锻压技术

某商用车前轴早期疲劳断裂失效模式及原因分析

英文标题：Early fatigue failure modes and cause analysis on front axle in a commercial vehicle

作者：王欢锐周彬刘荣田婧

单位：陕西汉德车桥有限公司

分类号：TG142.41

出版年,卷(期):页码：2020,45(7):192-197

摘要：

研究了某商用车前轴在垂直弯曲疲劳试验中的失效模式及失效位置的形貌，前轴的主要断裂位置均位于下受拉面的工字截面、矩形截面和拳头孔内侧。结合前轴的加工、锻造、修磨及强力喷丸等生产工艺过程，系统地分析了前轴失效的主要原因及机理，其原因主要包括：锻造过程中的表面折叠、脱碳，切飞边过程中切边模处缺陷导致的槽状拉痕和折叠，喷丸过程中喷丸强度不足，表面不平，修磨过程中导致的应力集中、微动磨损等。最后，针对上述失效原因，对前轴整个加工过程进行了优化，尤其是关键工艺过程，优化后的前轴疲劳台架试验寿命达到100万次。

The failure mode and the morphology in failure position appearing in vertical bending fatigue test for front axle in a commercial vehicle were studied, and the main fracture positions of front axle were located in the I-section, rectangular section and inner of fist hole in lower tension surface. Combined with the production process of machining, forging, grinding and strong shot peening for front axle, the main reasons and mechanism of front axle failure were systematically analyzed, and the main reasons included surface folding and decarburization during the forging process, groove-like pull marks and folds caused in defects at the trimming die during the trimming process, insufficient shot peening strength during the shot peening process, uneven surface, stress concentration and fretting wear caused in the grinding process. Finally, aiming at above failure reasons, the entire process of front axle was optimized, especially the key technological process, and the life of optimized front axle in fatigue bench test reached one million cycles.

基金项目：

王欢锐（1983-），女，硕士，高级工程师 E-mail：happywhr@163.com

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