An Investigation of the Contact Fatigue Characteristics of an RV Reducer Crankshaft, Considering the Hardness Gradients and Initial Residual Stress
Abstract
:1. Introduction
2. Failure Analysis of Crankshaft
3. Methodology
3.1. Stress Analysis of RV Reducer
3.2. Modeling of Residual Stress and Hardness Gradient
3.3. FEM-Based Elasto-Plastic Contact Analysis
3.4. Contact Fatigue Life Assessment Model
4. Results and Discussion
4.1. Effect of Friction Coefficient and Normal Stress on Fatigue Damage
4.2. Effect of Initial Residual Stress on Plastic Strain
4.3. Effect of Initial Residual Stress on Fatigue Life
5. Conclusions
- (1)
- The location of the maximum shear strain depends on the friction coefficient. When the friction coefficient is low, the position of the maximum shear strain is still on the subsurface. Meanwhile, the fatigue initial location moves from the subsurface to the surface, and the fatigue damage increases as the friction coefficient μ increases.
- (2)
- The initial residual stress plays an influential role in fatigue damage and crack initiation depth by altering the distribution of the maximum normal stress, σn,max, near the contact surface. The compressive residual stress can reduce σn,max by 48.4% compared with that without residual stress. Therefore, the ratio of maximum normal stress to shear stress in the modified FS fatigue criterion can better consider the interaction effect between the residual stress and the shear stress, which significantly improves the prediction accuracy of the contact fatigue life model.
- (3)
- The ICRS makes the plastic region shrink and improves the contact fatigue performance by delaying the time of cracks propagating to the surface. Under the rated load condition, the minimum contact fatigue life with ICRS is 9.03 × 107, which is 29.6% larger than that without IRS, while the minimum contact fatigue life with SPRS is 125.7% larger than that with ICRS. Residual stress distribution introduced by shot peening significantly enhances the fatigue life of the crankshaft.
- (4)
- Moreover, the fatigue life could be maximized by designing appropriate shot peening parameters to obtain optimized residual stress distribution. The experimental verification of the proposed fatigue life assessment method can also be conducted in future study though it is costly and time-consuming.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Parameters | Value | Parameters | Value |
---|---|---|---|
Crankshaft rotation speed (r/min) | ns = 585 | Rated output torque (N·m) | Tout = 800 |
Radius of the rolling element (mm) | R1 = 4.0 | Rolling element material | GCr15 |
Radius of the eccentric cylindrical surface (mm) | R2 = 16.6 | Crankshaft material | 20CrNi2MoA |
Length of the rolling element (mm) | l1 = 12.0 | Young’s modulus (GPa) | E1 = 219, E2 = 210 |
Radius of needle tooth distribution circle (mm) | Rz = 82 | Poisson ratio | v1 = 0.3, v2 = 0.275 |
Radius of crankshaft distribution circle (mm) | ro = 46.77 | Eccentricity (mm) | e = 1.5 |
Number of teeth of needle wheel | z4 = 39 | Number of crankshafts | n = 3 |
Number of teeth of cycloid gear | z5 = 40 | Short amplitude coefficient | k = 0.7317 |
Element | C | Mn | Cr | Ni | Si | Mo | Cu | S | P | Fe |
---|---|---|---|---|---|---|---|---|---|---|
Wt.% | 0.21 | 0.63 | 0.57 | 1.8 | 0.33 | 0.25 | 0.30 | 0.015 | 0.02 | Bal. |
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Li, X.; Shao, W.; Tang, J.; Ding, H.; Zhou, W. An Investigation of the Contact Fatigue Characteristics of an RV Reducer Crankshaft, Considering the Hardness Gradients and Initial Residual Stress. Materials 2022, 15, 7850. https://doi.org/10.3390/ma15217850
Li X, Shao W, Tang J, Ding H, Zhou W. An Investigation of the Contact Fatigue Characteristics of an RV Reducer Crankshaft, Considering the Hardness Gradients and Initial Residual Stress. Materials. 2022; 15(21):7850. https://doi.org/10.3390/ma15217850
Chicago/Turabian StyleLi, Xin, Wen Shao, Jinyuan Tang, Han Ding, and Weihua Zhou. 2022. "An Investigation of the Contact Fatigue Characteristics of an RV Reducer Crankshaft, Considering the Hardness Gradients and Initial Residual Stress" Materials 15, no. 21: 7850. https://doi.org/10.3390/ma15217850