Life Prediction of Gearbox Body by Modified Quasi-static Superposition Method
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摘要: 针对某型内燃机车齿轮箱箱体出现裂纹的情况,建立齿轮箱箱体有限元模型,提出了一种根据实测动应力修正准静态叠加法的应力时间历程计算方法,对单位加速度激励下的响应进行修正。分别用准静态叠加法和基于实测动应力修正的准静态叠加法计算绝对值最大主应力时程,使用雨流计数法对应力时程进行循环计数,根据Miner累积损伤理论对齿轮箱箱体寿命进行预测,后者预测结果与实际结果较为接近。两种方法计算结果差异较大,初步推测所测齿轮箱体发生共振,并通过对比加速度谱的频谱分析结果与齿轮箱箱体模态分析结果进行了验证。该研究为齿轮箱箱体结构设计和优化时疲劳寿命的预测提供了参考。Abstract: In order to trace the cause of gearbox body cracks of a diesel locomotive, a finite element model for the gearbox was established. A modified quasi-static superposition method according to the real dynamic stress was proposed to correct the response produced by unit acceleration and obtain the stress-time history. The maximum absolute principal-stress-time history was respectively acquired by the quasi-static superposition method and modified quasi-static superposition method. Then, the rain flow counting method was used to count the cycle of stress-time history. Finally, the fatigue life of the gearbox body was predicted with Miner's cumulative damage theory. The result of the latter method is in a good agreement with the experimental. The significant difference between the result via two methods is preliminarily believed to be caused by the resonance of gearbox body. It is proved by comparison between the acceleration spectrum analysis and the gearbox body modal analysis. This investigation provides references for predicting the fatigue life of gearbox body in structural design and optimization.
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Key words:
- gearbox body /
- fatigue life /
- modified quasi-static superposition method /
- resonance
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表 1 齿轮箱箱体预测和实际疲劳寿命对比
km 疲劳损伤D 疲劳寿命L 预测结果 1.013×10-4 1.916×106 实际统计 1.293×10-3 1.500×105 表 2 各位置实测及虚拟测试动应力最大值对比
测点位置 测点编号 实际测试最大动应力/MPa 虚拟测试最大动应力/MPa 比值
(实际虚拟)齿轮箱上箱体
车轮侧立板
合口拐角处1-0° 67.98 78.17 0.870 1-45° 51.70 65.93 0.784 1-90° 12.36 14.81 0.835 齿轮箱上箱体
电机侧立板
合口拐角处2-0° 53.32 62.08 0.859 2-45° 23.46 29.36 0.799 2-90° 13.44 15.37 0.874 挡油板与齿轮箱
下箱体焊缝附近3 87.02 100.74 0.864 抱轴箱安装座
上部焊缝附近4 69.83 79.01 0.884 表 3 危险位置损伤及疲劳寿命值
km 位置 损伤D 疲劳寿命L 齿轮箱上箱体车轮侧
立板合口拐角处4.142×10-4 4.684×105 齿轮箱上箱体电机侧
立板合口拐角处1.123×10-3 1.727×105 挡油板与齿轮箱下箱体焊缝 1.085×10-3 1.788×105 抱轴箱安装座上部焊缝 8.434×10-4 2.300×105 抱轴箱安装座下部焊缝 4.558×10-5 4.256×106 表 4 齿轮箱箱体模态计算结果
阶数 固有频率/Hz 模态形式 1 57.57 轮对侧侧板一阶局部振动 2 71.12 两侧侧板一阶局部振动 3 86.63 轮对侧侧板二阶局部振动+
电机侧侧板一阶局部振动4 100.22 两侧侧板二阶局部振动 5 109.81 轮对侧侧板二阶局部振动 6 117.06 两侧侧板二阶局部振动 7 125.01 轮对侧侧板三阶局部振动+
电机侧侧板一阶局部振动8 134.49 轮对侧侧板二阶局部振动 9 157.52 电机侧侧板三阶局部振动 10 163.81 轮对侧侧板四阶局部振动 -
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