高性能斜圈弹簧形变机理及可靠性设计理论研究

Due to its unique structure and performance characteristics, canted coil springs are crucial parts of electrical fittings and high performance seal. Compared with imported products, domesticly produced canted coil springs have less reliability, lower fatigue life and poorer deformation curves flatness. In addition to the impacts of materials and manufacturing process, these significant disparities are mainly caused by the weakness of basic theory research and the lackness of test means on canted coil springs. .This project will take canted coil springs as the object of study. An universally applicable analysis model for canted coil springs considering variety of design factors will be set up in this project. The relationship between the design parameters and deformation curve flatness will be explored based on theoretical analysis and numerical simulation method. With the aid of the supposition - verification parameter estimation method and the proportion risk model, reliability assessment will be carried out. The reliability design research will be conducted using reliability assignment and the optimized algorithm method. An auto sizing device which is fast, highly effective and precise for canted coil springs test will be developed. Canted coil springs performance evaluation indicator system and the appraisal standard will be established; Canted coil springs elastic curve flatness test experiments will be carried out; Accelerated life tests of canted coil springs under the condition of static stress and alternate stresses will be investigated and the performance test database will be established. .All the above research works would help us fundamentally grasp the domestically produced canted coil springs design and the key performance test technologies so as to enhance canted coil springs design and performance test level in our country.

斜圈弹簧由于具有独特结构和性能特点，是电气连接件和高性能密封件的关键零件。目前国产斜圈弹簧在可靠性，疲劳寿命、变形曲线平直度等方面与进口产品存在较大差距。究其原因，除材料、制造工艺等方面的因素外，对其形变机理认识不足、设计方法陈旧、测试检验手段匮乏亦是重要原因。本项目拟针对斜圈弹簧建立考虑多种设计参数的普适分析模型，基于理论分析和数值仿真方法进行其设计参数与变形曲线平直度关系机理研究；借助假设-校验参数估计方法、比例风险模型进行可靠性评价；通过可靠度分配和优化算法进行可靠性设计；建立斜圈弹簧性能评价指标体系和评价规范，开发快速、高效、精确的斜圈弹簧变形曲线平直度自动测量装置，开展斜圈弹簧变形曲线平直度测试试验，在交变应力和静应力两种条件下进行加速寿命试验，建立性能试验数据库。旨在从根本上阐明高性能斜圈弹簧形变机理，掌握其可靠性设计方法和性能测试关键技术，提高我国斜圈弹簧设计和质量检验水平。

斜圈弹簧具有独特结构和力学性能特点，是电气连接件和高性能密封件的关键零件。本项目建立了包含多种结构要素的斜圈弹簧数学模型，给出了其曲率、挠率计算公式，推导了斜圈弹簧前角、后角、曲率、挠率等几何参数与其倾斜角之间的关系。基于莫尔积分法对其进行了力学性能分析，推导了斜圈弹簧弯矩与扭矩计算公式，利用弹性力学中的单位载荷法推导了斜圈弹簧的载荷—位移关系，给出了斜圈弹簧刚度计算理论公式；在ANSYS软件平台上基于APDL语言进行参数化编程，建立了斜圈弹簧力学性能分析的有限元模型，仿真计算了其在不同工况下的应力、应变值，探讨了斜圈弹簧各设计参数与其力—变形曲线之间的关系。 针对斜圈弹簧的变形及受力特点，提出了斜圈弹簧刚度测量的基本原理，完成了装夹夹具与斜圈弹簧刚度测量试验台的方案设计和样机制造，实测了多种型号斜圈弹簧在不同温度（室温至175℃）下的位移—载荷、时间—载荷、加载时间—加载速度等特性曲线，获得了大量试验数据。为评估斜圈弹簧的力学性能提供了可靠的实验数据。 针对斜圈弹簧极小样本无实效数据的特点，基于应力—强度干涉理论、强度退化模型、Monte-Carlo法和多层Bayes方法对斜圈弹簧可靠性分析与设计方法进行了研究，分析并模拟了斜圈弹簧在电力连接工作中的应力分布与强度分布，推导了其可靠度计算公式，分析了率参数与强度标准差对其可靠度的影响规律，为高质量高可靠性斜圈弹簧的研发与设计提供了理论指导。