千米深井提升钢丝绳多轴微动疲劳损伤演化与寿命预测研究

The hoisting rope is the key transmission component of coalmine hoisting equipment. Service lives of hoisting ropes in 47 km deep coalmines in China range only from 3 to 6 months, which greatly affects the safety production and the security of personnel life in coalmine. The hoisting rope in km deep coalmine will be taken as the research object in this project. Firstly, a virtual prototype model of a vertical shaft friction hoist system and a finite element model of hoisting rope-liner-drum are established to study the effects of working condition parameters of coalmine hoist on load spectrums, and on fretting damage and fatigue parameters of the hoisting rope under cyclic bending, respectively. Secondly, In order to quantitatively reveal the dynamic wear evolution, fretting fatigue crack initiation and propagation laws of steel wires, and to develop the multiaxial fretting fatigue life prediction model of steel wires, the finite element model of fretting fatigue damage evolution of steel wires under combined tension and torsion is established and the fretting fatigue tests of steel wires under combined tension and torsion is carried out. Finally, the dynamic fracture order criterion of steel wires in hoisting rope is proposed. The bending fatigue life prediction model of the rope is developed based on the dynamic multiaxial fretting fatigue fracture of steel wires. The roles of working condition parameters of coalmine hoist on the bending fatigue life of hoisting rope is studied in order to obtain the optimized working condition parameters of coalmine hoist to increase the rope life. In order to validate the bending fatigue life prediction model, the bending fatigue tests of steel wire rope are carried out under multiple cyclic stress levels. Research results will improve the safety and reliability of the deep shaft hoist system and avoid safety accidents.

提升钢丝绳是矿山提升装备的关键传动部件，全国千米深井达47个，其提升钢丝绳寿命仅为3-6个月，严重影响煤矿安全生产和矿工生命安全。本项目以千米深井提升钢丝绳为研究对象，构建摩擦提升系统虚拟样机和钢丝绳-衬垫-滚筒有限元模型，掌握循环弯曲提升钢丝绳的载荷谱与微动损伤和疲劳参数及其受提升机工况参数的影响规律；构建拉伸-扭转复合载荷下钢丝微动疲劳损伤演化有限元模型，开展拉扭复合作用下钢丝微动疲劳实验，定量揭示钢丝的动态磨损演化、微动疲劳裂纹萌生和扩展规律，构建钢丝多轴微动疲劳寿命预测模型；提出钢丝绳内钢丝的动态断裂次序判别准则，建立基于钢丝动态多轴微动疲劳断裂的钢丝绳弯曲疲劳寿命预测模型，研究提升机工况参数对提升钢丝绳弯曲疲劳寿命的影响规律，获得提高钢丝绳寿命的最优提升机工况参数，开展多级交变应力下钢丝绳弯曲疲劳实验进行验证。研究成果对提高深井提升系统安全性与可靠性、避免安全事故发生有重要意义。

已探明煤炭资源53%深埋在千米以深地层，千米深井提升装备的关键传动部件—提升钢丝绳服役寿命短严重影响煤矿安全生产和矿工生命安全，扭转应力严重制约着提升钢丝绳寿命。因此，本项目开展了千米深井提升钢丝绳多轴微动疲劳损伤演化与寿命预测研究。依据立井摩擦式提升系统虚拟样机模型、提升静、动力学分析，获得了提升循环中钢丝绳动态张力、动态扭矩等演化；通过直拉和弯曲钢丝绳有限元分析获得了不同提升工况参数下钢丝绳内部钢丝间、股间的微动损伤和拉扭疲劳参数以及钢丝绳-摩擦衬垫间动态接触和滑移参数；运用自制试验台开展钢丝多轴微动疲劳实验，结合CT和有限元仿真技术、疲劳和断裂力学理论定量揭示了多轴微动疲劳过程中钢丝动态磨损演化、裂纹萌生和扩展规律，构建了钢丝多轴微动疲劳寿命预测模型；运用自制试验台开展钢丝绳变载弯曲疲劳实验，提出了弯曲提升钢丝绳内部钢丝的动态断裂次序判别准则，构建了基于绳内钢丝动态多轴微动疲劳断裂的钢丝绳弯曲疲劳寿命预测模型，通过实验验证所建模型有效性，探讨了钢丝绳弯曲疲劳寿命与提升机工况参数的关联关系。结果表明，动态张力和扭矩均呈波动状变化，微动损伤和拉扭疲劳参数范围均随矿井提升参数的增加而呈扩大或上升扩大趋势；在不同交叉角下，随着疲劳次数的增加，椭圆状磨痕磨损深度、磨损面积均呈增大趋势，磨损系数先增或减后保持稳定，裂纹扩展深度和扩展速率增加；随着接触载荷和微动振幅的增加，疲劳钢丝接触面裂纹萌生变得困难和容易；随着接触载荷和扭转角增加，椭圆磨痕长轴轴向偏转角、磨损尺寸、摩擦系数和最大裂纹深度均呈增大趋势，多轴微动疲劳损伤加剧；垂直交叉角时疲劳钢丝多轴微动疲劳寿命预测值与实验值吻合较好；报废时弯曲提升钢丝绳断丝主要发生在直股-螺旋股接触部位，而其它部位主要为磨损；小提升质量和高提升速度导致较大钢丝绳弯曲疲劳寿命。研究成果对提高深井提升系统安全性与可靠性和避免安全事故发生有重要意义。