多轴非比例载荷谱条件下高强度螺栓疲劳强度分析
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摘要
以风机主齿轮箱的箱体连接螺栓疲劳强度分析为研究背景,提出一种在多轴非比例载荷谱作用下高强度螺栓连接疲劳强度的分析方法。该方法基于多轴疲劳理论,将外部多轴非比例的风力载荷谱通过连接箱体模型有限元应力计算及雨流计数处理,转化为螺栓各对应载荷方向上的应力雨流谱,然后在螺栓各计算点处进行各载荷方向上的应力合成,按照德国VDI2230标准的计算方法,结合螺栓材料的应力寿命(S-N)曲线,计算得到螺栓各计算点的疲劳损伤率,最后依据线性损伤累计理论,得出连接螺栓的疲劳安全系数。依据本文中的分析方法编制螺栓疲劳强度计算程序,再以某一型号风机齿轮箱的扭力臂与齿圈连接螺栓为例,计算得到该螺栓在风机20年工作寿命内的疲劳安全系数为1. 819。提出的方法为今后计算复杂载荷工况下的螺栓疲劳强度提供了一个新方向。
A method about fatigue strength analysis of high-strength joint bolts was proposed on the background of gearbox housing joint design of the wind turbine. The method was based on the theory of multi-axial fatigue. And the calculation process of the method described as following: first,the multi-axial non-proportional loads,which loading on the hub blade because of natural wind,were transformed into corresponding stress spectrum after the process of the stress calculation of housing FE model and the stress treated according to the rain-flow counting rules. Second,the Mises stress was synthesized at the calculation nodal location of the bolt cross section from the multi-axial stress spectrum. And third,the fatigue damage of the nodal location was calculated according to the VDI2230 standard under the consideration of the bolt material S-N curve. Finally,the fatigue safety factor of the joint bolts was obtained according to the theory of Palmgren-Miner. Application software was programmed according to the method. With the software,a case of high-strength joint bolt fatigue strength was analyzed,and the fatigue safety factor is1. 819 within the design life of 20 years. The paper proposes a new way to evaluate the fatigue strength of high-strength joint bolts under complex loading condition.
A method about fatigue strength analysis of high-strength joint bolts was proposed on the background of gearbox housing joint design of the wind turbine. The method was based on the theory of multi-axial fatigue. And the calculation process of the method described as following: first,the multi-axial non-proportional loads,which loading on the hub blade because of natural wind,were transformed into corresponding stress spectrum after the process of the stress calculation of housing FE model and the stress treated according to the rain-flow counting rules. Second,the Mises stress was synthesized at the calculation nodal location of the bolt cross section from the multi-axial stress spectrum. And third,the fatigue damage of the nodal location was calculated according to the VDI2230 standard under the consideration of the bolt material S-N curve. Finally,the fatigue safety factor of the joint bolts was obtained according to the theory of Palmgren-Miner. Application software was programmed according to the method. With the software,a case of high-strength joint bolt fatigue strength was analyzed,and the fatigue safety factor is1. 819 within the design life of 20 years. The paper proposes a new way to evaluate the fatigue strength of high-strength joint bolts under complex loading condition.
引文
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[8]International Standard.IEC 61400-4:2012(E)Wind Turbines Part 4[R].Design Requirements for Wind Turbine Gearboxes,2012:83.
[9]VDI2230 Part 1.Systematic Calculation of High Duty Bolted Joints,Joints with One Cylindrical Bolt.Verein Deutsche Ingenieure,Düsseldorf,Germany,February,2003:62-74;2003:79-80.
[10]李舜酩,机械疲劳与可靠性设计[M].北京:科学出版社,2006:118-120.LI ShunMing,Mechanical fatigue and reliability design[M].Beijing:Science Press,2006:118-120(In Chinese).
[2]杨建伟,张建国.机械设备连接螺栓的失效分析[J].机械强度,2008,30(4):683-686.YANG Jian Wei,ZHANG Jian Guo.Failure analysis on coupling bolts for machinery equipment[J].Journal of Mechanical Strength,2008,30(4):683-686(In Chinese).
[3]王辉,李晓龙,王罡,等.大型风电齿轮箱的失效问题及其设计制造技术的国内外现状分析[J].中国机械工程,2013,11(6):1542-1549.WANG Hui,LI Xiao Long,WANG Gang et al.Research on failure of wind turbine gearbox and recent development of its design and manufacturing technologies[J].China Mechanic Engineering,2013,11(6):1542-1549(In Chinese).
[4]谢里阳,刘建中,吴宁祥,等.风电装备传动系统及零部件疲劳可靠性评估方法[J].机械工程学报,2014,50(11):1-8.XIE Li Yang,LIU JianZhong,WU NingXiang et al.Fatigue reliability evaluation method for gearbox component and system of wind turbine[J].Journal of Mechanical Engineering,50(11):1-8(In Chinese).
[5]李振强.兆瓦级风力发电机高强度螺栓联接静力学性能分析[D].长沙:湖南大学,2013:28-48.LI ZhenQiang.Static analysis on high strength bolt connection in the MW wind turbine generator system[D].Changsha:Hunan University,2013:48-48(In Chinese).
[6]MARCELO,A.L.,UEHARA,A.Y.,et al.Fatigue Properties of High Strength bolts[J].Procedia Engineering,2011,10:1297-1302.
[7]尹益辉,余绍蓉.基于3D有限元模拟的螺栓接头变形-内力关系及设计中的应用[J].机械强度,2008,30(6):947-952.YIN Yi Hui,YU ShaoRong.Relations between internal forces and deformation of a bolt joint with their application to design based on3D FEM simulation[J].Journal of Mechanical Strength,2008,30(6):947-952(In Chinese).
[8]International Standard.IEC 61400-4:2012(E)Wind Turbines Part 4[R].Design Requirements for Wind Turbine Gearboxes,2012:83.
[9]VDI2230 Part 1.Systematic Calculation of High Duty Bolted Joints,Joints with One Cylindrical Bolt.Verein Deutsche Ingenieure,Düsseldorf,Germany,February,2003:62-74;2003:79-80.
[10]李舜酩,机械疲劳与可靠性设计[M].北京:科学出版社,2006:118-120.LI ShunMing,Mechanical fatigue and reliability design[M].Beijing:Science Press,2006:118-120(In Chinese).