CN113343526B - Fatigue limit load prediction method for quenched steel crankshaft - Google Patents
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Abstract
The invention discloses a fatigue limit load prediction method of a quenched steel crankshaft, which comprises the steps of establishing a three-dimensional finite element model of a crankshaft-coil, carrying out magneto-thermal coupling numerical simulation on an induction heating process of the three-dimensional finite element model of the crankshaft-coil, carrying out thermo-mechanical coupling numerical simulation on a cooling process to obtain a residual stress strain state of the crankshaft after cooling, and the like. Based on the combination of the structure and material characteristics of the crankshaft, the bending fatigue strength of the quenched crankshaft is predicted by combining the KBM multiaxial fatigue model. The fatigue limit load of the crankshaft can be predicted more accurately, the prediction error is reduced, and the method has wider practical engineering application value.
Description
Technical Field
The invention relates to the technical field of prediction of fatigue limit load of crankshafts, in particular to a method for predicting the fatigue limit load of a quenched steel crankshaft.
Background
The prior researches show that for metal engine parts such as crankshafts, more than 85% of reliability problems are caused by fatigue failure. The main reason for this phenomenon is that the parts are subjected to continuous action of non-proportional alternating loads from different excitation sources during the running process of the automobile, so that the parts are subjected to fatigue damage, and finally the engine and even the whole automobile are damaged.
In response to this problem, researchers at home and abroad have made a great deal of research in recent years. It has been proposed to predict the fatigue limit load of the crankshaft by a crack simulation method and perform optimization study on model parameters; someone intercepts materials from a crankshaft to prepare a standard test piece, and a comparison research result shows that the numerical value of the S-N curve of the crankshaft obtained by the method is lower than the result obtained based on fatigue analysis software; the angle and fatigue strength of crack initiation of the crankshaft under the action of multiaxial load are analyzed by someone, and a corresponding analysis model is provided; some people analyze a failed crankshaft and carry out different test and inspection, and the inspection result shows that the too high quenching temperature can form hidden micro cracks on the surface of the crankshaft and lead the hidden micro cracks to finally fail.
In the domestic aspect, some students simulate residual stress fields caused by different rolling strengthening processes at the fillet parts of the crankshaft through a finite element method, and analyze the influence of the stress fields on the fatigue strength of the crankshaft; some scholars use a mode superposition method and a multi-layer feedback BP neural network to optimally design a certain style of crankshaft, and comparison results show that the method can effectively carry out structure lightweight design and strength optimization on the crankshaft; some scholars consider the influence of residual stress on the fatigue life of the crankshaft, and research results show that compared with the traditional SLB model, the modified fatigue model has higher accuracy; some students adopt a two-dimensional simplified model to carry out numerical simulation on the induction hardening surface strengthening treatment process of the crankshaft, and carry out prediction research on corresponding fatigue limit loads.
In actual engineering at present, an electromagnetic induction quenching process is often adopted for a steel diesel engine crankshaft to increase the fatigue strength of the steel diesel engine crankshaft. The process reduces the average stress of the component when subjected to alternating loads by subjecting the crankshaft to a heating-cooling stage to form compressive residual stresses on its surface to increase its load carrying capacity. In the early stage research, some researchers carry out numerical simulation and simulation research on the process based on a two-dimensional simplified model, and obtain the distribution characteristics of a temperature field and a residual stress field in the processing process. However, for a three-dimensional entity such as a crankshaft, the stress state of the three-dimensional entity heated by induction quenching tends to show certain multiaxial characteristics, and a traditional model average stress model is adopted to cause larger error when predicting the fatigue limit load of the steel crankshaft, so that the error of a prediction result exceeds 10%, and the error cannot meet the precision requirement in practical engineering.
Disclosure of Invention
This section is intended to outline some aspects of embodiments of the invention and to briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this section as well as in the description summary and in the title of the application, to avoid obscuring the purpose of this section, the description summary and the title of the invention, which should not be used to limit the scope of the invention.
The present invention has been developed in view of the above-mentioned and/or problems associated with the fatigue limit loading of prior steel crankshafts.
Therefore, the invention aims to provide the fatigue limit load prediction method for the quenched steel crankshaft, which can improve the prediction accuracy of the fatigue limit load of the steel crankshaft, reduce the prediction error and meet the precision requirement in actual engineering.
In order to solve the technical problems, according to one aspect of the present invention, the following technical solutions are provided:
a fatigue limit load prediction method for a quenched steel crankshaft comprises the following specific steps:
1) Based on the structure of the crankshaft, extracting a submodule of a crank pin part to establish a three-dimensional finite element model of the crankshaft-coil;
2) Performing magneto-thermal coupling numerical simulation on the induction heating process of the three-dimensional finite element model of the crankshaft-coil;
3) Performing thermal engine coupling numerical simulation on the cooling process of the three-dimensional finite element model of the crankshaft-coil after induction heating to obtain the residual stress strain state of the crankshaft after cooling;
4) Analyzing the residual stress strain state of the cooled crankshaft by adopting a coordinate transformation method to obtain the critical plane coordinates of the crankshaft and the shear strain gamma and the normal strain epsilon in the critical plane coordinates n And normal stress sigma n ；
5) A bending stress analysis model of the crankshaft is established, and the stress state of the bending stress analysis model of the crankshaft under the given bending moment load of 1000 N.m is analyzed to obtain the normal strain epsilon of the crankshaft under the bending moment load n ' and normal stress sigma n ′；
6) Predicted fatigue limit load of crankshaftHas a value of X and applies a shear strain gamma and a normal strain epsilon to the crankshaft in the critical plane coordinates n And normal stress sigma n And a normal strain ε under a given 1000 N.m bending moment load n ' and normal stress sigma n And solving the superposition calculation to obtain a specific value of the predicted fatigue limit load value X of the crankshaft.
As a preferable mode of the fatigue limit load predicting method for a quenched steel crankshaft according to the present invention, in the step 6), the shear strain γ and the normal strain ε of the crankshaft in the critical plane coordinates are n And normal stress sigma n And a normal strain ε under a given 1000 N.m bending moment load n ' and normal stress sigma n The expression for the' superposition calculation solution is:
wherein, gamma max Is the maximum value of shear strain in the critical plane, sigma f ' is the fatigue strength coefficient of the material, τ -1 The symmetrical shearing fatigue limit of the material selected for the steel crankshaft is G, and the shearing modulus of the material selected for the steel crankshaft is G.
As an optimized scheme of the fatigue limit load prediction method of the quenched steel crankshaft, in the step 3), the heat engine coupling numerical simulation is carried out on the cooling process of the model after induction heating, and the specific steps of obtaining the residual stress strain state of the crankshaft after cooling are as follows: taking temperature field data at the end time of rapid cooling of the crankshaft subjected to induction quenching heating by adopting cooling liquid as initial load of a cooling temperature field in calculated air, changing temperature boundary conditions, and calculating to obtain data results of an air cooling temperature field; and taking the temperature data of all moments of the air cooling temperature field as the process load for solving the residual stress field, and finally obtaining the residual stress strain state of the crankshaft after induction quenching.
As a preferable mode of the fatigue limit load predicting method for a quenched steel crankshaft according to the present invention, the material of the crankshaft is 42Crmo quenched and tempered steel.
As a preferable mode of the fatigue limit load predicting method for a quenched steel crankshaft according to the present invention, in the step 2), a dense grid is provided between the induction coil and the air gap of the crankshaft surface and the induction coil during the induction heating process of the three-dimensional finite element model of the crankshaft-coil.
In the step 2), the induction coil is fixed during the induction heating process of the three-dimensional finite element model of the crankshaft-coil, and the crankshaft rotates around the center of the main shaft at a constant speed.
Compared with the prior art, the invention has the following beneficial effects: the method is characterized in that a three-dimensional magneto-thermal coupling model is established by adopting a finite element method through an electromagnetic induction quenching strengthening process of the steel crankshaft, and numerical simulation analysis is carried out on an induction heating-cooling process of the steel crankshaft, so that a residual stress field of the crankshaft after treatment is obtained. Based on the combination of the structure and material characteristics of the crankshaft, the bending fatigue strength of the quenched crankshaft is predicted by combining the KBM multiaxial fatigue model. The fatigue limit load of the crankshaft can be predicted more accurately, the prediction error is reduced, and the method has wider practical engineering application value.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following detailed description of the embodiments of the present invention will be given with reference to the accompanying drawings, which are to be understood as merely some embodiments of the present invention, and from which other drawings can be obtained by those skilled in the art without inventive faculty. Wherein:
FIG. 1 is a diagram showing N of a fatigue limit load prediction method of a quenched steel crankshaft according to the present invention 0 And N 1 Residual stress strain state diagrams of the two crankshafts after cooling;
FIG. 2 is a diagram showing N of a fatigue limit load prediction method for a quenched steel crankshaft according to the present invention 0 And N 1 Two typesA bending stress analysis model schematic diagram of the crankshaft.
Detailed Description
In order that the above objects, features and advantages of the invention will be readily understood, a more particular description of the invention will be rendered by reference to the appended drawings.
Next, the present invention will be described in detail with reference to the drawings, wherein the sectional view of the device structure is not partially enlarged to general scale for the convenience of description, and the drawings are only examples, which should not limit the scope of the present invention. In addition, the three-dimensional dimensions of length, width and depth should be included in actual fabrication.
For the purpose of making the objects, technical solutions and advantages of the present invention more apparent, embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.
The invention provides a fatigue limit load prediction method for a quenched steel crankshaft, which can improve the prediction accuracy of the fatigue limit load of the steel crankshaft, reduce the prediction error and meet the precision requirement in actual engineering.
The following selects N 0 And N 1 The two crankshafts specifically describe the fatigue limit load prediction method of the quenched steel crankshaft.
The fatigue limit load prediction method for the quenched steel crankshaft comprises the following specific steps:
1) N based on a quenched and tempered steel of 42Crmo 0 And N 1 Structure of two crankshafts extracts N 0 And N 1 The submodules of the two crank pin parts establish a three-dimensional finite element model of the crankshaft-coil;
2) For N 0 And N 1 In the present embodiment, during the induction heating process of the three-dimensional finite element model of the crank-coil, dense grids are arranged between the air gaps of the induction coil and the surface of the crank and the induction coil, and during the induction heating process of the three-dimensional finite element model of the crank-coil, the induction coil is fixed, and the crank is wound around the main shaftThe center rotates at a constant speed.
3) To N after induction heating 0 And N 1 Performing thermal engine coupling numerical simulation in the cooling process of the three-dimensional finite element model of the two crankshafts and the coils to obtain N 0 And N 1 Residual stress strain state of two crankshafts after cooling, N is as follows 0 And N 1 The residual stress and strain states of the two crankshafts after cooling are shown in fig. 1, specifically, the heat engine coupling numerical simulation is performed on the cooling process of the model after induction heating, and the specific steps for obtaining the residual stress and strain states of the crankshafts after cooling are as follows: taking temperature field data at the end time of rapid cooling of the crankshaft subjected to induction quenching heating by adopting cooling liquid as initial load of a cooling temperature field in calculated air, changing temperature boundary conditions, and calculating to obtain data results of an air cooling temperature field; and taking the temperature data of all moments of the air cooling temperature field as the process load for solving the residual stress field, and finally obtaining the residual stress strain state of the crankshaft after induction quenching.
4) The obtained residual stress and strain state of the crankshaft after cooling is analyzed by adopting a coordinate transformation method to obtain N 0 Critical plane coordinates of crankshaft and shear strain gamma within critical plane coordinates 1 Normal strain epsilon n1 And normal stress sigma n1 And N 1 Critical plane coordinates of crankshaft and shear strain gamma within critical plane coordinates 2 Normal strain epsilon n2 And normal stress sigma n2 。
N 0 And N 1 The shear strain, normal strain and normal stress of the two crankshafts in the critical plane coordinates are shown in table 1:
TABLE 1
5) Build N 0 And N 1 The bending stress analysis model of the two crankshafts is shown in figure 2 and is applied to N 0 And N 1 The bending stress analysis model of the two crankshafts analyzes the stress state under the given bending moment load of 1000 N.m to obtain N 0 Normal strain epsilon of crankshaft under the action of bending moment load n1 ' and normal stress sigma n1 ' and N 1 Normal strain epsilon of crankshaft under the action of bending moment load n2 ' and normal stress sigma n2 ′。
N 0 And N 1 The shear strain, normal strain and normal stress for two types of strain under a given bending moment load of 1000 N.m are shown in Table 2.
TABLE 2
6) Let N be 0 The predicted fatigue limit load value of the crankshaft is X 1 And to N 0 Shear strain gamma of crankshaft in critical plane coordinates 1 Normal strain epsilon n1 And normal stress sigma n1 And a normal strain ε under a given 1000 N.m bending moment load n1 ' and normal stress sigma n1 ' superposition calculation solution to obtain predicted fatigue limit load value X of crankshaft 1 Specific numerical value of (1) is set N 1 The predicted fatigue limit load value of the crankshaft is X 1 And to N 1 Shear strain gamma of crankshaft in critical plane coordinates 2 Normal strain epsilon n2 And normal stress sigma n2 And a normal strain ε under a given 1000 N.m bending moment load n2 ' and normal stress sigma n2 ' superposition calculation solution to obtain predicted fatigue limit load value X of crankshaft 2 Specific values of (2).
Specifically, N 0 Shear strain gamma of crankshaft in critical plane coordinates 1 Normal strain epsilon n1 And normal stress sigma n1 And a normal strain ε under a given 1000 N.m bending moment load n1 ' and normal stress sigma n1 The expression for the' superposition calculation solution is:
wherein,is N 0 Maximum value of shear strain, sigma, of crankshaft in critical plane f1 ' is the fatigue strength coefficient of the material, +.>Is N 0 Symmetrical shearing fatigue limit of crankshaft material G 1 Is N 0 The crankshaft is made of material with shearing modulus.
Calculating to obtain X 1 =5270n·m. And N 0 Actual fatigue limit load value of crankshaft: the 5480 N.m error is within 5%.
Specifically, N 1 Shear strain gamma of crankshaft in critical plane coordinates 2 Normal strain epsilon n2 And normal stress sigma n2 And a normal strain ε under a given 1000 N.m bending moment load n2 ' and normal stress sigma n2 The expression for the' superposition calculation solution is:
wherein,is N 1 Maximum value of shear strain, sigma, of crankshaft in critical plane f2 ' is>Is N 1 Symmetrical shearing fatigue limit of crankshaft material G 2 Is N 1 The crankshaft is made of material with shearing modulus.
Calculating to obtain X 2 =4780n·m. And (3) withN 1 Actual fatigue limit load value of crankshaft: the error of 4980 N.m is within 5 percent.
Based on the specific method, the invention can be known that the three-dimensional magneto-thermal coupling model is built by adopting a finite element method through the electromagnetic induction quenching strengthening process of the steel crankshaft, and the numerical simulation analysis is carried out on the induction heating-cooling process of the steel crankshaft, so that the residual stress field of the crankshaft after the treatment is obtained. Based on the combination of the structure and material characteristics of the crankshaft, the bending fatigue strength of the quenched crankshaft is predicted by combining the KBM multiaxial fatigue model. The fatigue limit load of the crankshaft can be predicted more accurately, the prediction error is reduced, and the method has wider practical engineering application value.
Although the invention has been described hereinabove with reference to embodiments, various modifications thereof may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In particular, the features of the disclosed embodiments may be combined with each other in any manner as long as there is no structural conflict, and the exhaustive description of these combinations is not given in this specification merely for the sake of omitting the descriptions and saving resources. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims (4)
1. A fatigue limit load prediction method for a quenched steel crankshaft is characterized by comprising the following specific steps:
1) Based on the structure of the crankshaft, extracting a submodule of a crank pin part to establish a three-dimensional finite element model of the crankshaft-coil;
2) Performing magneto-thermal coupling numerical simulation on the induction heating process of the three-dimensional finite element model of the crankshaft-coil;
3) Performing thermal engine coupling numerical simulation on the cooling process of the three-dimensional finite element model of the crankshaft-coil after induction heating to obtain the residual stress strain state of the crankshaft after cooling;
4) The obtained crankshaft is cooled by adopting a coordinate transformation methodAnalyzing the residual stress and strain state to obtain critical plane coordinates of the crankshaft and shear strain gamma and normal strain epsilon in the critical plane coordinates n And normal stress sigma n ；
5) A bending stress analysis model of the crankshaft is established, and the stress state of the bending stress analysis model of the crankshaft under the given bending moment load of 1000 N.m is analyzed to obtain the normal strain epsilon 'of the crankshaft under the bending moment load' n And normal stress sigma' n ；
6) The predicted fatigue limit load value of the crankshaft is set as X, and the shear strain gamma and the normal strain epsilon of the crankshaft in the critical plane coordinate are set n And normal stress sigma n And a normal strain ε 'under a given bending moment load of 1000 N.m' n And normal stress sigma' n Superposition calculation solution is carried out, and a specific numerical value of a predicted fatigue limit load value X of the crankshaft is obtained;
wherein in the step 6), the shear strain gamma and the normal strain epsilon of the crankshaft in the critical plane coordinate are adopted n And normal stress sigma n And a normal strain ε 'under a given bending moment load of 1000 N.m' n And normal stress sigma' n The expression for the superposition calculation solution is:
wherein, gamma max Is the maximum value of shear strain in the critical plane, sigma' f For the fatigue strength coefficient of the material τ -1 The symmetrical shearing fatigue limit of the material selected for the steel crankshaft is G, and the shearing modulus of the material selected for the steel crankshaft is G;
in the step 3), the thermal engine coupling numerical simulation is performed on the cooling process of the model after induction heating, and the specific steps of obtaining the residual stress strain state of the crankshaft after cooling are as follows: taking temperature field data at the end time of rapid cooling of the crankshaft subjected to induction quenching heating by adopting cooling liquid as initial load of a cooling temperature field in calculated air, changing temperature boundary conditions, and calculating to obtain data results of an air cooling temperature field; and taking the temperature data of all moments of the air cooling temperature field as the process load for solving the residual stress field, and finally obtaining the residual stress strain state of the crankshaft after induction quenching.
2. The method for predicting the fatigue limit load of a quenched steel crankshaft according to claim 1, wherein the material of the crankshaft is 42Crmo quenched and tempered steel.
3. The method for predicting fatigue limit load of a quenched steel crankshaft according to claim 1, wherein in the step 2), a dense mesh is provided between the induction coil and the air gap of the crankshaft surface and the induction coil during induction heating of the three-dimensional finite element model of the crankshaft-coil.
4. The method for predicting the fatigue limit load of a quenched steel crankshaft according to claim 1, wherein in the step 2), the induction coil is fixed during the induction heating of the three-dimensional finite element model of the crankshaft-coil, and the crankshaft rotates at a constant speed around the center of the main shaft.
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| MX2012001976A (en) * | 2011-03-08 | 2012-09-07 | Gm Global Tech Operations Inc | Material property distribution determination for fatigue life calculation using dendrite arm spacing and porosity-based models. |
| CN104102778A (en) * | 2014-07-16 | 2014-10-15 | 上汽通用五菱汽车股份有限公司 | Crankshaft kinetic analysis method |
| CN110017981A (en) * | 2019-05-24 | 2019-07-16 | 南京林业大学 | Based on the crankshaft fatigue ultimate load prediction technique for improving non-proportional loading model |
| CN110059449A (en) * | 2019-05-24 | 2019-07-26 | 南京林业大学 | Based on the crankshaft fatigue ultimate load prediction technique for improving stress standard-field strength method |
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| MX2012001976A (en) * | 2011-03-08 | 2012-09-07 | Gm Global Tech Operations Inc | Material property distribution determination for fatigue life calculation using dendrite arm spacing and porosity-based models. |
| CN104102778A (en) * | 2014-07-16 | 2014-10-15 | 上汽通用五菱汽车股份有限公司 | Crankshaft kinetic analysis method |
| CN110017981A (en) * | 2019-05-24 | 2019-07-16 | 南京林业大学 | Based on the crankshaft fatigue ultimate load prediction technique for improving non-proportional loading model |
| CN110059449A (en) * | 2019-05-24 | 2019-07-26 | 南京林业大学 | Based on the crankshaft fatigue ultimate load prediction technique for improving stress standard-field strength method |
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