万向节十字轴总成失效分析外文文献翻译、中英文翻译

附录Cross-axisgimbalassemblyFailureAnalysisThemainfunctionofjointsindifferentaxispassingbetweentherotatingshafttorque,ithasbeenwidelyusedinvarioustypesoftruckaxleshaftconnectedbetweenthecrosssection,usuallyinthecourseofcross-axisuniversaljointoftheNeedleRollerBearingsforrotarymovementisnot,butfortherotationoftheswingmovement,theloadcyclechangessubmitted.Basedontheheavy-dutyvehicleWX0082Cross-axisgimbalassemblyoflessthanlifepiecesofthefailuremodeoffailure,failure,structuralparametersandmaterialsusedandtheperformanceoffiniteelementanalysisandothermethodstoconductacomprehensivecomparativeanalysisofproductperformanceadesignimprovement.

1.ObliqueimprintTheauthorofacompanyfromtheprovisionofthreepacksofthethreepacksofServicereturnedfailurecasesobservedthatthecross-axisobliquejournalimprintisrelativelyserious,bearingringsalsoproducetheinnerwalloftheimprint,butthedepthofcross-axisthanthelight.Bytheanalysisofjointsinstalledonthebearingassembly,whenthetotalspacebearingalargercircle,theneedleeasilyskewed,withtheresultthatjournalhaveacross-axistiltanglewiththeaxisoftheembossing,theembossingdepthoftheexpansionofmoredeep,theneedlewillnotbeabletospin,thusincreasingfrictionalresistance,exacerbatedbytheextensionofindentation.Thetotalcircumferenceofitsappropriatespaceshouldbecontrolledintherangeof0.1~0.4mminside,JB/T3232inagivenspaceforatotalcircumferenceofnotmorethan0.5mm.2.FatiguespallingShaftangleintheuseofasmallerstate,universaljointassemblyoftheneedlebearingjournaldiameterandcross-axisangleintheframeworkofrepeatedsmallerswing,whenthecross-axiswiththebearingradialclearancewiththewearandtearexpansionwillleadtoconcentrationofload,theloadwillbelargelocalindentationfatigueprematurelyinordertodevelopintoalargeareaoffthefatigue.Especiallyinthecross-axisthefirstaxis,thestressconcentrationduetotheimpactofpartsoftheirsetwasalmostallthechamferingeat,severehightemperaturesinteringunderastateofthephenomenon.Becauseusersdonotuselubricantsorasaresultoftimeaddedontheuniversaljointsbearingssealedproperly,resultinginearlylossofoil-bearingmaterialsaswellasthedusttemperatureintolerance,lipoilsealsinthewintercoldweatheragingcracksundersothattheearlylossofgrease.Inaddition,theuniversaljointassemblylessoilinoperationduetohightemperaturegenerated,sothatshaftbearingsandkilled,resultinginabrokenneedleandthedamagetosealsanddustjacket,tracesofferrulesurfaceablation,thefailuremodeofbothfailuremodeisnon-normal.4.NeedlefailureIlapsedfromtheuniversaljointassemblyobservedinthesamplefoundthatthemajorityofneedlepointofthesurfacethereareMa,MaHang,andlarge-scalefatiguespalling,asmallnumberofneedleheadwasbroken,asmallnumberofneedlefromtheneedleabout1.5mmDepartmentheadMaHang,andtheexistenceofalargerphenomenonofbitewounds,themajorityofneedlefracturefracturefromhere,thisoccurrenceofthemainbearingstructureandthesizeparametersandthecirculardesignofthetotalgap.5.GasketfailureGasketisthefirstuniversaljointassemblyofthecomponentsfailure,theformofgasketfailurenylonfractureandwearpads.Icarefullyanalyzedsamplesgasketfailurefoundthattheoutergaskethasobviouscracks,gaskethascracksanddebrisoutside.Obviously,thegasketisthegasketbytheexternalforceresultinginriseofthelocalstressconcentration,oncethegasketexternaldamagetotheaxialforcewillbebornebytherestofthepadstobear,thebearpadsperunitareawillincreasethepower,theentirepadtabletstobebroken.Hencetheneedforwell-designedshapeandbearingstructurepads.Atthesametime,eachgasketfailureduetodamageandwearhasbeenassociatedwithfailure,thegasketmaterialmustbeselectedhighstrengthandwearresistanceofmaterials.6.Cross-axisfractureCrossshaftfractureisusuallyaseriousoverloadingtheuserunderthepremiseofthefactorsorunusualconditionsoccur,asjointsinthedesignoftheDepartmentoffullcompliancewiththestandardsofuniversaljointsJB/T8925-2008statictorsionalstrengthsafetyfactorof2.5timestheprovisionsofHowever,OEMsfaultoccurredduringthethreepacksoftheproportionofthetotalfailurestillaccountsfor2%~5%ofsuchcasesissudden,butinevitable,universaljointsandthereforethestatictorsionalstrengthofmatch,wemustmaximumoutputtorqueintheengine3timesmorespecificinordertoavoidoverloadingcausedtheemergenceofsuddenfailure.7.MetallographictestanalysisCasesoffailuretocarryoutphysicalandchemicalanalysis,respectively,inthecrossshaft,ferruleandneedleselectionofthetypicalcharacteristicsofthelocationofthesite,cuttingunderthespecimenandalongtheverticalcross-sectionmetallographicsamplepreparation,themicrostructure-levelqualified.Todeterminethecrossshaft,ferruleandthecenterneedlehardness,respectively,bymicro-hardnessofvariouspartsofagradientdistributionofVickershardnessmeasured,anditsbasicallyinlinewiththehardnessofthehardnessdistribution.Checkthecross-axisuniversaljoints,atestpieceoftheouterringandanumberofneedlesamplesin50%hydrochloricacidaqueoussolutionheatedto70~80℃,heatingofabout1h,checkforhotacidfoundinvariouspartsuseburnphenomenonexists.Thisburnistodetermineuniversaljointssealedasaresultofpoorperformanceandfatlosspropertiesoftheoilwell,resultinginfeverbearinguniversaljointsburntoosoonafterthefailureoftheparts.万向节十字轴总成失效分析万向节的主要作用是在不同轴线上的轴之间传递旋转转矩，它被广泛应用于各类卡车的传动轴联接轴节叉之间，通常在使用过程中万向节十字轴上的滚针轴承不是作旋转运动，而是作旋转摆动的运动，其载荷呈交变的周期变化。本文是通过对重型载车用WX0082万向节十字轴总成寿命不足失效件的失效形式、失效原因进行分析。分析结果如下：1.斜压印从某公司三包服务处提供的三包退回失效件中观察到，十字轴轴颈斜压印情况比较严重，轴承套圈内壁也产生相应的压印，但深度要比十字轴轻。经分析，安装在万向节总成上的轴承，当轴承圆周总间隙较大时，滚针易产生歪斜，致使十字轴轴颈产生与轴线倾斜一定角度的压印，当压印深度扩展较深时，滚针就不能自转，因此使摩擦阻力增大，加剧压痕的延伸。其合适的圆周总间隙应控制在0.1～0.4mm范围内，JB/T3232中给定的圆周总间隙为不超过0.5mm。2.疲劳剥落在传动轴摆角较小的使用状态下，万向节总成上的滚针轴承内径与十字轴轴颈在较小角度范围内反复摆动，当十字轴与轴承径向游隙随着磨损而扩大时，会导致产品载荷集中，载荷大的地方就会过早地产生疲劳压痕，从而发展成为大面积的疲劳剥落。特别是在十字轴轴头处，由于应力集中影响，其受载部位的倒角几乎全部被啃掉，严重时会在高温状态下出现烧结现象。3.缺油烧蚀由于在使用过程中用户不按期加注润滑油或由于万向节上的轴承密封不好，导致轴承早期失油以及防尘罩材料不耐低温，油封唇口在冬季寒冷气候下产生老化裂纹，使润滑脂早期流失。另外，万向节总成在运行中因缺油而产生高温，使轴承与轴径咬死，致使滚针折断以及密封和防尘外罩损坏，套圈表面有烧蚀痕迹，这种失效形式均属于非正常失效形式。4.滚针失效从万向节总成失效样品中观察发现，大多数滚针表面都存在麻点、麻坑