15900D+63246 computational chart 2Di, calculate dispersion degree EL、ED:
S7, defect check and accept classification:
Dispersion degree is required to be not more than 1 planar disfigurement contained by aluminium alloy cylindrical body and volume defect.EL=0.21 and ED=
0.12 is all satisfied the requirement.It is required defect being divided into 3 grades according to the Life Design of aluminium alloy cylindrical body:
The first order, the service life of aluminium alloy cylindrical body are 10000, utilize formula NL=f (L)=39140L-0.989It is calculated first
The planar disfigurement size of grade is not more than 3.9mm, utilizes formula NDThe volume of the first order is calculated in=g (D)=- 15900D+63246
Flaw size is not more than 3.3mm.
The second level, the service life of aluminium alloy cylindrical body are 20000, utilize formula NL=f (L)=39140L-0.989It is calculated second
The planar disfigurement size of grade is not more than 2.0mm, utilizes formula NDThe volume of the second level is calculated in=g (D)=- 15900D+63246
Flaw size is not more than 2.7mm.
The third level, the service life of aluminium alloy cylindrical body are 50000, utilize formula NL=f (L)=39140L-0.989Third is calculated
The planar disfigurement size of grade is not more than 0.8mm, utilizes formula NDThe volume of the third level is calculated in=g (D)=- 15900D+63246
Flaw size is not more than 0.9mm.
Using above-mentioned examination stage division, the defect of aluminium alloy cylindrical body can be carried out an acceptance inspection according to ratings above, plane
Aluminium alloy cylindrical body of the flaw size no more than 3.9mm and volume defect size no more than 3.3mm is divided into the first order, planar disfigurement
Aluminium alloy cylindrical body of the size no more than 2.0mm and volume defect size no more than 2.7mm is divided into the second level, planar disfigurement size
Aluminium alloy cylindrical body no more than 0.8mm and volume defect size no more than 0.9mm is divided into the third level.
Finally, it should be noted that above-described each embodiment is merely to illustrate technical solution of the present invention, rather than it is limited
System；Although the present invention is described in detail referring to the foregoing embodiments, those skilled in the art should understand that: its
It can still modify to technical solution documented by previous embodiment, or part of or all technical features are carried out
Equivalent replacement；And these modifications or substitutions, technical solution of various embodiments of the present invention that it does not separate the essence of the corresponding technical solution
Range.
Claims (7)
1. the component of machine defect under a kind of fatigue load effect checks and accepts stage division, it is characterised in that: it includes following step
It is rapid:
S1, the defect type for determining component of machine and maximum boundary size:
Component of machine is carried out non-destructive testing, Non-destructive Testing Data is analyzed, determines its existing defect type and most
Big boundary dimensions；
S2, mischief ruleization processing are characterized with damage:
Classify according to the geometrical characteristic of defect, the defect with planar disfigurement feature is characterized as crackle by rule, characterizes
Crack size is L, the defect with volume defect feature is characterized as spherical or elliposoidal defect by rule, characterization is spherical or ellipse
Sphere sizes are D；
S3, the component of machine fatigue life prediction containing defect:
S31, the finite element model for establishing component of machine simultaneously carry out finite element analysis computation, analyze zero mechanical under service load
The stress and deformation behaviour of part；
S32, be characterized as crackle planar disfigurement crack propagation life expression formula are as follows:
Wherein: a is half crack length, and N is stress-number of cycles, and C and m are material constant, and Δ K is stress intensive factor range value,
Δ K=Kmax-Kmin；KmaxFor the stress intensity factor of alternating load maximum value calculation, KminIt is calculated for alternating load minimum value
Stress intensity factor；
S33, using step S31 component of machine stress characteristics and material fracture toughness KIC, determine that component of machine allows
Existing maximum crack size aL, relational expression are as follows:
Wherein: aLTo allow existing maximum crack size, KICFor material fracture toughness, f is crack size and component geometry
Function, σ are stress；
S34, the characterization size L based on planar disfigurement, calculate it using step S32 and extend to maximum allowable crack size aLIt needs
Life Cycle times NL,
S35, for volume defect, the S-N curve of bond material calculates fatigue life, the fit correlation formula of the S-N curve of material
Are as follows:
Sm′N=C '
In formula, S is stress, and N is Life Cycle number, and m ' and C ' are material constant；
S36, the characterization dimension D based on volume defect establish the component of machine finite element analysis model comprising volume defect, meter
The stress distribution and deformation around defect are calculated, calculates the tired of different flaw sizes using the S-N curve matching relational expression of step S35
Labor Life Cycle times ND；
S4, mechanical component lifetime and planar disfigurement size L, volume defect size are established respectively using the prediction result of step S3
Functional relation between D:
NL=f (L), ND=g (D)
The verification test of S5, mechanical component lifetime containing defect:
Carry out the verification test of the mechanical component lifetime containing defect, specific test method uses the first test method, second
Kind of test method or the first test method and second of two kinds of test method of combination:
The first test method are as follows: according to the stress characteristics of component of machine key position, design simulation testpieces simulates the portion
The geometry and stress characteristics of position, carry out the verification test of simulation test piece, are respectively L for size containing planar disfigurement1,L2,…Ln
The n simulation test piece of (n >=1), obtaining its fatigue life cycles number for extending to maximum allowable crack size is respectivelyFor containing volume defect having a size of D1,D2,…DmThe m simulation test piece of (m >=1), obtains it
Fatigue life cycles number is
Second of test method are as follows: directly carry out the mechanical component lifetime containing defect with the component of machine of contracture grade to be tested and try
It tests, for containing planar disfigurement having a size of L1,L2,…LnThe n simulation test piece of (n >=1) obtains it and extends to maximum allowable split
The fatigue life cycles number of line size is respectivelyFor containing volume defect having a size of D1,D2,…
DmThe m simulation test piece of (m >=1), obtaining its fatigue life cycles number is
S6, formula N is utilizedL=f (L) Calculation Plane flaw size is respectively L1,L2,…LnThe expansion of the n simulation test piece of (n >=1)
It opens up to the fatigue life cycles times N of maximum allowable crack sizeLi=f (Li), utilize formula ND=g (D), which is calculated, contains volume defect
Having a size of D1,D2,…DmIts fatigue life cycles times N of the m simulation test piece of (m >=1)Di=g (Di), utilize step S5
Test result, calculate dispersion degree EL、ED:
S7, defect check and accept classification:
If dispersion degree EL、EDMeet respectively: EL≤ P, ED≤ Q, wherein P, Q are respectively planar disfigurement dispersion degree threshold value and volume defect
Defect is then divided into M grades according to the life requirements of component of machine by dispersion degree threshold value:
The first order: mechanical component lifetime N1, utilize formula NL=f (L) and NDIt is L that=g (D), which calculates the flaw size allowed,1、
D1, planar disfigurement is 0~L1And volume defect is 0~D1Component of machine be divided into the first order；The second level: component of machine
Service life is N2, utilize formula NL=f (L) and NDIt is L that=g (D), which calculates the flaw size allowed,2、D2, planar disfigurement is 0~L2And body
Product defect is 0~D2Component of machine be divided into the second level；And so on, M grades, mechanical component lifetime NM, utilize formula
NL=f (L) and NDIt is L that=g (D), which calculates the flaw size allowed,M、DM, planar disfigurement is 0~LMAnd volume defect is 0~DM's
Component of machine is divided into M grades；Wherein, L1> L2> L3。
2. the component of machine defect under fatigue load effect according to claim 1 checks and accepts stage division, feature exists
In: the method for the non-destructive testing be one of ray, ultrasound, vortex, magnetic powder and infiltration or a variety of.
3. the component of machine defect under fatigue load effect according to claim 1 checks and accepts stage division, feature exists
In: the principle of foundation includes iso-stress intensity factor when in step S2 by with the progress regularization of the defect of planar disfigurement feature.
4. the component of machine defect under fatigue load effect according to claim 1 checks and accepts stage division, feature exists
In: in step S2, regularization processing is carried out according to planar disfigurement and with volume defect two types method particularly includes:
Planar disfigurement: the defect by planar disfigurement rule process includes crackle, incomplete fusion and incomplete penetration defect, and planar disfigurement is equivalent
It is characterized for crackle, equivalent crack characterizes size L by the height of defect boundary rectangle and long determination；
For burying type defect, if actual measurement maximum length of the defect along surface is l, the actual measurement maximum oneself height of through-thickness
For h, the shortest distance of defect to outer surface is respectively p1 and p2, and p1≤p2, then makees regularization processing in the following way:
A) as p1≤p2 < 0.4h, rule turns to the penetrated crack of 2a=l+2h；
B) as p1 < 0.4h≤p2, rule turns to the surface half-ellipse crack of a=h+p1,2c=l；
C) as 0.4h≤p1≤p2: as h < l, the ellipse that rule turns to 2c=l, 2a=h buries crackle；As h >=l,
The ellipse that rule turns to 2c=l, 2a=h buries crackle；
Volume defect: including stomata, slag inclusion and pit by the defect that volume defect regularization is handled, for volume flaw, table
Sign is spherical or elliposoidal defect.
5. the component of machine defect under fatigue load effect according to claim 1 checks and accepts stage division, feature exists
In: in step S4, functional relation is established by exponential function or Polynomial curve-fit.
6. the component of machine defect under fatigue load effect according to claim 1 checks and accepts stage division, feature exists
In: the simulation test piece of the first test method of step S5 is by manufacturing artificial defect or directly from the machinery zero containing defect
It is cut on component.
7. the component of machine defect under fatigue load effect according to claim 1 checks and accepts stage division, feature exists
In: if dispersion degree E > P or ED> Q, then the functional relation of the Life Prediction Model in amendment step S3 and step S4 again,
Until EL≤ P and ED≤Q。
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