冲击载荷作用下旋耕机机架焊接接头疲劳性能分析方法设计

Design of fatigue performance analysis method for welded joints of rotary tiller frame under impact load

  • 摘要: 旋耕机机架焊接接头在田间作业中承受由非均匀介质诱发的多轴冲击-随机振动复合载荷,其焊缝区域的局部应力场呈现高度非线性、非比例与非稳态演化特征,导致传统疲劳分析方法基于线性静力假设的名义应力法或热点应力法无法反映冲击载荷下应力波传播与反射叠加所形成的瞬态应力集中效应;导致有限元法在焊趾奇异场区因网格奇异性抑制失效,使疲劳损伤定位与寿命评估产生系统性偏差,提出一种引入虚拟缺口半径法的疲劳性能分析方法。该方法首先基于Ansys Workbench构建旋耕机机架有限元模型,通过模态分析与谐响应计算获取冲击载荷作用下焊接接头的动态应力响应;进而引入虚拟缺口半径法对焊趾区域进行应力重分布,结合应力集中系数与当量应力幅构建疲劳寿命预测模型,实现对焊接接头疲劳性能的精确评估。实验结果表明,在不同焊缝距离条件下,该方法预测寿命与实测值的相对误差保持在0.0371~0.0213之间,裂纹扩展速率预测精度高,归一化损伤比随网格尺寸变化波动小于0.1,具有良好的计算鲁棒性与工程适应性。该方法有效解决了传统方法在非比例多轴加载下精度不足、网格敏感性强等问题,为农机结构抗疲劳设计与可靠性评估提供了理论支撑与技术路径。

     

    Abstract: The welded joints of the rotary tiller frame are subjected to multi axis impact random vibration composite loads induced by non-uniform media during field operations. The local stress field in the weld area exhibits highly nonlinear, non proportional, and non steady state evolution characteristics, which leads to the inability of traditional fatigue analysis methods based on linear static assumptions such as nominal stress method or hot spot stress method to reflect the transient stress concentration effect formed by the propagation and reflection superposition of stress waves under impact loads; A fatigue performance analysis method incorporating the virtual notch radius method is proposed to address the systematic deviation in fatigue damage localization and life assessment caused by the suppression of mesh singularity in the weld toe singular field region of the finite element method. This method first constructs a finite element model of the rotary tiller frame based on Ansys Workbench, and obtains the dynamic stress response of the welded joint under impact load through modal analysis and harmonic response calculation; Furthermore, the virtual notch radius method is introduced to redistribute stress in the weld toe area, and a fatigue life prediction model is constructed by combining the stress concentration factor and equivalent stress amplitude, achieving accurate evaluation of the fatigue performance of welded joints. The experimental results show that under different weld distance conditions, the relative error between the predicted life and the measured value of this method remains between 0.0371 and 0.0213. The prediction accuracy of crack propagation rate is high, and the normalized damage ratio fluctuates less than 0.1 with the change of grid size. It has good computational robustness and engineering adaptability. This method effectively solves the problems of insufficient accuracy and strong grid sensitivity of traditional methods under non proportional multi axis loading, providing theoretical support and technical path for the anti fatigue design and reliability evaluation of agricultural machinery structures.

     

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