SCM435钢偏心螺栓疲劳断裂失效分析与改进验证

Fatigue Fracture Failure Analysis and Improvement Verification of SCM435 Bolts

  • 摘要: ​:本文针对某主机厂路试车后上控制臂与制动器连接处的偏心螺栓疲劳断裂失效案例,通过宏观断口分析、微观断口观察、化学成分检测、硬度测试及金相组织分析等方法,系统研究螺栓断裂机理。结果表明:螺栓材质(SCM435钢)及热处理状态符合标准要求,但由于四轮定位时未按标准力矩装配导致螺栓松动,在交变载荷作用下,螺纹底部应力集中引发裂纹萌生与扩展,最终导致疲劳断裂。基于此,提出优化装配工艺(高精度扭矩控制、残余扭矩监控)和改进螺栓设计(增大过渡圆角、优化螺纹结构)等措施,经试验验证后未再发生同类失效。研究成果为类似金属构件的疲劳失效预防提供了工程参考。

     

    Abstract: ​: This paper systematically investigates the fatigue fracture mechanism of an eccentric bolt at the connection between the rear upper control arm and the brake of a test vehicle in an automotive OEM. Through macroscopic fracture analysis, microscopic fracture observation, chemical composition detection, hardness testing, and metallographic structure analysis, the study reveals that: The bolt material (SCM435 steel) and heat treatment state met standard requirements. However, improper torque application during wheel alignment caused bolt loosening. Under cyclic loading, stress concentration at the thread root initiated crack nucleation and propagation, ultimately leading to fatigue fracture. Based on these findings, improvement measures were proposed, including optimized assembly processes (high-precision torque control, residual torque monitoring) and bolt design modifications (increased transition fillet radius, optimized thread structure). Subsequent validation tests confirmed the elimination of similar failures. This research provides practical engineering references for preventing fatigue failures in analogous metal components.

     

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