航空发动机榫连接结构微动疲劳寿命研究
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摘要
被称为“工业癌症”的微动损伤广泛存在于机械构件的各种紧密配合件中，而榫连接结构中的微动疲劳失效则是航空发动机故障高发的原因之一。由于微动疲劳的影响因素众多，目前在试验和理论各方面对微动疲劳的研究还不是很成熟。因此，开展榫连接结构的微动疲劳试验与寿命技术研究具有重要的理论意义和工程实用价值。
本文采用试验与理论相结合的研究方法，进行了大量的微动疲劳试验，并根据目前微动疲劳理论的最新研究成果，对微动疲劳损伤理论及寿命技术问题进行了深入研究。
首先，基于临界平面理论和微动促进了裂纹萌生和早期扩展的损伤机理，定义了一种微动损伤参量CSE（considering the multi-factor in the calculating of the Strain Energy），提出了微动疲劳寿命预测模型，开展了微动疲劳寿命的定量化研究。参量CSE考虑了几何特性、材料特性、载荷特性和表面状况等微动疲劳影响因素，不仅能够表征微动损伤中的能量耗散，而且可以解释微动疲劳现象中特有的接触特征。微动疲劳寿命CSE预测模型包含了材料普通疲劳特性，待定参数较少，适用于合金材料连接结构的微动疲劳寿命预测。
其次，基于封闭力系框架的结构设计，以疲劳试验机为平台，设计并实现了一套微动疲劳试验装置，开展了钛合金TC11与TC11接触、单晶高温合金DD3与粉末高温合金FGH95接触以及定向凝固高温合金DZ125与FGH95接触三种不同材料配对的微动疲劳试验研究，得到了相关的微动疲劳规律。微动疲劳试验研究表明：法向载荷的加载稳定，试验成功率高和可操作性强，所设计的试验装置性能良好；微动疲劳显著降低了材料的疲劳性能和疲劳寿命；法向载荷和轴向载荷对微动疲劳寿命均有影响，其中轴向载荷是微动疲劳寿命最主要的影响因素。
最后，将微动疲劳寿命的理论和试验研究相结合，开展了相关的数值分析研究，对各向同性材料和各向异性材料微动疲劳裂纹的萌生位置和方向以及寿命预测模型进行验证和对比，探讨了不同材料的微动损伤规律及损伤机理。研究表明：钛合金试验件以及榫连接结构预测结果的误差分散带在2倍因子以内，DD3的误差分散带在2.6倍因子以内，而DZ125的误差分散带则在2.8倍因子以内；新的微动损伤参量CSE能够较好地表征不同材料的微动疲劳特性，有效地预测裂纹萌生位置和生长方向，并且与试验结果基本吻合；各向异性材料的抗微动疲劳特性要优于各向同性材料。
Fretting damage known as "industry cancer", widely occurs to the junction between twomechanical components. Fretting fatigue failure in dovetail joints is one of main causes in aero-enginefailure. However, the experimental and theoretical research is not mature currently because of somany influence factors on fretting fatigue. Therefore, systematical research on fretting fatigueexperiments and life technology of dovetail joints are required and will contribute significant valuesin theoretical study and practical engineering applications.
The fretting fatigue experiments were conducted by the combination of theoretical andexperimental methods. According to the latest research of current fretting fatigue theories, in-depthresearch has been explored in this paper in order to solve the fretting damage and life technologyproblems.
First, a new fretting damage parameter CSE（considering the multi-factor in the calculating ofthe Strain Energy） was introduced and the quantitative research on a new fretting fatigue lifeprediction model was carried out, based on the critical plane theory and the damage mechanism, thefretting induced crack initiation and early propagation. The fretting damage parameter CSE considersmany factors including geometry characteristic, material characteristics, load characteristics, surfacecondition and so on，which can represent the energy loss in the fretting damage and explain thephenomenon of stress concentration in the fretting fatigue. The fretting fatigue life prediction modelof CSE contains general fatigue properties and less undetermined parameter, which is suitable for thelife prediction of a link structure of an alloy material.
Second, employing the concept of the overall balance framework in the structure design, aunique fretting fatigue test apparatus based on a fatigue testing machine has been designed andfabricated to characterize the fretting fatigue damage process with a facility to observe the crackwhich is being initiated in and around the contact zone during the test. There are three types ofcontacting pair among the fretting specimen and the pad including titanium alloy TC11and TC11,single crystal nickel DD3and powder metallurgy superalloy FGH95, directionally solidifiedsuperalloy DZ125and FGH95, and a relevant fretting fatigue law is obtained. The result shows goodloading stability of the normal load, high success rate and strong test maneuverability, and theequipment works well. Fretting fatigue significantly reduces fatigue performance and fatigue life ofthe material. The fretting fatigue life is affected by the normal load and the axial load, and the axialload is the most important influencing factor for the fretting fatigue life.
Finally, numerical analysis was carried out by the combination of theoretical and experimentalresearch on fretting fatigue life. The initiation location and orientation of the fretting fatigue crack andthe life prediction model for isotropic and anisotropic materials were validated and compared. Thefretting damage laws and damage mechanisms of different materials were also discussed. The resultof the CSE prediction model shows good agreement with experimental results. The CSE critical planeapproach is appropriate for predicting the initiation location and growth orientation of the frettingfatigue crack. The anisotropic material shows better resistance in fretting fatigue than the isotropicmaterial.
本文采用试验与理论相结合的研究方法，进行了大量的微动疲劳试验，并根据目前微动疲劳理论的最新研究成果，对微动疲劳损伤理论及寿命技术问题进行了深入研究。
首先，基于临界平面理论和微动促进了裂纹萌生和早期扩展的损伤机理，定义了一种微动损伤参量CSE（considering the multi-factor in the calculating of the Strain Energy），提出了微动疲劳寿命预测模型，开展了微动疲劳寿命的定量化研究。参量CSE考虑了几何特性、材料特性、载荷特性和表面状况等微动疲劳影响因素，不仅能够表征微动损伤中的能量耗散，而且可以解释微动疲劳现象中特有的接触特征。微动疲劳寿命CSE预测模型包含了材料普通疲劳特性，待定参数较少，适用于合金材料连接结构的微动疲劳寿命预测。
其次，基于封闭力系框架的结构设计，以疲劳试验机为平台，设计并实现了一套微动疲劳试验装置，开展了钛合金TC11与TC11接触、单晶高温合金DD3与粉末高温合金FGH95接触以及定向凝固高温合金DZ125与FGH95接触三种不同材料配对的微动疲劳试验研究，得到了相关的微动疲劳规律。微动疲劳试验研究表明：法向载荷的加载稳定，试验成功率高和可操作性强，所设计的试验装置性能良好；微动疲劳显著降低了材料的疲劳性能和疲劳寿命；法向载荷和轴向载荷对微动疲劳寿命均有影响，其中轴向载荷是微动疲劳寿命最主要的影响因素。
最后，将微动疲劳寿命的理论和试验研究相结合，开展了相关的数值分析研究，对各向同性材料和各向异性材料微动疲劳裂纹的萌生位置和方向以及寿命预测模型进行验证和对比，探讨了不同材料的微动损伤规律及损伤机理。研究表明：钛合金试验件以及榫连接结构预测结果的误差分散带在2倍因子以内，DD3的误差分散带在2.6倍因子以内，而DZ125的误差分散带则在2.8倍因子以内；新的微动损伤参量CSE能够较好地表征不同材料的微动疲劳特性，有效地预测裂纹萌生位置和生长方向，并且与试验结果基本吻合；各向异性材料的抗微动疲劳特性要优于各向同性材料。
Fretting damage known as "industry cancer", widely occurs to the junction between twomechanical components. Fretting fatigue failure in dovetail joints is one of main causes in aero-enginefailure. However, the experimental and theoretical research is not mature currently because of somany influence factors on fretting fatigue. Therefore, systematical research on fretting fatigueexperiments and life technology of dovetail joints are required and will contribute significant valuesin theoretical study and practical engineering applications.
The fretting fatigue experiments were conducted by the combination of theoretical andexperimental methods. According to the latest research of current fretting fatigue theories, in-depthresearch has been explored in this paper in order to solve the fretting damage and life technologyproblems.
First, a new fretting damage parameter CSE（considering the multi-factor in the calculating ofthe Strain Energy） was introduced and the quantitative research on a new fretting fatigue lifeprediction model was carried out, based on the critical plane theory and the damage mechanism, thefretting induced crack initiation and early propagation. The fretting damage parameter CSE considersmany factors including geometry characteristic, material characteristics, load characteristics, surfacecondition and so on，which can represent the energy loss in the fretting damage and explain thephenomenon of stress concentration in the fretting fatigue. The fretting fatigue life prediction modelof CSE contains general fatigue properties and less undetermined parameter, which is suitable for thelife prediction of a link structure of an alloy material.
Second, employing the concept of the overall balance framework in the structure design, aunique fretting fatigue test apparatus based on a fatigue testing machine has been designed andfabricated to characterize the fretting fatigue damage process with a facility to observe the crackwhich is being initiated in and around the contact zone during the test. There are three types ofcontacting pair among the fretting specimen and the pad including titanium alloy TC11and TC11,single crystal nickel DD3and powder metallurgy superalloy FGH95, directionally solidifiedsuperalloy DZ125and FGH95, and a relevant fretting fatigue law is obtained. The result shows goodloading stability of the normal load, high success rate and strong test maneuverability, and theequipment works well. Fretting fatigue significantly reduces fatigue performance and fatigue life ofthe material. The fretting fatigue life is affected by the normal load and the axial load, and the axialload is the most important influencing factor for the fretting fatigue life.
Finally, numerical analysis was carried out by the combination of theoretical and experimentalresearch on fretting fatigue life. The initiation location and orientation of the fretting fatigue crack andthe life prediction model for isotropic and anisotropic materials were validated and compared. Thefretting damage laws and damage mechanisms of different materials were also discussed. The resultof the CSE prediction model shows good agreement with experimental results. The CSE critical planeapproach is appropriate for predicting the initiation location and growth orientation of the frettingfatigue crack. The anisotropic material shows better resistance in fretting fatigue than the isotropicmaterial.
引文
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