| 引用本文: | 王燕礼,朱有利,刘忠伟,唐亮.HXD1机车牵引电机转轴组件断裂失效分析[J].材料科学与工艺,2016,24(4):67-73.DOI:10.11951/j.issn.1005-0299.20160410. |
| WANG Yanli,ZHU Youli,LIU Zhongwei,TANG Liang.Fracture failure analysis of the pulling motor revolving shaft subassembly of HXD1 locomotive[J].Materials Science and Technology,2016,24(4):67-73.DOI:10.11951/j.issn.1005-0299.20160410. |
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| 摘要: |
| HXD1型电力机车的牵引电机转轴和小齿轮轴采用圆锥过盈配合传动结构(下称转轴组件)，使用中该组件出现了早期断裂失效.本文通过理化检测、断口和配合面宏/微观形貌观察等失效分析技术对失效组件进行了分析.结果表明，材料成分、组织和显微硬度正常，小齿轮轴和电机转轴的失效形式分别为高周疲劳断裂和微动疲劳断裂.造成组件失效的原因和过程是，小齿轮轴近齿端油槽-油孔交界线处有较大的结构应力集中，油槽底部周向加工刀痕造成附加应力集中，在应力集中和旋转弯曲疲劳载荷作用下油孔边两个应力集中点萌生了疲劳裂纹并扩展；随小齿轮轴裂纹的不断扩展转轴组件结构刚度减小，继而诱发了与小齿轮轴匹配的电机轴配合面的微动疲劳，电机轴疲劳裂纹萌生于微动区的边缘处；电机转轴先于小齿轮轴完全断裂.基于本文的分析结果提出了提高组件抗疲劳断裂的技术措施.
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| 关键词: 机车 转轴组件 应力集中 微动疲劳 高周疲劳 圆锥过盈配合 |
| DOI：10.11951/j.issn.1005-0299.20160410 |
| 分类号:TJ811 |
| 文献标识码:A |
| 基金项目: |
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| Fracture failure analysis of the pulling motor revolving shaft subassembly of HXD1 locomotive |
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WANG Yanli1,ZHU Youli1,LIU Zhongwei2,TANG Liang2
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(1.Faculty of Maintenance and Remanufacture Engineering, Academy of Armored Force Engineering, Beijing 100072,China; 2.CSR Qishuyan Locomotive & Rolling Stock Technology Research Istitute, Changzhou 213011, China)
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| Abstract: |
| The pulling motor revolving shaft subassembly of HXD1 locomotive produced early fracture failure, which is interference fits composed of a gear shaft and a motor shaft. Physical test, chemical test, macroscopical morphology and microcosmic morphology analysis for the fractured surfaces and interference fit surfaces are performed. It shows that, with proper chemical composition, microstructure, and micro-hardness, the gear shaft is high cycle fatigue fracture and the motor shaft is fretting fatigue. The failure causation and procedure are that, the structure stress concentration at the inter-spot of the oil groove and oil hole close to the gear conjunction with the additional stress concentration due to hoop machine mark on the oil groove surface contributed to the fatigue crack initiation at the both stress concentration points of the gear shaft; and then, the increased fatigue cracks of gear shaft reduced the coupling stiffness of subassembly, which gave rise to fretting between the surfaces of crack-corresponding interference fits, hence, fretting brought fatigue cracks nucleation sites at the micro-cracks induced fretting at the edges of bedding; the motor shaft fractured clearly prior to the gear shaft. Recommendations for improving anti-fatigue performance of subassembly were suggested based on the failure analysis conclusion.
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| Key words: locomotive revolving shaft subassembly stress concentration fretting fatigue high cycle fatigue cone interference fits |
