Improved fatigue design method and experimental verification of low-pressure turbine shaft
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摘要:
总结了轴高低周复合疲劳设计名义应力法的两种传统方法：大扭矩当量稳态剪应力方法和多轴等效应力方法。由于这两种传统方法存在以下适用局限性：大扭矩当量稳态剪应力方法仅适用于轴弯矩载荷可忽略的部位；多轴等效应力方法仅适用于应力集中系数可忽略的部位疲劳储备评估，不适用于疲劳寿命及累积损伤评估。参考了多份相关资料中的疲劳设计方法，提炼优点，规避缺点，提出了适用范围更广泛、理论原理更合理的轴改进疲劳设计方法，应用于某低压涡轮轴高低周复合疲劳设计，并经试验验证分析。结果表明：该改进方法计算结果与两个阶段试验现象吻合，疲劳损伤偏差为12.6%，明显好于传统方法的84.7%，满足寿命分析结果误差控制在2倍散度以内(即误差范围为−50%～100%)的通常工程要求。
Abstract:Two traditional methods of nominal stress method for shaft high-low cycle combined fatigue design were summarized: large torque equivalent steady-state shear stress method and multi-axis equivalent stress method. These two traditional methods have the following limitations: the large torque equivalent steady-state shear stress method is only suitable for shaft parts with negligible bending moment load; and the multi-axis equivalent stress method is only suitable for fatigue reserve evaluation of parts with negligible stress concentration coefficient, but not for fatigue life and cumulative damage evaluation. Referring to the fatigue design methods in many related books, the advantages were refined while avoiding the disadvantages, an improved fatigue design method of shaft with wider application scope and more reasonable theoretical principle was put forward, which was then applied to the high-low cycle combined fatigue design of a low-pressure turbine shaft, and also the experimental verification. The results showed that the calculation results of this improved method coincided with the phenomena of the two-stage test, and the fatigue damage deviation was 12.6%, which was significantly better than that of the traditional method (84.7%), and met the engineering needs of the life analysis results within 2 times the scattering error control (i.e., error range: −50%—100%) of the usual requirements.
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图 4 低压涡轮轴二维结构（含典型截面位置）示意图
Figure 4. Schematic diagram of two-dimensional structure of low-pressure turbine shaft （including typical section position）
图 5 低压涡轮轴有限元仿真模型
Figure 5. Finite element simulation model of low-pressure turbine shaft
图 7 低压涡轮轴高低周复合疲劳试验加载载荷谱
Figure 7. Load spectrum of low-pressure turbine shaft in high-low cycle combined fatigue test
图 9 低周载荷作用下的等效应力分布图
Figure 9. Equivalent stress distribution diagram under low cycle load
图 10 高周载荷作用下的等效应力分布图
Figure 10. Equivalent stress distribution diagram under high cycle load
图 11 高低周复合载荷作用下的等效应力分布图
Figure 11. Equivalent stress distribution diagram under high-low cycle combined load
表 1 分散系数u、f4和f5的取值建议
Table 1. Suggestions on the values of dispersion coefficients u, f4 and f5
参数 锻件或机械加工件 焊接件或铸件 u 1.1 1.3 f4 1.1 1.3 f5 1.4 1.9 
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表 2 两个阶段复合疲劳试验载荷谱的具体试验加载载荷
Table 2. Specific test load of two-stage combined fatigue test load spectrum
参数 第1阶段
（载荷谱1）第2阶段
（载荷谱2）低周载荷 轴向力/N 71990 84000 主扭矩/（N·m） 21682 24500 高周载荷 振动扭矩/（N·m） 2760 3000 弯矩/（N·m） 2740 3700 高低周载荷频率比 1112 ∶11112 ∶1
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表 3 有限元局部应力计算结果
Table 3. Finite element calculation results of local stress
参数 主循环（低周）局部
等效应力最大处次循环（高周）局部
等效应力最大处主次循环（高低周）复合局部
等效应力最大处节点号 43306 45261 45604 离轴外表面距离/mm 1.03 1.04 1.73 主循环（低周）局部
应力分量σr,l/MPa 106 101 176 σθ,l/MPa 472 340 529 σz,l/MPa 544 623 503 τrθ,l/MPa −6 −26 0 τzθ,l/MPa 495 433 501 τzr,l/MPa 4 −26 −6 主循环（低周）局部
等效应力σeq,l/MPa 948 879 932 次循环（高周）局部
应力分量σr,h/MPa 12 18 24 σθ,h/MPa 51 70 96 σz,h/MPa 58 139 96 τrθ,h/MPa −1 3 7 τzθ,h/MPa 53 93 94 τzr,h/MPa 0 6 6 次循环（高周）局部
等效应力σeq,h/MPa 101 193 179
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表 4 疲劳强度储备、寿命和累积损伤计算结果
Table 4. Calculation results of fatigue strength reserve, life and cumulative damage
参数 传统方法一 传统方法二 改进方法一 改进方法二 疲劳强度储备最低的节点号 45604 45261 45261 试验载荷谱1 轴疲劳储备系数Kf 1.94 0.98 1.39 1.41 轴考虑分散系数的疲劳储备系数$K'_{\mathrm{f}} $ 1.49 1.06 1.09 轴复合疲劳的低周寿命Ni 76456 14487 18411 轴经历的低周循环数ni 9000 9000 9000 9000 轴的累积损伤Di 0.1177 0.6213 0.4888 试验载荷谱2 轴疲劳储备系数Kf 1.73 0.85 1.20 1.22 轴考虑分散系数的疲劳储备系数$K'_{\mathrm{f}} $ 1.33 0.91 0.93 轴复合疲劳的低周寿命Ni 43076 1875 2391 轴经历的低周循环数ni 1523 1523 1523 1523 轴的累积损伤Di 0.0354 0.8124 0.6369 2个试验载荷谱轴的总累积损伤Dz 0.1531 1.4336 1.1257 总累积损伤Dz的误差（计算相对于试验结果）/% −84.7 43.4 12.6
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