特种设备钢丝绳的应力和疲劳寿命仿真分析

doi:10.3969/j.issn.1000-1093.2018.04.020

摘要/Abstract

摘要： 为分析钢丝绳在提升工作过程中绳上的应力分布和疲劳失效情况，以某型特种设备用6× 36 WS钢丝绳为研究对象，对钢丝绳在轴向拉伸和绕滑轮弯曲状态下的应力和疲劳寿命进行了仿真研究。建立钢丝绳的有限元模型，仿真分析了其在轴向拉伸和绕滑轮弯曲状态下的应力分布情况；进行钢丝的疲劳试验，得到了钢丝疲劳寿命数据；根据钢丝疲劳数据和钢丝绳有限元分析结果，依据Miner线性累积损伤理论进行了钢丝绳的疲劳寿命仿真分析。结果表明：钢丝绳在相邻钢丝接触区域、相邻绳股接触区域以及钢丝绳与滑轮接触区域应力较大，应力越大的部位，最先发生疲劳失效，疲劳寿命越小。

关键词: 钢丝绳, 有限元, 应力, Miner法则, 疲劳寿命

Abstract: The stress and fatigue life of 6×36 WS wire rope of a special equipment under axial tension and the bending state around the pulley are studied to analyze the stress distribution and fatigue failure of steel wire rope during the working process. A finite element model of the steel wire rope is established，and the stress distribution under the axial tension and the bending state around the pulley are simulated and analyzed. Then the fatigue test of the steel wire is carried out to obtain the fatigue life data. Based on the fatigue data of the steel wire and the finite element analysis results of the rope，the fatigue life simulation analysis of the wire rope is carried out according to Miner linear accumulated damage theory. The results show that the stress of steel wire rope is larger in the contact areas of the adjacent wires and rope strands, and the contact area between wire rope and pulley. The greater the stress is，the shorter the fatigue life is. Key

Key words: steelwirerope, finiteelement, stress, Minertheorem, fatiguelife

中图分类号:

V553.1⁺9

杜文正，马保珠，曹大志. 特种设备钢丝绳的应力和疲劳寿命仿真分析[J]. 兵工学报, 2018, 39(4): 798-809.

DU Wen-zheng, MA Bao-zhu, CAO Da-zhi. Simulation Analysis on the Stress and Fatigue Life of a Special Equipment's Wire Rope[J]. Acta Armamentarii, 2018, 39(4): 798-809.

参考文献

［1］刘小正. 起重机钢丝绳特点及维护方法探讨［J］. 中国新技术新产品,2015(16):45.
LIU Xiao-zheng. Discussion on the characteristics and maintenance methods of crane steel wire rope［J］. China New Technologies and Products, 2015(16):45.(in Chinese)
［2］刘修海, 吴天成, 张志高,等. 港机用钢丝绳生产及应用［J］. 金属制品, 2016, 42(1):13-16.
LIU Xiu-hai, WU Tian-cheng, ZHANG Zhi-gao, et al. Production and application of steel wire rope for port machinery［J］. Metal Products, 2016, 42(1):13-16. (in Chinese)
［3］王建波, 邱郡. 钢丝绳失效致起重伤害事故分析及预防［J］. 科技信息, 2011(16): 383.
WANG Jian-bo, QIU Jun. Accident analysis and prevention of hoisting injury caused by failure of wire rope［J］. Science & Technology Information, 2011(16): 383. (in Chinese)
［4］陈向阳, 张瑾, 唐文亭. 1×7+IWS结构钢丝绳服役中的有限元模拟［J］. 铸造技术, 2014, 35(4): 676-678.
CHEN Xiang-yang, ZHANG Jin, TANG Wen-ting. Finite element simulation of 1×7+IWS steel wire ropes in service［J］. Foundry Technology, 2014, 35(4): 676-678.(in Chinese)
［5］杜文正, 马保珠, 曹大志, 等. 摩擦因数对钢丝绳应力和疲劳寿命的影响分析［J］. 工矿自动化, 2017, 43(3):43-47.
DU Wen-zheng, MA Bao-zhu, CAO Da-zhi, et al. Analysis of affection of friction factor on stress and fatigue life of steel wire rope［J］. Industry and Miner Automation, 2017, 43(3):43-47.(in Chinese)
［6］张敏, 寇子明, 李婷. 基于ABAQUS的钢丝绳扭矩分析［J］. 煤矿安全, 2016, 47(2):113-115.
ZHANG Min, KOU Zi-ming, LI Ting. Analysis of torque for steel wire rope based on ABAQUS［J］. Safety in Coal Mines, 2016, 47(2): 113-115.(in Chinese)
［7］马军, 葛世荣, 张德坤. 钢丝绳股内钢丝应力-应变分布的计算模型及数值模拟［J］. 机械工程学报, 2009, 45(11):277-282.
MA Jun, GE Shi-rong, ZHANG De-kun. Calculating model and numerical simulation of stress-strain distribution of wires within strands［J］. Journal of Mechanical Engineering, 2009, 45(11):277-282.(in Chinese)
［8］鲁信辉, 马平, 王志勇. 钢丝绳应力场与疲劳寿命研究［J］. 机械设计与制造, 2014(10):119-122.
LU Xin-hui, MA Ping, WANG Zhi-yong. The research of stress field and fatigue life of the 6×7+IWS steel wire ropes［J］. Machinery Design & Manufacture, 2014(10):119-122.(in Chinese)
［9］贾小凡, 张德坤. 承载钢丝绳在不同预张力下的弯曲疲劳损伤研究［J］. 机械工程学报, 2011, 47(24):31-37.
JIA Xiao-fan, ZHANG De-kun. Bending fatigue damage behavior of bearing wire rope on different pre-tension ［J］. Journal of Mechanical Engineering, 2011, 47(24):31-37.(in Chinese)
［10］ Wang D G, Zhang D K, Zhang Z F, et al. Effect of various kinematic parameters of mine hoist on fretting parameters of hoisting rope and a new fretting fatigue test apparatus of steel wires［J］. Engineering Failure Analysis, 2012, 22(2): 92-112.
［11］ Peterka P, KreAsˇG2ák J, Kropuch S, et al. Failure analysis of hoisting steel wire rope［J］. Engineering Failure Analysis, 2014, 45(1): 96-105.
［12］ Giglio M, Manes A. Life prediction of a wire rope subjected to axial and bending loads［J］. Engineering Failure Analysis, 2005, 12(4): 549-568.
［13］任志乾, 于宗乐, 陈循. 钢丝绳弹塑性损伤本构模型研究［J］. 机械工程学报, 2017, 53(1): 121-129.
REN Zhi-qian, YU Zong-yue, CHEN Xun. Study on wire rope elastic-plastic damage constitutive model［J］. Journal of Mechanical Engineering, 2017, 53(1): 121-129.(in Chinese)
［14］任志乾, 于宗乐, 陈循, 等. 基于弹塑性本构的单股钢丝绳受力分析［J］. 兵工学报, 2015, 36(9): 1782-1789.
REN Zhi-qian, YU Zong-yue, CHEN Xun, et al. Stress analysis of single strand wire rope based on elastic plastic constitutive model ［J］. Acta Armamentarii, 2015, 36(9): 1782-1789. (in Chinese)
［15］ Wang D G, Zhang D K, Wang S, et al. Finite element analysis of hoisting rope and fretting wear evolution and fatigue life estimation of steel wires［J］. Engineering Failure Analysis, 2013, 27(1): 173-193.
［16］沈燕, 张德坤, 王大刚. 接触载荷对钢丝微动磨损行为影响的研究［J］.摩擦学学报, 2010, 30(4):404-408.
SHEN Yan, ZHANG De-kun, WANG Da-gang. Effect of contact load on the fretting wear behavior of steel wire［J］. Tribology, 2010, 30(4):404-408.(in Chinese)
［17］ Cruzado A, Leen S B, Urchegui M A. Finite element simulation of fretting wear and fatigue in thin steel wires［J］. International Journal of Fatigue, 2013, 55(5):7-21.
［18］孙土贵, 史天录. 钢丝绳数学模型及有限元分析［J］. 五邑大学学报:自然科学版, 2016, 30(1): 64-68.
SUN Tu-gui, SHI Tian-lu. Mathematical model and finite element analysis of wire ropes［J］. Journal of Wuyi University:Natural Science Edition, 2016, 30(1): 64-68.(in Chinese)
［19］张向冈, 陈宗平, 薛建阳, 等. 圆钢管再生混凝土柱抗震性能试验与有限元分析［J］. 应用基础与工程科学学报, 2016(3): 582-594.
ZHANG Xiang-gang, CHEN Zong-ping, XUE Jian-yang, et al. Test and finite element analysis of seismic performance for recycled aggregate concrete filled circular steel tube column［J］. Journal of Basic Science and Engineering, 2016(3): 582-594.(in Chinese)
［20］成大先. 机械设计手册［M］. 北京:化学工业出版社, 2004:7-9.
CHENG Da-xian. Mechanical design manual［M］. Beijing: Chemical Industry Press, 2004:7-9.(in Chinese)
［21］肖毅华, 董晃晃, 平学成. 基于 ABAQUS的SPH粒子生成及其在高速冲击计算中应用［J］. 振动与冲击, 2016, 35(17): 140-145.
XIAO Yi-hua, DONG Huang-huang, PING Xue-cheng. A SPH particle generation method based on ABAQUS and its application in high velocity impact calculation［J］. Journal of Vibration and Shock, 2016, 35(17): 140-145.(in Chinese)
［22］聂建国, 王宇航. ABAQUS 中混凝土本构模型用于模拟结构静力行为的比较研究［J］. 工程力学, 2013(4): 59-67.
NIE Jian-guo, WANG Yu-hang. Comparison study of constitutive model of concrete in ABAQUS for static analysis of structures［J］. Engineering Mechanics, 2013(4): 59-67.(in Chinese)
［23］吴娟, 寇子明, 刘玉辉, 等. 弯曲钢丝绳股内钢丝应力应变数值模拟［J］. 煤炭学报, 2015, 40(6): 1463-1468.
WU Juan, KOU Zi-ming, LIU Yu-hui, et al. Numerical simulation of stress-strain of bended wire rope［J］. Journal of China Coal Society, 2015, 40(6): 1463-1468.(in Chinese)

第39卷
第4期2018 年4月兵工学报ACTA
ARMAMENTARIIVol.39No.4Apr.2018

[1]	王雷，李毅，马智慧. 基于Mooney-Rivlin模型的车辆环形橡胶减震器径向刚度计算与参数优化[J]. 兵工学报, 2022, 43(S1): 35-45.
[2]	潘霄，姜毅，王勃漫，任烨波. 火箭多级筒燃气弹射动力学特性及影响因素[J]. 兵工学报, 2022, 43(6): 1277-1287.
[3]	何新智, 王志斌, 李德才. 屈服应力对磁性液体密封启动扭矩的影响[J]. 兵工学报, 2022, 43(4): 892-898.
[4]	李旭, 刘彦, 安丰江, 王虹富, 许迎亮. 行星式球磨颗粒流场分布与形貌变化规律[J]. 兵工学报, 2022, 43(4): 876-891.
[5]	许晓东，唐圣金，谢建，于传强，王凤飞，韩洋洋. 随机退化应力作用下设备剩余寿命预测方法[J]. 兵工学报, 2022, 43(3): 712-719.
[6]	张瑞, 易力力, 刘志鹏. 多股螺旋弹簧疲劳寿命影响因素[J]. 兵工学报, 2022, 43(2): 458-466.
[7]	程申申，陶如意，王浩，薛绍，林庆育. 弹丸不同结构尼龙弹带挤进过程的阻力特性[J]. 兵工学报, 2021, 42(9): 1847-1857.
[8]	王子标，孙剑飞，李湉，张力仁，张晟玮. 基于斜面法原理的7075-T651铝合金板材内部三维残余应力分布[J]. 兵工学报, 2021, 42(9): 2004-2012.
[9]	王超，王文龙，孙芹东，孙文祺. 同振式矢量水听器耐压球壳优化设计[J]. 兵工学报, 2021, 42(8): 1744-1752.
[10]	邹利波，于存贵，冯广斌，侯保林，仲建林，刘宪福. 基于温度修正的弹丸挤进身管过程摩擦模型[J]. 兵工学报, 2021, 42(6): 1148-1156.
[11]	张明宇, 王琦, 于洋. 基于长短时记忆算法的热应力下半导体器件故障预测模型[J]. 兵工学报, 2021, 42(6): 1265-1274.
[12]	汤伟江, 刘卫东, 高卓, 张凯, 赵培东. 潜水器用光纤线团应力分布及影响因素[J]. 兵工学报, 2021, 42(5): 1053-1064.
[13]	洪舟振森，张虹，马朝臣，吴新涛. 变海拔环境下离心压气机叶轮多场应力响应[J]. 兵工学报, 2021, 42(3): 478-486.
[14]	刘江超，高文学，张声辉，李小帅. 水间隔装药孔壁爆炸应力分布规律[J]. 兵工学报, 2021, 42(12): 2646-2654.
[15]	林锋，姚婉，秦国华，叶海潮，陶江. 飞机整体结构件加工变形的初始残余应力-初始几何误差耦合影响与控制[J]. 兵工学报, 2021, 42(12): 2731-2742.