城市处置危险废物固体泵闸板断裂失效机理研究

Failure Mechanism of the Gate of the Solid Pump for Urban Hazardous Waste Disposal

  • 摘要: 城市处置危险废物是国家解决危险废物问题的重点项目,开展闸板断裂失效分析研究,不仅为危险废物处置行业进行产品设计提供了基础数据,而且打破国外设备在国内的垄断,突破卡脖子的技术封锁,研发出替代进口的核心零部件,降低危废处置单位的维护成本。本课题首先分析固体泵闸板断裂失效的3种形式,对断口进行宏观形貌观察、材料化学元素测定、力学性能检验、硬度测量、金相分析、SEM形貌分析,在闸板的横向、纵向剖面和纹源处凹坑都呈现显微疏松特征,然后根据断口基本形态判定是由于残余内应力造成断裂失效,再基于有限元仿真研究,建立力学模型,确定施加载荷,划分网格,通过有限元分析得出材料强度是否满足设计要求,同时得出应力集中位置螺纹处和圆弧刃处是易发生断裂的位置。最后优化设计机械结构和热处理工艺,采用去机械加工应力、深冷和多次回火工艺,新闸板能够完全满足性能需求,工程应用中再未发生闸板断裂失效。

     

    Abstract: Urban disposal of hazardous waste is a key project for the country to solve the problem of hazardous waste. Conducting analysis and research on gate fracture failure not only provides basic data for product design in the hazardous waste disposal industry, but also breaks the monopoly of foreign equipment in China, breaks through the bottleneck technology blockade, develops core components to replace imports, and reduces maintenance costs for hazardous waste disposal units. This project first analyzes the three forms of fracture failure of solid pump gate plates. Macroscopic morphology observation, material chemical element determination, mechanical properties, hardness measurement, metallographic analysis, and SEM morphology analysis are carried out on the fracture surface. The transverse and longitudinal sections of the gate plate and the pits at the grain source show obvious loose characteristics. Then, based on the basic morphology of the fracture surface, it is determined that the fracture failure is caused by residual internal stress. Based on finite element simulation research, a mechanical model is established to determine the applied load, divide the grid, and determine whether the material strength meets the strength design requirements through finite element analysis. At the same time, it is found that the stress concentration position at the thread and the circular arc edge are the locations where fracture is prone to occur. Finally, the mechanical structure and heat treatment process were optimized, and the new gate was able to fully meet performance requirements by using stress reduction, deep cooling, and multiple tempering processes. No gate fracture failure occurred in engineering applications.

     

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