XD6113增压柴油机曲轴断裂故障分析与改进设计

发布时间：2018-04-12 21:11

本文选题：曲轴 + 失效分析　；参考：《广西大学》2016年硕士论文

【摘要】：曲轴是柴油机最重要的零部件之一,它的任务是将活塞的往复运动转换旋转运动,并向外输出功率。XD6113机型缸径为增压柴油机,在市场使用过程中出现了曲轴早期断裂的故障,出现故障的平均行驶里程为10万公里左右,曲轴的断裂位置均发生在曲轴曲柄销部位。本文通过对故障曲轴进行了回场分析,通过运用常规理化检验对断口部位、曲轴的材料组成进行失效分析,以及采用对曲轴进行有限元受力分析等方法,对曲轴曲柄销的断裂原因进行了综合分析,结果表明：由于XD6113机型的爆压过高,而曲轴的设计在与同等机型相比尺寸偏小,曲轴的安全系数储备不足,导致曲轴在使用过程中出现了疲劳断裂的故障。为了加强曲轴的疲劳强度,本文通过加宽加厚曲轴的曲柄、加大曲柄销圆角半径以及降低发动机爆压等手段进行了改进,并完善了曲轴制造工艺,增加了曲轴表面淬火层厚度,改善了曲轴表面强度,最终提高了曲轴的抗疲劳强度。经过疲劳试验,改进后的曲轴疲劳强明显提高。为了验证整改效果,对改进后的曲轴进行装机投放市场做跟踪验证,至今再无断裂反馈。本文对曲轴断裂的分析改进综合考虑了尺寸、生产工艺优化、用户的使用等情况,比较全面地阐述了曲轴断裂故障的改进方法,对今后的类似的故障分析具有现实的指导意义。
[Abstract]:Crankshaft is one of the most important parts of diesel engine. Its task is to convert the reciprocating motion of piston into rotational motion, and output power to the engine. XD6113 cylinder diameter is supercharged diesel engine. In the process of market use, the crankshaft breaks down in the early stage.The average driving mileage of failure is about 100000 km, and the fracture position of crankshaft occurs in the crankshaft crank pin.In this paper, the failure analysis of fault crankshaft, the failure analysis of fracture surface, the material composition of crankshaft, and the finite element force analysis of crankshaft are carried out by routine physical and chemical inspection.The fracture reason of crankshaft crank pin is analyzed synthetically. The results show that the design of crankshaft is smaller than that of the same type, and the safety coefficient of crankshaft is insufficient because of the high explosion pressure of the XD6113 model, and the design of crankshaft is smaller than that of the same type.The failure of the crankshaft caused by fatigue fracture occurred in the process of using the crankshaft.In order to strengthen the fatigue strength of the crankshaft, this paper has improved by widening the crank of the crankshaft, increasing the radius of the crank pin and reducing the explosion pressure of the engine, and perfecting the manufacturing process of the crankshaft and increasing the thickness of the quenched layer on the surface of the crankshaft.The surface strength of the crankshaft is improved, and the fatigue strength of the crankshaft is improved.After fatigue test, the fatigue strength of the improved crankshaft is obviously improved.In order to verify the effect of rectification, the improved crankshaft was put on the market to track and verify, so far no fracture feedback.In this paper, the analysis and improvement of crankshaft fracture have considered the dimensions, production process optimization and the usage of users, and the improvement method of crankshaft fracture fault has been expounded comprehensively, which has practical guiding significance for similar fault analysis in the future.
【学位授予单位】：广西大学
【学位级别】：硕士
【学位授予年份】：2016
【分类号】：TK428

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