线控制动系统滚珠丝杠副断裂分析与优化

Fracture Analysis and Optimization of Ball Screw in Brake-by-Wire Systems

  • 摘要: 针对线控制动系统滚珠丝杠副断裂情况,采用化学成分分析、硬度测试、金相组织分析、宏微观断口形貌分析、力学性能测试、应力仿真分析等方法,最终确定断裂原因为丝杠整体淬火热处理工艺导致其芯部韧性较差,同时丝杠结构设计存在应力集中,二者综合导致了丝杠的脆性断裂。针对该失效原因,给出调整丝杠热处理工艺、优化丝杠结构设计等改进措施并通过测试验证。

     

    Abstract: To address the fracture failure of ball screw in brake-by-wire systems, a comprehensive investigation was conducted by using chemical composition analysis, hardness testing, metallographic analysis, macro/microscopic fractography analysis, mechanical property testing, and stress simulation analysis. The fracture was ultimately attributed to two synergistic factors: insufficient core toughness due to improper through-hardening heat treatment of the screw, and structural stress concentration in the screw design. These combined effects resulted in brittle fracture of the screw. Corresponding improvement measures, including optimized heat treatment processes and structural design modifications, were proposed and validated through rigorous testing.

     

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