表面残余损伤及内部损伤耦合作用下的可再制造性评价

Remanufacturability assessment is important for machinery remanufacturing processes, which determines whether the failed parts should be remanufactured according to the rules of damage formation and evolution. Previous studies found that: the residual surface damage and internal damage is the core factor which affects the residual intensity of remanufacturing object. Project intends to carry out research from three aspects: "damage features detection and characterization","residual intensity and remaining life prediction","remanufacturability evaluation model construction": (1)Detecting damage features of remanufacturing objects, researching the mechanism of damages formation, revealing transition rule of surface damage states, to determine the particularity of remanufacturing objects relative to new parts. (2) Analyzing and verifying the stress and strain field with the combined effects of residual surface damage and internal damage, predicting the residual intensity and remaining life based on the fatigue coupling theory, drawing the damage probability atlas with considering damage uncertainties, to solving the problem that life prediction technology of homogeneous material do not fully applicable to remanufacturing objects. (3) Studying the principle and method of determining fatigue critical threshold, constructing the multi-levels, multi-dimensions remanufacturability assessment model. The research results would have positive significance to enhance remanufacturability evaluation capacity.

可再制造性评价是机械装备再制造过程面临的首要问题，此类研究以损伤形成及演化规律为主要内容。前期研究发现："表面残余损伤"及"内部损伤"是影响再制造对象剩余寿命的核心因素。 项目从"损伤特性检测与描述"、"剩余强度/剩余寿命预测"、"可再制造性评价模型构建"3个环节展开研究：（1）检测再制造对象损伤特征，研究损伤形成机理，揭示"表面初始损伤-残余损伤"跃迁规律，描述损伤随机特征，以把握再制造对象特殊性；（2）分析、验证表面残余损伤及内部损伤耦合作用下的应力场、应变场，基于疲劳损伤耦合理论建立损伤演化场及剩余强度/寿命预测模型，考虑初始损伤随机特征建立概率损伤图谱，以突破均质材料寿命预测技术不完全适用于再制造对象的难题；（3）研究再制造对象损伤临界阈值界定原理与方法，建立多层次多维度可再制造性评价模型，系统评价机械装备可再制造性。研究成果对于提高我国废旧装备可再制造性评价能力具有积极意义。

项目组按计划完成了预定的各项研究内容，达到了研究计划预期的研究目标，项目围绕表面残余损伤及内部损伤耦合作用下的可再制造性评价，从多尺度、多损伤机制、多学科等角度对表面损伤及内部损伤检测、统计与分析技术，表面残余损伤-内部损伤耦合的寿命模型建立，再制造对象的剩余强度/剩余寿命预测与可靠性分析，可再制造型评价模型等进行了系统深入的研究。提出并形成了 3 点表面残余损伤与内部损伤耦合作用下疲劳寿命预测理论：基于位错滑移、能量理论和断裂力学的高周-超高周内部损伤疲劳理论，基于表面粗糙度等残余损伤疲劳寿命模型理论，基于改进灰色关联度的叶轮疲劳强度数据转换模型理论；突破了 2 项利用内部损伤理论模型进行可再制造性评价的关键技术：基于实验频率与工况差异性的超高周疲劳寿命数据修正技术，根据GBF 区域尺寸预测离心压缩机叶轮叶片可再制造性技术；建立了基于概率损伤疲劳和灰色关联度模型的离心压缩机叶轮疲劳强度评价标准和可再制造性评价。项目相关内容在国内外重要学术期刊发表 13 篇论文，其中在国际期刊发表 7篇、SCI 收录论文 7 篇、EI 收录论文 2 篇，获得发明专利 7 项。