Effect of nonuniform stress between holes on failure behavior of thin plate with holes
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摘要:
针对燃气涡轮发动机中带密布孔薄壁结构特征引起的疲劳-蠕变开裂问题，设计了带单孔、双孔的DZ125薄壁平板试样，开展了850 ℃、应力比为0.1的高温疲劳-蠕变试验研究。基于双孔薄板的弹塑性有限元分析结果，确定两孔之间的应力最大路径为关键区域，定义了描述多孔平板复杂应力状态的孔间等效应力。有限元分析和试验结果表明：孔间非均匀应力是决定多孔平板循环寿命的关键因素，循环寿命随孔间等效应力的增加而减小；沿加载方向的拉伸应力是带孔薄板疲劳-蠕变破坏的主导应力，裂纹起源于边缘孔高应力区。距径比在临界值4.22左右，等效应力变化较大，在设计时应将距径比控制在该临界值以上。
Abstract:In view of the problem of creep-fatigue cracking caused by thin-walled structure with dense holes in gas turbine engine, the DZ125 thin-walled plate specimens with holes were designed, and the creep-fatigue test was carried out at 850 ℃. Based on the elastic-plastic finite element analysis results of double-hole thin plate, the maximum stress path between two holes was defined as the critical area, and the equivalent stress between holes describing the complex stress state of the plate with holes was proposed. The finite element analysis and test results illustrated that the non-uniform stress between holes is the key factor to determine the cycle life; the cycle life decreased with the increase of the equivalent stress between holes. In addition, the tensile stress along the loading direction is the dominant stress of creep-fatigue failure of thin plate with holes; and the crack was originated from the high stress area of edge holes. Finally, when the the ratio of distance between adjacent holes to the diameter was about 4.22, the equivalent stress changed significantly, so the parameter should be controlled above this critical value in the design.
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图 2 带孔平板550 MPa含孔截面名义应力下的拉伸应力云图
Figure 2. Tensile stress distribution of flat specimen under nominal stress of 550 MPa
图 3 近似无限大带双孔平板100 MPa含孔截面名义应力下的拉伸应力云图
Figure 3. Tensile stress distribution of approximately infinite double-holes plate under nominal stress of 100 MPa
图 6 带双孔平板的孔间等效应力及理论应力集中因子随RDD的变化规律
Figure 6. Law of equivalent stress between holes and stress concentration factor of double-holes flat plate with RDD
图 7 归一化孔间等效应力与归一化Kt分布
Figure 7. Comparison of normalized equivalent stress between holes and normalized Kt of double-holes flat plate
图 10 带单孔平板试样在550 MPa名义应力、120 s保载时间条件下的断口及断后侧面形貌
Figure 10. Fracture morphology and side morphology of single-hole plate under 550 MPa nominal stress and 120 s holding times
图 11 带双孔平板试样（RDD=2）在550 MPa名义应力、120 s保载时间条件下的断口及断后侧面形貌
Figure 11. Fracture morphology and side morphology of double-holes plate （RDD=2） under 550 MPa nominal stress and 120 s times
表 1 试验矩阵
Table 1. Test matrix
类型 编号 R ${\sigma _{ {\text{nom} } }/ }$
MPa保载时间/s 单孔板 S0-1 0.1 450 30 S0-2 550 30 S0-3 550 60 S0-4 550 120 双孔板
（RDD =2）D2-1 0.1 450 30 D2-2 550 30 D2-3 550 60 D2-4 550 120 双孔板
（RDD =3）D3-1 0.1 550 30 D3-2 550 60 D3-3 550 120 
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表 2 试样有限元模型网格和单元数
Table 2. Mesh attribute parameters of the finite element model of each sample
试样类型 单元数 节点数 单孔板 142052 154656 双孔板 （RDD=2） 51520 59081 双孔板 （RDD=3） 52500 61226
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表 3 两距径比带双孔板试验结果对比
Table 3. Comparison of two-diameter ratio double-hole flat plate
RDD 循环寿命（${\sigma _{{\text{nom}}}}$=550 MPa） Kt ${\sigma _{ {{\rm{equ}}} } }$/MPa t=30 s t=60 s t=120 s 2 1089 400 362 2.500 777.4 3 1526 1057 580 2.502 619.4
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