Finite element study on effect of fretting wear on crack initiation of dovetail
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摘要:
研究了燕尾榫连接结构微动磨损对裂纹萌生的影响。基于球/平面模型，通过与已有文献对比验证了有限元微动磨损模拟和Smith-Watson-Topper（SWT）参数值计算的正确性。建立燕尾榫连接结构二维有限元分析模型，计算接触表面的SWT参数值，通过对比发现：随着循环次数的增加磨损加剧导致SWT参数值下降，即微动磨损降低了裂纹萌生的风险；同时还发现未发生磨损时，SWT参数最大值出现在接触表面上边缘，磨损后由于上边缘磨损量远大于下边缘，SWT最大值转移到下边缘，即燕尾榫裂纹萌生的位置从未磨损时的上边缘转移到磨损后的下边缘。考虑微动磨损的影响，讨论了摩擦因数、底角和离心力对燕尾榫SWT参数值的影响规律，研究发现：随着摩擦因数的减小表面接触状态从部分滑移变成完全滑移，表面磨损量逐渐增加，SWT参数值会不断减小；45°的燕尾榫底角与其他角度时相比，SWT参数值最小且结构最可靠；随着离心力增加接触表面变形和应力都会增大，所以SWT参数值会逐渐增加。
Abstract:The influence of fretting wear on crack initiation of dovetail joint structure was studied. The ball/plane finite element model was established, and the method of the fretting wear simulation and Smith-Watson-Topper (SWT) parameter calculation was given and verified by comparing with existing literature. A two-dimensional finite element analysis model of dovetail structure was established, and SWT parameter values of contact surface were calculated. It was found that fretting wear made stress distribution uniform and the SWT parameter values decline, so the risk of crack initiation was reduced. Because the wear on the upper edge was much greater than that on the lower edge, the location of SWT maximum value transferred from the upper edge of initial stage (no wear) to the lower edge, then, fretting wear made crack initiate on the lower edge. Considering fretting wear, the influences of friction coefficient, base angle and centrifugal force on SWT parameters of dovetail were discussed, and the fretting behavior between contact surfaces of dovetail structure was studied. The results showed that with the decrease of friction coefficient, the surface contact state changed from partial slip to complete slip, and the increase of surface wear resulted in the decline of SWT parameter. When the dovetail angle was 45°, the SWT parameters value was the smallest and the structure was the most reliable. With the enlargement of centrifugal force, the contact surface deformation and stress increased, so the SWT parameter could gradually augment.
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Key words:
- dovetail /
- fretting wear /
- fretting fatigue /
- finite element analysis /
- crack initiation
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图 5 燕尾榫图和燕尾榫连接结构示意图
Figure 5. Dovetail tenon and schematic of dovetail joint structure
图 13 磨损后的磨损深度图和SWT 参数值分布
Figure 13. Wear depth map and SWT parameter distribution after wear
图 14 不同磨损次数后的SWT最大值和最大值坐标
Figure 14. SWT maximum value and maximum coordinates after different wear times
图 18 不同摩擦因数下的相对滑移图
Figure 18. Relative slip diagram for different friction coefficients
图 19 不同摩擦因数下的SWT参数值分布
Figure 19. SWT parameter distribution under different friction coefficients
图 20 不同摩擦因数下的SWT最大值
Figure 20. SWT maximum value under different friction coefficients
图 22 不同底角的SWT最大值和最大值坐标
Figure 22. SWT parameter distribution with different base angles
图 23 不同离心力下的SWT参数值分布
Figure 23. SWT parameter distribution under different centrifugal forces
图 24 不同离心力下的SWT参数值分布
Figure 24. SWT maximum and maximum coordinates under different centrifugal forces
表 1 不同摩擦因数下磨损深度和SWT参数值
Table 1. Wear depth and SWT parameter values under different friction coefficients
摩擦
因数最大磨损
深度/μmSWT最大值/
MPa裂纹起裂
位置0.9 1.24 3.10 上边缘 0.5 1.57 1.89 下边缘 0.1 5.46 0.56 上边缘 
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