CN114840943B - Fatigue crack propagation simulation piece design method based on consistency of crack propagation path and stress intensity factor - Google Patents
Fatigue crack propagation simulation piece design method based on consistency of crack propagation path and stress intensity factor Download PDFInfo
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Abstract
The invention relates to a fatigue crack propagation simulation piece design method based on the consistency of a crack propagation path and a stress strength factor, which comprises the following steps: determining a typical failure mode according to the load and the environmental characteristics of a real structure, carrying out static strength analysis of the real structure, and determining a maximum first main stress part as a dangerous part; carrying out a material-grade fracture toughness test and a crack propagation test; developing a crack propagation finite element simulation of a real structure to determine a crack propagation path, extracting a stress intensity factor change rule on the crack propagation path, determining a key geometric dimension generating main influence, and preliminarily designing the geometric shape of an evaluation part of a simulation piece on the premise of ensuring that the critical geometric dimension is not changed; by adjusting the width of the simulation piece along the crack propagation direction and combining the crack propagation simulation of the simulation piece, the stress intensity factor and the critical crack length under different crack lengths are consistent with the real structure; the clamping section of the simulation part is designed to be a thread, a pin hole or a wedge, and the strength is checked under the conditions of checking load and environment.
Description
Technical Field
The invention belongs to the technical field of structural mechanics tests, and particularly relates to a fatigue crack propagation simulation piece design method based on the consistency of a crack propagation path and a stress intensity factor.
Background
The complex mechanical system represented by an aircraft engine has double complexity of load and structure, a key force bearing structure of the complex mechanical system, such as a wheel disc structure of the aircraft engine, is often used as a few broken key parts and service life limiting parts to be managed, the design of damage tolerance is a key factor for ensuring the service life reliability of the wheel disc, and the accurate crack extension life evaluation is the core content of the design of the damage tolerance.
The method for determining the fatigue life of the load-bearing structure through test is a life determination method commonly adopted in engineering and is also the content of regulation of relevant standards and regulations. However, the overall test cost is high, the cycle is long, and the test is difficult to be carried out at the initial stage of design, and the material-grade test based on the standard test piece is difficult to reflect the influence of the structural characteristics on the fatigue life. Therefore, life assessment based on simulation is considered to be an effective means for sufficiently exposing problems at the early stage of design and accelerating the iteration of the scheme.
With the continuous development of structural strength design technology, partial preliminary results have been formed in the technical field, but the following problems still exist: 1) The failure mode is mainly a low-cycle fatigue single failure mode and cannot reflect a composite fatigue failure mode presented by a specific key part of a bearing structure; 2) Stress is usually adopted as a damage control parameter which mainly influences the crack propagation life, but the crack propagation life of a simulation piece cannot be ensured to be consistent with a real structure due to boundary influence; 3) Most of the cases are only suitable for specific objects, and the design method has low universality.
For example: the traditional Chinese invention patent CN 201810808785.3 'design method for turbine disc mortise crack propagation simulation piece' discloses a design method for a turbine disc mortise crack propagation simulation piece, which only considers a low-cycle fatigue failure mode, determines the plane shape of the simulation piece according to the maximum stress and the gradient thereof along the stretching direction at the notch of the simulation piece, and determines the thickness of the simulation piece through a stress intensity factor. The method neglects the influence of the simulation piece boundary on the stress intensity factor in the crack propagation process, and the simulation piece crack propagation life and the real structure have larger deviation when the critical crack length is longer.
The traditional Chinese invention patent CN 201810797101.4 'a design method for a crack propagation characteristic simulation piece of a centrifugal impeller center hole', discloses a design method for a crack propagation characteristic simulation piece of a centrifugal impeller center hole, which only considers a low-cycle fatigue failure mode, determines the plane shape of the simulation piece according to the maximum stress and the gradient thereof along the stretching direction at the symmetrical circular arc of the simulation piece, and determines the thickness of the simulation piece through a stress intensity factor. The method neglects the influence of the simulation piece boundary on the stress intensity factor in the crack propagation process, and the simulation piece crack propagation life and the real structure have larger deviation when the critical crack length is longer.
Disclosure of Invention
In order to overcome the problem of insufficient universality in the design of a fatigue crack initiation simulation piece in the prior art, the invention provides a fatigue crack initiation simulation piece design method based on the consistency of a crack propagation path and a stress strength factor. The method comprises the following implementation steps:
step (1): determining a typical failure mode according to the load and the environmental characteristics of a real structure, carrying out real structure static strength analysis, determining a maximum first main stress part as a dangerous part, and taking a plane vertical to the first main stress as an initial crack plane;
step (2): developing a material-level fracture toughness test and a crack propagation test, wherein the test conditions cover the load and temperature states of the examined part, and determining the fracture toughness consistent with the structural stress and strain states, and a crack propagation model and parameters thereof under a given failure mode;
and (3): developing a real structure crack propagation finite element simulation to determine a crack propagation path, extracting a change rule of a stress intensity factor on the crack propagation path, determining a key geometric dimension which mainly influences the stress intensity factor on the crack propagation path, and preliminarily designing the geometric shape of an evaluation part of a simulation piece on the premise of ensuring that the key geometric dimension is unchanged;
and (4): by adjusting the width of the simulation piece along the crack propagation direction, developing the crack propagation simulation of the simulation piece based on finite element analysis, so that the stress intensity factor and the critical crack length under different crack lengths are consistent with the real structure;
and (5): designing a clamping section of the simulation part as a thread, a pin hole or a wedge, checking the strength under the examination load and the environment, wherein the clamping section has enough strength reserve relative to the examination section;
and (6): and designing a pre-crack form of the simulation piece at the notch by wire electrical discharge machining, so that the pre-crack form is consistent with the initial crack form of the real structure.
Further, the test piece used in the test in the step (2) is in the form of a compact tensile, single-edge notch or central crack standard.
Further, the step (2) specifically includes: the fracture toughness consistent with the structural stress and strain states is determined by adjusting the thickness of a test piece, a crack propagation model under a given failure mode is selected, and parameters of the crack propagation model are determined by fitting crack propagation rate and stress intensity factor amplitude data obtained through tests.
Further, the critical geometric dimensions in step (3) include a notch radius of curvature, a cross-sectional width, and a thickness.
Further, the sufficient strength reserve in the step (5) means that the predicted fatigue life value of the clamping section is more than 2 times of that of the examination section.
Compared with the prior art, the invention has the effective gains that:
the existing Chinese invention patents CN 201810808785.3, namely a design method for a turbine disc mortise crack propagation simulation piece and CN 201810797101.4, namely a design method for a centrifugal impeller center hole crack propagation characteristic simulation piece respectively provide a crack propagation simulation piece design method aiming at a single structural characteristic and a low-cycle fatigue failure mode, and the method generally adopts stress components and spatial distribution thereof as design basis while ensuring the similarity of geometric shapes. However, in the crack propagation process, as the crack length increases, the influence of the corresponding boundary in the crack propagation direction is gradually enhanced, and it is difficult to ensure the consistency of the stress intensity factors under different crack lengths only by the design method of the stress component and the distribution thereof, thereby causing the crack propagation life of the simulation piece and the real structure to be deviated. The invention provides a design basis for adopting stress intensity factors and critical crack lengths under different crack lengths as crack propagation simulation pieces from the physical process of crack propagation, and has higher application and practical values. The method is used for carrying out life assessment and design verification on dangerous parts of key bearing structures (such as aircraft engine wheel discs) of complex mechanical systems, and timely discovering and exposing the problem of damage tolerance existing in the primary design of the structures, thereby being beneficial to shortening the design iteration cycle and reducing the design cost.
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FIG. 1 is a flow chart of a fatigue crack propagation simulation design method based on consistent crack propagation path and stress intensity factor in accordance with the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and do not limit the invention. In addition, the technical features involved in the respective embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
The technical scheme of the fatigue crack initiation simulation piece design method based on the consistency of the crack propagation path and the stress intensity factor is further explained by embodiments in the following with the accompanying drawings. As shown in fig. 1, the method of the invention comprises the following steps:
the method comprises the steps of firstly, determining typical failure modes such as low cycle fatigue and creep-fatigue of an aircraft engine wheel disc according to real structural load and environmental characteristics, carrying out real structural static strength analysis, determining a position with the maximum first principal stress as a dangerous position, and taking a plane perpendicular to the first principal stress as an initial crack plane.
And secondly, carrying out a material-level fracture toughness test and a crack propagation test, wherein the test piece is in the form of a compact tensile standard piece, a single-side notch, a central crack and other standard pieces, the test conditions cover the load and temperature states of the examined part, the fracture toughness consistent with the structural stress and strain states is determined by adjusting the thickness of the standard piece, a crack propagation model under a given failure mode is selected, and parameters of the crack propagation model are determined by fitting the data of the crack propagation rate (da/dN) and the stress intensity factor amplitude (delta K) obtained by the test, such as:
low cycle fatigue:
in the formula, C and n are fitting parameters.
Creep-fatigue:
wherein C, n, A and m are fitting parameters, K max Maximum stress intensity factor, t h Is the holdup time.
And thirdly, developing a real structure crack propagation finite element simulation to determine a crack propagation path, extracting a stress intensity factor change rule on the crack propagation path, and determining a key geometric dimension which mainly influences the stress intensity factor on the crack propagation path. The critical geometry includes the notch radius of curvature, section width, thickness, etc. And on the premise of ensuring that the key geometric dimension is not changed, preliminarily designing the geometric shape of the evaluation part of the simulation piece by adopting a flat plate configuration.
And fourthly, developing the crack propagation simulation of the simulation piece based on finite element software by adjusting the width of the simulation piece along the crack propagation direction, wherein the larger the width is, the slower the stress intensity factor is reduced along with the crack length, and acquiring the change rule of the stress intensity factor on the crack propagation path, so that other geometric dimensions are adjusted under the condition of not changing the key geometric dimension of the simulation piece, and the stress intensity factor and the critical crack length under different crack lengths are consistent with the real structure.
Fifthly, designing the clamping section of the simulation part as a thread, a pin hole or a wedge, performing strength check under the checking load and environment, wherein the clamping section has enough strength reserve relative to the checking section, namely the predicted value of the fatigue life of the clamping section is more than 2 times of that of the checking section;
and sixthly, designing the prefabricated crack form, such as a corner crack, a penetrating crack and the like, of the notch of the simulation piece by wire electric discharge machining, so that the prefabricated crack form is consistent with the initial crack form of the real structure.
The above examples are merely provided to illustrate specific embodiments of the present invention and are not intended to limit the scope of the present invention. The scope of the invention is defined by the appended claims. Various equivalent substitutions and modifications can be made without departing from the spirit and principles of the invention, and are intended to be included within the scope of the invention.
Claims (4)
1. A fatigue crack propagation simulation piece design method based on the consistency of a crack propagation path and a stress intensity factor is characterized by comprising the following steps:
step (1): determining a typical failure mode according to the load and the environmental characteristics of a real structure, carrying out real structure static strength analysis, determining a maximum first main stress part as a dangerous part, and taking a plane vertical to the first main stress as an initial crack plane;
step (2): developing a material-level fracture toughness test and a crack propagation test, wherein the test conditions cover the load and temperature states of the examined part, and determining the fracture toughness consistent with the structural stress and strain states, and a crack propagation model and parameters thereof under a given failure mode;
and (3): developing a real structure crack propagation finite element simulation to determine a crack propagation path, extracting a change rule of a stress intensity factor on the crack propagation path, determining a key geometric dimension which mainly influences the stress intensity factor on the crack propagation path, and preliminarily designing the geometric shape of an evaluation part of a simulation piece on the premise of ensuring that the key geometric dimension is unchanged;
and (4): by adjusting the width of the simulation piece along the crack propagation direction, developing the crack propagation simulation of the simulation piece based on finite element analysis, so that the stress intensity factor and the critical crack length under different crack lengths are consistent with the real structure;
and (5): designing a clamping section of the simulation piece to be a thread, a pin hole or a wedge, carrying out strength check under the examination load and environment, wherein the clamping section has enough strength reserve relative to the examination section;
and (6): designing a pre-crack form of the simulation piece at the notch by wire electrical discharge machining, so that the pre-crack form is consistent with the initial crack form of the real structure;
the step (2) specifically comprises: the fracture toughness consistent with the structural stress and strain states is determined by adjusting the thickness of a test piece, a crack propagation model under a given failure mode is selected, and parameters of the crack propagation model are determined by fitting crack propagation rate and stress intensity factor amplitude data obtained through tests.
2. The method for designing a fatigue crack propagation simulator based on the consistency of the crack propagation path and the stress-intensity factor according to claim 1, wherein the method comprises the following steps: the test piece used in the test in the step (2) is in the form of a compact stretching standard piece, a single-edge notch standard piece or a central crack standard piece.
3. The method for designing a fatigue crack propagation simulator based on the consistency of the crack propagation path and the stress-intensity factor according to claim 1, wherein the method comprises the following steps: the critical geometry of step (3) includes a notch radius of curvature, a cross-sectional width, and a thickness.
4. The method for designing a fatigue crack propagation simulator based on the consistency of the crack propagation path and the stress-intensity factor according to claim 1, wherein the method comprises the following steps: the sufficient strength reserve in the step (5) means that the predicted fatigue life value of the clamping section is more than 2 times of that of the examination section.
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