基于圆角滚压工艺的曲轴疲劳行为研究

利用有限元计算软件Abaqus,采用三维显式动力学计算,模拟曲轴圆角滚压过程。利用软件自带的二次开发程序,编写数据采集程序,得到了曲轴圆角表面和内部的应力分布情况。参照曲轴真实疲劳试验,对曲轴进行模拟弯曲疲劳试验,得到不同弯矩水平下曲轴圆角应力分布情况。将模拟弯曲疲劳试验得到的圆角工作应力与滚压后的圆角残余应力进行耦合计算,获得更为准确的曲轴疲劳强度,并依此对曲轴滚压参数进行优化,优化后的曲轴疲劳极限弯矩提高15.7%。

Fatigue Analysis of Crankshaft Based on Fillet Rolling Process

With the ABAQUS software,the fillet rolling process of crankshaft was simulated based on the three-dimensional explicit dynamic calculation.The data acquisition program was compiled based on the software-owned secondary development function.The distribution of surface and interior stress for the crankshaft was obtained.Referring to the actual fatigue test,the simulated fatigue bending test was carried out and the stress distribution of crankshaft fillet under different bending moments was acquired.Coupling the simulated working pressure and the rolling residual stress of fillet,the more accurate crankshaft fatigue strength was acquired and the rolling parameters were further optimized.By optimization,the crankshaft fatigue strength was improved by 15.7%.