CN114065558B - Floating friction plate full-flow damage identification and service life prediction method and equipment - Google Patents
Floating friction plate full-flow damage identification and service life prediction method and equipment Download PDFInfo
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Abstract
The invention provides a method and equipment for identifying full-process damage and predicting service life of a floating friction plate, wherein the method comprises the following steps: the floating friction plate runs in a simulated service environment; measuring in-plane deformation and out-of-plane displacement images of the floating friction plate in a non-contact manner by using a three-dimensional DIC (digital image computer) technology and carrying out data analysis to obtain a relation between a complete damage accumulation item of the floating friction plate and fatigue life prediction in an experiment; and importing the image information of the floating friction plate into the relationship to perform damage identification and service life prediction. The invention can measure the experimental state data of the floating friction plate in a non-contact way, simultaneously pays attention to two factors of in-plane deformation and out-of-plane displacement which have great influence on the data analysis of the floating friction plate, and improves the service life prediction accuracy of the floating friction plate.
Description
Technical Field
The invention belongs to the field of friction plate detection, and particularly relates to a method and equipment for identifying full-process damage and predicting service life of a floating friction plate.
Background
In the use process of the floating friction plate, the working environment is severe, and small cracks are easy to be generated at a plurality of parts of the friction plate. Under the continuous service working environment, a plurality of small cracks of the floating friction plate can further expand and can be suddenly broken, so that danger is generated. Therefore, the full-process damage identification and service life prediction of the floating friction plate have important significance for the safe application of equipment.
For the detection of the floating friction plate, the currently mainly adopted means is detection based on strain, and the strain detection mainly has two ideas, one is contact measurement and the other is non-contact measurement. The contact measurement is represented by a strain gauge, but the strain gauge can only measure a certain point, and the strain field of the floating friction plate cannot be obtained, so that the damage identification and the service life prediction of the floating friction plate cannot be further performed. The strain gauge also has the problem of easy falling during measurement under the bad service condition of the floating friction plate, and the strain gauge also has an inherent defect of contact measurement, namely, extra additional mass is introduced during measurement. For non-contact measurement, such as acoustic emission detection, the generated signal is smaller in magnitude. Under the actual service working condition, the floating friction plate can be subjected to violent vibration and impact working conditions, so that the noise of an acoustic emission detection signal is overlarge. The existing detection method depends on the experience of detection personnel too much, and a set of theoretically complete, effective and repeatable evaluation means is lacked for the full-process damage identification and the service life prediction of the floating friction plate.
Disclosure of Invention
The invention provides a method and equipment for identifying full-flow damage and predicting service life of a floating friction plate, and solves the problems of insufficient coverage of a measurement range in contact measurement of the floating friction plate and unstable detection signals in non-contact measurement.
A method for identifying damage and predicting service life of a floating friction plate in a whole flow comprises the following steps:
the floating friction plate runs in a simulated service environment;
measuring in-plane deformation and out-of-plane displacement images of the floating friction plate in a non-contact manner by using a three-dimensional DIC (digital image computer) technology and carrying out data analysis to obtain a complete damage accumulation term and fatigue life prediction relation of the floating friction plate in an experiment;
and importing the image information of the floating friction plate at any time into the relation, and performing damage identification and service life prediction.
Further, the data analysis process in the three-dimensional DIC technology is as follows:
step 101, obtaining an in-plane deformation image and an out-of-plane displacement image of a floating friction plate in each fixed rotation period in a non-contact measurement mode, and further obtaining a strain field and an out-of-plane displacement field of the surface of the floating friction plate;
102, calculating the strain field change quantity and the out-of-plane displacement change quantity in each fixed rotation period according to the result of the step 101; further obtaining a strain accumulation related item and an out-of-plane displacement accumulation related item corresponding to each fixed rotation period;
step 103, combining the method of step 102, intercepting the strain accumulation related terms and the out-of-plane displacement accumulation related terms of a plurality of fixed rotation periods in the time period, and respectively obtaining all the strain accumulation related terms and the out-of-plane displacement accumulation related terms in the time period;
and step 104, analyzing all the strain accumulation related terms and the out-of-plane displacement accumulation related terms in the step 103, and establishing a complete damage accumulation term and fatigue life prediction relation of the floating friction plate.
Further, the calculation formula of all the accumulated relevant terms of strain in the cutting time period in step 103 is as follows:
in the formula, D1The strain accumulation-related term is characterized,
the modulus of elasticity of the floating friction pad material is characterized,
the strain components of different positions of the floating friction plate are represented,
and characterizing the dimensionless normalized conversion parameters of the strain components.
Further, in step 103, the calculation formula of all the out-of-plane displacement cumulative correlation terms in the truncation time period is as follows:
in the formula, D2The accumulated correlation terms of the out-of-plane displacement are characterized,
the modulus of elasticity of the floating friction pad material is characterized,
representing the out-of-plane displacement components of different positions of the floating friction plate,
representing dimensionless normalized conversion parameters of the out-of-plane displacement components,
characterizing the characteristic thickness of the floating friction plate.
Further, the relationship formula between the complete damage accumulation term and the fatigue life prediction in step 104 is as follows:
wherein D represents the integral damage accumulation term, D1Characterizing the cumulative dependence of strain, D2Characterizing the cumulative correlation term for out-of-plane displacement, wherein
Is a correction term which is a parameter related to the shape of the floating friction plate,
representing the residual fatigue life of the floating friction plate under any complete damage accumulation term,
the functional relation constructed by experimental modeling between the fatigue life and the integral damage accumulation items is characterized,
the maximum fatigue life is characterized by the following characteristics,
the maximum cumulative amount of damage is characterized,
characterizing a process correction parameter with a value of 1, recalibrating it according to the maximum fatigue life and the maximum damage cumulant if the process changes
。
In a second aspect of the present invention, based on the above prediction method, there is provided a floating friction plate full-process damage identification and life prediction device, including:
the floating friction plate is fixedly arranged on the experiment generating device to carry out a working condition simulation experiment;
the experiment control device is connected with the experiment generating device and used for sending an instruction to the experiment generating device to set experiment working condition parameters;
the display device is connected with the experiment control device and is used for displaying the set parameters and the real-time parameters in the experiment process;
the three-dimensional DIC shooting device monitors and records images of in-plane deformation and out-of-plane displacement of the floating friction plate in the whole process;
and the data processing system is connected with the three-dimensional DIC shooting device to receive the shot image information, analyze the data in real time, and perform damage identification and service life prediction.
Furthermore, the experiment generating device is provided with a vibration generator for controlling the loading of the vibration working condition and a rotation generator for controlling the loading of the rotation working condition.
Further, the three-dimensional DIC shooting device comprises at least two imaging devices used for collecting images of in-plane deformation and out-of-plane displacement of the floating friction plate in the whole process.
Compared with the prior art, the invention has the following beneficial effects:
1. according to the method for identifying the full-flow damage and predicting the service life of the floating friction plate, provided by the invention, the image data of the floating friction plate in the experimental process is measured in a non-contact manner, the state of the floating friction plate in the experiment is not influenced, the measurement range comprises the whole floating friction plate, and compared with point measurement in contact type measurement, the analysis result is more accurate.
2. In the invention, the influence of working conditions such as rotation, vibration and the like on the floating friction plate in the experimental process is considered, so that two factors which have great influence on the data analysis of the floating friction plate, namely in-plane deformation and out-of-plane displacement are collected, the damage identification and the service life prediction of the floating friction plate are carried out, and the accuracy of the grasping of the influencing factors synchronously improves the accuracy of the data analysis result.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below. It should be apparent that the drawings in the following description are merely exemplary, and that other embodiments can be derived from the drawings provided by those of ordinary skill in the art without inventive effort.
FIG. 1 is a schematic flow chart of a method for identifying damage and predicting service life of a floating friction plate in a full flow process according to the present invention;
FIG. 2 is a graph of life prediction for a floating friction plate of the present invention under different parameters;
FIG. 3 is a schematic structural diagram of a floating friction plate full-flow damage identification and life prediction device according to the present invention;
reference numbers in the figures:
100-experiment control device, 200-display device, 300-data processing system;
3-base, 4-floating friction plate mounting position, 5-vibration generator, 6-rotation generator, 7-high-speed camera, 9-LED light source, 10-synchronous trigger device and 11-exchanger.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Under actual service, the floating friction plate is continuously subjected to dynamic load with strong randomness, so that the surface of the floating friction plate is very easy to generate micro-cracks. Under a continuous service environment, the floating friction plate continuously suffers from dynamic load with strong randomness, so that microcracks continuously evolve, and finally macrocracks are formed, and the floating friction plate is broken and fails. The whole process of crack initiation, crack propagation and fracture can obtain relevant information through non-contact measurement of the surface strain field.
When the floating friction plate is in actual service, the rotation of the gears (as shown in figure 3 at the position 4) can cause the impact between the gears, and the impact strength and the randomness between the gears are greatly increased due to the external vibration excitation. This results in extremely complex deformations of the gear surface. The surface of the gear can not only generate in-plane deformation, but also generate large out-of-plane displacement, and damage identification and service life prediction of the floating friction plate can be realized by comprehensively considering the influence of in-plane deformation and out-of-plane displacement.
The invention provides a full-flow damage identification and service life prediction method for a floating friction plate, which comprises the following steps as shown in figure 1:
the floating friction plate runs in a simulated service environment;
measuring in-plane deformation and out-of-plane displacement images of the floating friction plate in a non-contact manner by using a three-dimensional DIC (digital image computer) technology and carrying out data analysis to obtain a relation between a complete damage accumulation item of the floating friction plate and fatigue life prediction in an experiment;
and importing the image information of the floating friction plate at any moment into the relation, and performing damage identification and service life prediction.
According to the invention, the data is measured and analyzed by the three-dimensional DIC technology, the three-dimensional shape and deformation of the surface of the measured object can be measured, the method is very suitable for monitoring the in-plane deformation and out-of-plane displacement images of the floating friction plate in a non-contact manner in real time and carrying out data analysis, the damage identification and the service life prediction of the floating friction plate are carried out, and the analysis result is more accurate.
In a specific embodiment, the data analysis process in the three-dimensional DIC technology of the present invention is as follows:
step 101, obtaining an in-plane deformation image and an out-of-plane displacement image of a floating friction plate in each fixed rotation period in a non-contact measurement mode, and further obtaining a strain field and an out-of-plane displacement field of the surface of the floating friction plate;
102, calculating the strain field variation and the out-of-plane displacement variation in each fixed rotation period by making a difference between the strain field and the out-of-plane displacement field in the adjacent fixed rotation periods according to the result of the step 101; calculating the strain field change amount in each fixed rotation period to obtain a strain accumulation related item and an out-of-plane displacement accumulation related item corresponding to each fixed rotation period;
step 103, combining the method of step 102, intercepting the strain accumulation related terms and the out-of-plane displacement accumulation related terms of a plurality of fixed rotation periods in the time period, and respectively obtaining all the strain accumulation related terms and the out-of-plane displacement accumulation related terms in the time period;
and step 104, analyzing all the strain accumulation related terms and the out-of-plane displacement accumulation related terms in the step 103, and establishing a relation between the complete damage accumulation term of the floating friction plate and the fatigue life prediction.
In one specific embodiment, the principal formula is as follows:
the calculation formula of all the strain accumulation related terms in the interception time period is as follows:
in the formula, D1A correlation term representing the accumulation of strain is expressed,
the modulus of elasticity of the floating friction pad material is characterized,
the strain components of different positions of the floating friction plate are represented,
and characterizing the dimensionless normalized conversion parameters of the strain components.
The calculation formula of all the out-of-plane displacement accumulation related terms in the interception time period is as follows:
in the formula, D2Representing the cumulative correlation term for the out-of-plane displacement,
the modulus of elasticity of the floating friction pad material is characterized,
representing the out-of-plane displacement components of different positions of the floating friction plate,
representing dimensionless normalized conversion parameters of the out-of-plane displacement components,
characterizing the characteristic thickness of the floating friction plate.
The relation formula of the complete damage accumulation term and the fatigue life prediction is as follows:
wherein D represents a complete damage accumulation term, wherein
Is a correction term which is a parameter related to the shape of the floating friction plate,
the residual fatigue life of the material under any complete damage accumulation term is characterized,
characterizing the functional relationship between fatigue life and integral damage accumulation terms through experimental modeling,
the maximum fatigue life is characterized by the following characteristics,
the maximum cumulative amount of damage is characterized,
and characterizing a process correction parameter, taking the value as 1, and recalibrating according to the maximum fatigue life and the maximum damage cumulant if the process is changed. This scheme is in rough calculation
Can directly take the value as 1, and can be recalibrated according to the maximum fatigue life and the maximum damage cumulant if the subsequent process is changed
Without the need for
A change is made.
And substituting the state data of the floating friction plate at any moment into a formula relation by combining the relationship between the complete damage accumulation term and fatigue life prediction, so as to obtain the residual life of the floating friction plate.
The prediction method provided by the invention comprehensively considers the strain accumulation related term and the out-of-plane displacement accumulation related term. If only the strain accumulation related term is considered for life prediction, the relationship between the remaining life and the strain accumulation related term is shown by the dotted line in fig. 2. The method comprehensively considers the strain accumulation related term and the out-of-plane displacement accumulation related term, and the relation between the residual life and the damage factor is shown as a solid line in FIG. 2. The curve obtained by the prediction method provided by the invention has more gradual change, avoids the sudden change of the slope of the curve at the later stage, increases the effectiveness of the life prediction result of the floating friction plate, and reduces the potential safety hazard of sudden failure in the service cycle.
Based on the prediction method, the invention provides a device for identifying the damage of the floating friction plate in the whole process and predicting the service life, as shown in fig. 3, comprising:
the experimental generating device is used for carrying out a working condition simulation experiment by installing and fixing the floating friction plate on the experimental generating device;
experiment controlling means 100 connects experiment generating device and is used for sending the instruction to experiment generating device and sets up experiment operating mode parameter, and the operating mode that mainly can set for includes: basic functions such as rotation working condition setting, vibration working condition setting, experiment starting and ending and the like;
the display device 200 is connected with the experiment control device and is used for displaying the set parameters and the real-time parameters in the experiment process; in the embodiment, the experiment conditions set by the experiment are displayed through the display screen, wherein the experiment conditions comprise rotation working condition parameters, vibration working condition parameters, real-time monitored actual experiment parameters, the time length of the experiment and other parameters, so that an operator can conveniently and visually obtain the conditions set by the experiment and the current state and progress;
the three-dimensional DIC shooting device monitors and records images of in-plane deformation and out-of-plane displacement of the surface of the floating friction plate in the whole process;
and the data processing system 300 is connected with the three-dimensional DIC shooting device, receives the shot image information, performs data analysis, and performs damage identification and service life prediction.
The data processing system 300 mainly includes a high performance workstation and a real-time processing program based on the above prediction method, which is called a complete damage accumulation item calculation and analysis fitting program, and by using the high performance workstation and the program, the complete damage accumulation items of the floating friction plate at different times can be counted in real time and fitting analysis can be performed. During the experiment, the damage cumulant of the device can be analyzed in real time in the whole process through the device, the damage of the floating friction plate is identified, and after the experiment is completed, the relation between the residual fatigue life T and the complete damage cumulant D under the random complete damage cumulant of the floating friction plate can be fitted through the data processing system 300. And subsequently, a residual life prediction result of the floating friction plate can be given through a complete damage accumulation item at any moment or image information of the floating friction plate at any moment.
In a specific embodiment, the experiment generating device comprises a base 3, a floating friction plate mounting position 4, a vibration generator 5 and a rotation generator 6, wherein a main body frame and a balancing weight of the experiment generating device with the floating friction plate are arranged in the base 3 and are fixed on the ground to ensure that the experiment is smoothly carried out; the installation position 4 of the floating friction plate is positioned on the outer shell of the base 3 and sleeved on the outer ring of the rotation generator 6, and the rotation generator 6 is used for controlling the loading of the rotation working condition of the floating friction plate; the vibration generator 5 is arranged on the side surface of the base 3 and used for controlling the loading of the vibration working condition of the floating friction plate, and the vibration generator 5 and the rotation generator 6 work according to the instruction of the experiment control device 100; the floating friction plate is arranged on a position 4, the position is also a monitoring position of the three-dimensional DIC, the rotation generator 6 is positioned at the center of the position, and the vibration generator 5 and the rotation generator 6 are matched to simulate the service working condition of the floating friction plate.
In a specific embodiment, the three-dimensional DIC photographing device comprises at least two imaging devices for acquiring in-plane deformation and out-of-plane displacement images of the floating friction plate in the full-flow experimental process.
In another specific embodiment, the three-dimensional DIC photographing apparatus comprises two high-speed cameras 7, an LED light source 9, a synchronization triggering apparatus 10 and a switch 11. The two high-speed cameras 7 and 8 are connected and used for shooting the experimental process of the floating friction plate, and if only one camera is used, the off-plane displacement of the floating friction plate cannot be obtained. The device adopts two high-speed cameras, and can shoot out-of-plane displacement, so that the subsequent analysis of the accumulated related items of the out-of-plane displacement can be realized; the synchronous trigger device 10 is simultaneously connected with two high-speed cameras 7 and is used for controlling the starting and synchronous triggering of the two cameras; the switch 11 is connected to two high-speed cameras 7 at the same time, and is used for storing the data shot by the two high-speed cameras and transmitting the data to the data processing system 300, so that the full-flow continuous shooting of the high-speed cameras is ensured. The LED light source 9 is used for auxiliary lighting of the floating friction plate in the shooting process, so that the high-speed camera can be assisted to realize clear shooting with high sampling rate.
The above embodiments are only exemplary embodiments of the present application, and are not intended to limit the present application, and the protection scope of the present application is defined by the claims. Various modifications and equivalents may be made by those skilled in the art within the spirit and scope of the present application and such modifications and equivalents should also be considered to be within the scope of the present application.
Claims (7)
1. A full-flow damage identification and service life prediction method for a floating friction plate is characterized by comprising the following steps:
the floating friction plate runs in a simulated service environment;
measuring in-plane deformation and out-of-plane displacement images of the floating friction plate in a non-contact manner by using a three-dimensional DIC (digital image computer) technology and carrying out data analysis to obtain a complete damage accumulation term and fatigue life prediction relation of the floating friction plate in an experiment; the data analysis process in the three-dimensional DIC technology is as follows:
step 101, obtaining an in-plane deformation image and an out-of-plane displacement image of a floating friction plate in each fixed rotation period in a non-contact measurement mode, and further obtaining a strain field and an out-of-plane displacement field of the surface of the floating friction plate;
102, calculating the strain field change quantity and the out-of-plane displacement change quantity in each fixed rotation period according to the result of the step 101; further obtaining a strain accumulation related item and an out-of-plane displacement accumulation related item corresponding to each fixed rotation period;
step 103, combining the method of step 102, intercepting the strain accumulation related terms and the out-of-plane displacement accumulation related terms of a plurality of fixed rotation periods in the time period, and respectively obtaining all the strain accumulation related terms and the out-of-plane displacement accumulation related terms in the time period;
step 104, analyzing all the strain accumulation related terms and the out-of-plane displacement accumulation related terms in the step 103, and establishing a complete damage accumulation term and fatigue life prediction relation of the floating friction plate;
and importing the image information of the floating friction plate at any time into the relation, and performing damage identification and service life prediction.
2. The method for identifying damage and predicting life of a floating friction plate in the whole process according to claim 1, wherein the calculation formula of all the strain accumulation related terms in the intercepting time period in step 103 is as follows:
in the formula, D1The strain accumulation-related term is characterized,
the modulus of elasticity of the floating friction pad material is characterized,
the strain components of different positions of the floating friction plate are represented,
and characterizing the dimensionless normalized conversion parameters of the strain components.
3. The method for identifying damage and predicting life of a floating friction plate in the whole process according to claim 1, wherein the calculation formula of all accumulated correlation terms of the out-of-plane displacement in the intercepting time period in step 103 is as follows:
in the formula, D2The accumulated correlation terms of the out-of-plane displacement are characterized,
the modulus of elasticity of the floating friction pad material is characterized,
representing the out-of-plane displacement components of different positions of the floating friction plate,
representing dimensionless normalized conversion parameters of the out-of-plane displacement components,
characterizing the characteristic thickness of the floating friction plate.
4. The method for identifying and predicting the full-flow damage and the life of the floating friction plate according to claim 1, wherein the relational formula between the full damage accumulation term and the fatigue life prediction in the step 104 is as follows:
wherein D represents the integral damage accumulation term, D1Characterizing the cumulative dependence of strain, D2Characterizing the cumulative correlation term for out-of-plane displacement, wherein
Is a correction term which is a parameter related to the shape of the floating friction plate,
representing the residual fatigue life of the floating friction plate under any complete damage accumulation term,
the functional relation constructed by experimental modeling between the fatigue life and the integral damage accumulation items is characterized,
the maximum fatigue life is characterized by the following characteristics,
the maximum cumulative amount of damage is characterized,
characterize aThe process correction parameter is 1, and if the process is changed, the process is recalibrated according to the maximum fatigue life and the maximum damage cumulant
。
5. A prediction device applying the floating friction plate full-flow damage identification and service life prediction method of any one of claims 1 to 4, characterized by comprising:
the floating friction plate is fixedly arranged on the experiment generating device to carry out a working condition simulation experiment;
the experiment control device is connected with the experiment generating device and used for sending an instruction to the experiment generating device to set experiment working condition parameters;
the display device is connected with the experiment control device and is used for displaying the set parameters and the real-time parameters in the experiment process;
the three-dimensional DIC shooting device monitors and records images of in-plane deformation and out-of-plane displacement of the floating friction plate in the whole process;
and the data processing system is connected with the three-dimensional DIC shooting device to receive the shot image information, analyze the data in real time, and perform damage identification and service life prediction.
6. The prediction device according to claim 5, wherein the experiment generating device is provided with a vibration generator for controlling the loading of vibration conditions and a rotation generator for controlling the loading of rotation conditions.
7. The prediction device according to claim 5, wherein the three-dimensional DIC shooting device comprises at least two imaging devices for acquiring in-plane deformation and out-of-plane displacement images of floating friction plates in the whole process.
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| 孔边循环应变与疲劳循环次数相关性实验研究;朱金花等;《实验力学》;20050930(第03期);第388-392页 * |
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