Fatigue life prediction of hole edge structure of installation seat based on improved TCD-SWT model
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摘要:
为了对具有2D应力梯度的安装座孔边结构实现精确的疲劳寿命预测，提出了一种改进的TCD-SWT（theory of critical distance-Smith-Watson-Topper）寿命预测模型。针对厚度较大的安装座孔边结构，考虑其孔边2D应力梯度特征，对传统临界距离法进行改进；采用梯度下降法编制计算程序，提取出孔边应力集中处实际应力梯度线，并结合梯度线上的SWT参量确定临界距离，建立寿命预测模型。基于损伤等效原则发展了一种安装座孔边结构特征模拟件设计方法，实现模拟件与实际结构危险截面应力梯度及梯度线上的损伤参量分布均较为接近。通过开展模拟件高温疲劳试验，验证了改进TCD-SWT模型的预测精度。结果表明：改进模型相较于传统模型预测精度有较大提高，预测结果均在±1.4倍分散带以内。
Abstract:In order to accurately predict the fatigue life of the hole edge structure of the installation seat with a 2D stress gradient, an improved TCD-SWT (theory of critical distance-Smith-Watson-Topper) fatigue life prediction model was proposed. For the hole edge structure of the installation seat with relatively large thickness, the 2D stress gradient characteristics of the hole edge were considered, and the TCD method was improved. The gradient descent method was used to develop a computational program that extracted the actual stress gradient line at the stress concentration region of the hole edge. By combining the SWT parameters along the gradient line, the critical distance was determined, and a fatigue life prediction model was established. Based on the principle of damage equivalence, a feature simulation design method for the hole edge structure of the installation seat was developed, ensuring that the stress gradient and the distribution of damage parameters along the gradient line at the dangerous section of the simulated specimen closely resembled those of the actual structure. High-temperature fatigue tests on the simulated specimens were carried out to verify the prediction accuracy of the improved TCD-SWT model. The results showed that the improved model significantly enhanced the prediction accuracy compared with the traditional model, with prediction results consistently falling within a ±1.4 dispersion band.
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图 3 安装座及带孔薄板应力梯度云图
Figure 3. Stress gradient cloud map of installation seat and thin plate with hole
图 6 有效SWT参量$ {F_{{\text{SWT-eff}}}} $确定方法
Figure 6. Determination method of effective SWT parameter $ {F_{{\text{SWT-eff}}}} $
图 7 燃烧室机匣安装座仿真计算
Figure 7. Combustion chamber casing installation seat simulation calculation
图 8 安装座孔边模拟件设计图（单位：mm）
Figure 8. Design drawing of simulated component for hole edge of installation seat （unit：mm）
图 9 模拟件与机匣安装座危险截面应力梯度对比
Figure 9. Simulated parts and casing installation seat danger section stress gradient comparison
图 10 模拟件与机匣安装座危险截面损伤参量分布
Figure 10. Damage parameters distribution in the dangerous cross section of simulated parts and casing installation seat
图 14 安装座孔边模拟件典型疲劳断口
Figure 14. Typical fatigue breaks for hole edge of installation seat simulation
图 15 安装座孔边模拟件孔边裂纹萌生与扩展
Figure 15. Crack initiation and propagation of hole edge of installation seat simulation
图 18 模拟件$ L {\text{-}} N_{\text{f}}^* $曲线
Figure 18. $ L {\text{-}} N_{\text{f}}^* $curves of simulated parts
图 19 孔底边延长线损伤参量分布
Figure 19. Damage parameters distribution of the extension line at the bottom of seat hole
图 20 传统和改进TCD-SWT模型预测精度对比
Figure 20. Comparison of prediction accuracy between traditional and improved TCD-SWT models
表 1 SWT模型材料性能参数
Table 1. Material parameters of the SWT model
材料 温度/℃ $ {\dfrac{{ （{\sigma '_{\text{f}}}） }}{E}^2} $ $ {\varepsilon '_{\text{f}}}\sigma ' $ b c GH4169 600 11.185 8174.1 − 0.0759 − 1.0733 
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表 2 模拟件疲劳试验方案
Table 2. Fatigue test protocol for simulated parts
试验件 温度/℃ $ {\sigma _{{\text{nor}}}} $/MPa 数量/件 总计/件 安装座孔
边模拟件600 550 3 9 460 3 410 3
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表 3 模拟件600 ℃疲劳试验结果
Table 3. Fatigue test results of simulated parts at 600 ℃
$ {\sigma _{{\text{nor}}}} $/
MPa试验件
编号寿命$ {N_{\text{f}}} $/
周次平均寿命$ {\bar N_{\text{f}}} $/
周次550 GH-01 49369 59999 GH-02 59499 GH-03 71129 460 GH-04 134920 143693 GH-05 150247 GH-06 145912 410 GH-07 226672 246334 GH-08 271669 GH-09 240660
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表 4 不同载荷级临界距离
Table 4. Critical distances for different load levels
$ {\sigma _{{\text{nor}}}} $/MPa $ N_{\text{f}}^* $/周次 $ （\sigma _{\max }{\varepsilon _{\text{a}}}） _{{\text{eff}}}^{} $/MPa $ {D_{{\text{PM}}}} $ $ {D_{{\text{LM}}}} $ 550 58314 1.916 0.240 0.607 460 142177 1.667 0.262 0.618 410 252392 1.526 0.257 0.596
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表 5 模拟件平均临界距离
Table 5. Mean critical distance of simulated parts
方法 临界距离 PM 0.253r0 LM 0.607r0
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