机械零件疲劳损伤与磨损损伤强耦合模型及设计方法研究

The failure of mechanical products is mainly caused by fatigue damage and wear damage, and the single design method is widely used in traditional mechanical design. The traditional single design method reduces the precision of product design, and has seriously restricted the requirements of the performance and service life of modern mechanical products. At present, there is no coupled model and design method that can guide the mechanchcal design of fatigue-wear damage. This project aims to adopt theoretical research, numerical analysis and experimental testing methods to study the correlation and mechanism of the coupled effect of fatigue-wear damage, and put forward a design method and control strategy of coupled model of fatigue-wear damage. The research works as follow, the effect of key factors on acting law of surface crack initiation and growth, and relationship of fatigue-wear damage are analyzed, the relationship between numerical analysis index and experimental test index is established, the coupled mechanism is revealed. The contribution rate criterion for wear or fatigue damage to global damage is established, and coupled criterion without single significant damage is established, too. On the basis, the design method based on contribution rate and coupled of wear-fatigue damage are proposed. The sensitivity analysis of key factors is carried out, the responsivity function of coupled damage index is established, and the control strategy under the coupled action of fatigue-wear damage is put forward. In terms of theory and methodology, these innovative methods provide the support of applying active system design in engineering. Finally, to test the availability and the engineering value of the proposed methods, they are used to perform design, analysis and experimental testing of gear transmission system.

疲劳损伤和磨损损伤是导致机械零件失效主要模式，传统单一设计方法在传统机械设计中广泛应用，但是大大降低了产品设计精准度，严重制约现代机械产品性能及使用寿命提高。目前，还没有能够指导机械设计的疲劳损伤与磨损损伤耦合模型和设计方法。本项目采用理论研究、数值分析和实验测试方法，研究疲劳损伤与磨损损伤相关性和机理，建立耦合模型，提出一种疲劳损伤与磨损损伤强耦合设计方法。研究工作有：分析关重影响因素对表面裂纹萌生及扩展规律和损伤相关性，建立数值分析指标与实验测试指标关系，揭示耦合机理；建立疲劳损伤与磨损损伤对整体损伤贡献率判据，及无单一显著损伤强耦合判据，提出以贡献率为指标设计方法和疲劳损伤与磨损损伤强耦合设计方法；开展影响因素敏感度分析，建立耦合损伤指标响应度函数，提出控制策略。为工程荷载摩擦副系统设计提供理论和方法支撑。以齿轮传动系统为对象验证本项目所提方法的有效性和工程应用价值。

本项目针对同时存在疲劳损伤与磨损损伤耦合作用的荷载摩擦副系统开展研究。以典型荷载摩擦副系统为研究对象，以理论研究、数值仿真和试验相结合研究方法，以疲劳与磨损耦合损伤的同源关重影响因素作用特性分析，疲劳与磨损耦合损伤模型及设计分析方法建立，设计分析精准度和控制策略研究及齿轮传动的耦合损伤分析为主要研究内容。通过本项目的研究，确定了对疲劳损伤与磨损损伤共同作用的同源关重影响因素，得到了同源关重影响因素对耦合损伤的作用规律及寿命影响特性；基于旋转疲劳和摩擦磨损试验测试方法，研制了一种多功能磨损疲劳耦合试验测试装置，可以完成接触疲劳与磨损耦合损伤和弯曲疲劳与磨损耦合损伤的典型线接触耦合损伤试验测试；基于理论研究和试验方法，建立了弯曲疲劳与磨损耦合损伤模型及损伤判据，提出了一种弯曲疲劳与磨损耦合损伤设计分析方法；基于理论研究、数值分析和试验相结合的方法，建立了接触疲劳与磨损耦合损伤模型及损伤判据，提出了一种接触疲劳与磨损耦合损伤设计分析方法；基于Morris和Sobol两阶段灵敏度方法分析，提出了弯曲疲劳与磨损耦合损伤以及接触疲劳与磨损耦合损伤的控制策略，进而提出了具有针对性的提高耐磨损与疲劳损伤的方法和措施；完成了齿轮传动接触疲劳与磨损耦合损伤的分析研究，验证了研究提出的设计分析方法的有效性。本项目研究为典型线接触荷载摩擦副系统的设计分析提供了理论方法的有力支撑，可以有效提高高性能高可靠性要求的典型机械零件的设计精准度以及有效的控制策略。