CN114491863B - Threaded connection pair reliability simulation analysis method for main bearing seat of engine - Google Patents
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Abstract
A method for analyzing the reliability simulation of the threaded connection pair of a main bearing seat of an engine includes the steps of firstly calculating the dynamics of a crankshaft, and then coupling the boundary of an EHD load of the crankshaft to a bearing bush of a main bearing seat, so that the stress and fatigue safety coefficient of a global finite element model of the main bearing seat are calculated; and then establishing a threaded connection auxiliary finite element sub-model, so that the coordinates of the main bearing seat global finite element model and the threaded connection auxiliary finite element sub-model are completely consistent. And then, based on a displacement result of the main bearing seat global finite element model at the boundary of the threaded connection auxiliary finite element sub-model as a driving input, calculating the accurate stress of each threaded thread, and then, carrying out fatigue safety coefficient calculation and judgment on the accurate stress. The method can greatly improve the simulation precision of the threaded connection pair, well identify the reliability potential risk of the heavy threaded pair in the early design stage, and timely develop design optimization; effectively reduces the development period, lowers the repeated cost of subsequent experiments and avoids the quality problem of the product market.
Description
Technical Field
The invention belongs to the technical field of CAE simulation analysis, and particularly relates to an accurate CAE simulation calculation analysis technology for a threaded connection pair of an engine main bearing seat.
Background
As a main connection pattern between parts of a motor vehicle, in particular a power train, the reliability of the connection is critical; if the design does not reach the standard, the conditions of bolt fracture, sliding teeth and cracking of the connected piece can occur.
In the finite element strength calculation of the power assembly structure which is common in engineering, the shape of the threaded connection pair is simplified, and the characteristics of the threaded threads are not considered. Because of the finite element dimensions of the typical engineering power assembly of 2-3mm, and the single common pitch of 1.5mm. The geometric models of the power assembly body, such as a cylinder body, a cylinder cover and a transmission box body are complex, and a second-order tetrahedral grid with high rigidity which is automatically divided is generally adopted; the grid transition of different areas is poor; if the cell size of the grid model is too small (< 1 mm), the whole finite element model is huge in scale, the preprocessing time is long, the calculation time is too long or the calculation time cannot be converged, and the engineering requirement cannot be met.
For example, the main bearing seat of a six-hybrid supercharged engine with certain performance upgrading state has the phenomenon of repeated penetrating cracking of the thread root of the cylinder body in the development process, and the previous CAE analysis of the main bearing seat does not pay attention to and judge the reliability results (stress and safety coefficient) of the thread root due to the reasons of calculation precision and engineering experience; the modeling and calculating precision of the existing main bearing seat strength analysis has low sensitivity to optimization, design optimization cannot be designated, and engineering requirements cannot be met.
Disclosure of Invention
Aiming at the situation that the simulation accuracy of the reliability of the threaded connection pair of the existing power assembly is poor, the invention provides a simulation analysis method of the reliability of the threaded connection pair of the main bearing seat of an engine, and based on the design and development of the main bearing seat of the engine, a simulation method of the coupling of a global finite element model and a sub model (locally refined finite element) is established, so that the calculation accuracy is improved; and guiding the optimal design of the product and solving the engineering problem.
The technical scheme of the invention is as follows:
a method for analyzing the reliability simulation of a threaded connection pair of a main bearing seat of an engine comprises the following steps:
step 1, calculating three-dimensional EHD dynamics of a crankshaft; coupling a boundary of the crankshaft EHD dynamic load to a bearing shell surface of the main bearing housing;
and 2, calculating the strength and fatigue safety coefficient of the global finite element model of the main bearing pedestal based on bearing load input of crankshaft EHD dynamics.
And 3, establishing a threaded connection pair finite element sub-model, and enabling the threaded connection pair finite element sub-model to be completely consistent with the coordinates of the main bearing seat global finite element model. And taking a displacement calculation result of each load step of the main bearing seat global finite element model at the boundary of the threaded connection pair finite element sub-model as a driving boundary of the threaded connection pair finite element sub-model, so as to calculate the accurate stress and displacement of the threaded threads.
And 4, performing fatigue calculation and reliability evaluation on the stress result of the finite element sub-model of the threaded connection pair.
Further, the step 1 specifically includes:
And 1.1, performing finite element gridding division and modal compression on the main bearing seat and the crankshaft geometric model, extracting data information files such as a mass matrix, a stiffness matrix and the like of the main bearing seat and the crankshaft geometric model, and inputting cylinder pressure curves of different engine speeds into a crankshaft dynamics analysis model.
And 1.2, the main bearing load calculated by the three-dimensional EHD dynamics of the crankshaft is mapped onto a bearing bush inner surface node of a main bearing seat global finite element model and is used as load input of main bearing seat finite element analysis.
Further, the step 2 specifically includes:
and 2.1, constructing a main bearing seat global finite element model.
And 2.2, calculating a finite element result of the global finite element model of the main bearing seat, wherein the finite element result comprises stress and displacement.
And 2.3, calculating a safety coefficient distribution cloud chart according to the stress result of the main bearing housing global finite element model, and finding out a region with a smaller safety coefficient.
Step 2.4, judging whether the design needs to be optimized according to the safety coefficient calculation result of the step 2.3; if necessary, return to step 1.
Further, the step 3 specifically includes:
Step 3.1, establishing a fine micron-sized threaded connection pair finite element sub-model, and setting boundary grid nodes of the fine micron-sized threaded connection pair finite element sub-model to define driving nodes (BOUNDARY, SUBMODEL).
The method specifically comprises the following steps: dividing geometric feature details of the thread threads by using micron-sized grid size units, and setting the contact pair state of the thread pairs as a small sliding contact pair type; and the coordinates of the threaded connection pair finite element sub-model and the main bearing seat global finite element model are completely consistent.
And 3.2, inputting a displacement result of the driving boundary node defined in the STEP 3.1 of the main bearing seat global finite element model by using an input command as a boundary load condition of the threaded connection pair finite element sub-model in a corresponding crankshaft load STEP STEP, so as to calculate stress and displacement results of the threaded connection pair finite element sub-model.
Step 3.3, difference judgment: and (4) comparing the calculated displacement values of the main bearing seat global finite element model and the threaded connection pair finite element sub-model at the driving boundary, and if the difference meets the requirement, for example, less than or equal to 5%, performing step 4.
Further, the step 4 specifically includes:
step 4.1, calculating fatigue safety coefficients of the load crankshaft steps based on the stress calculation results of the load crankshaft steps of the threaded connection pair finite element sub-model;
and 4.2, index judgment: if the fatigue safety coefficient calculation result of the threaded connection pair finite element sub-model is lower than a judgment standard, for example, not less than 1.05, returning to the step 1 to optimize the main bearing structure; if the requirements are met, ending.
According to the technical scheme, the invention relates to a precise simulation calculation method for the reliability of a threaded connection pair of a power assembly (main bearing seat) structure, which comprises the following steps: firstly, calculating the dynamics of a three-dimensional EHD of a crankshaft, and then coupling the load boundary of the EHD of a main bearing onto the inner surface node of a main bearing bush finite element, so as to calculate the stress (strength) and fatigue safety coefficient of a main bearing seat global finite element model; and then, establishing an accurate threaded connection pair finite element sub-model (the micrometer-scale finite element unit size is used for accurately dividing the geometric shape of the screw teeth and setting a small sliding type threaded pair contact pair), and enabling the coordinates of the threaded connection pair finite element sub-model and the main bearing seat global finite element model to be completely consistent. And then inputting a displacement result of the main bearing seat global finite element model at the finite element boundary of the threaded connection pair as a driving load boundary, so as to calculate a precise stress value of the threaded thread, and then carrying out fatigue calculation and risk judgment on the stress value.
The CAE simulation analysis method flow can greatly improve the simulation precision of the threaded connection pair, well identify the potential reliability risk of the heavy threaded pair in the early design stage, optimize the design in time, reduce the development period and the round cost of the test, and effectively avoid the market quality problem of the product.
Drawings
Fig. 1 is a block diagram of a main bearing of an engine according to the background art.
Fig. 2 is a finite element sub-model of a threaded connection.
FIG. 3 is a logic flow diagram of the method of the present invention.
Wherein in the figure:
1-main bearing seat, 2-main bearing cap, 3A-left fastening bolt, 3B-right fastening bolt, 4-upper main bearing bush, 5-lower main bearing bush, 6A-main bearing cap left spigot positioning, 6B-main bearing cap right spigot positioning, 7-main journal load, 8-inclined oil duct, 9-threaded connection pair finite element sub-model boundary condition, 10A-threaded hole geometric model, 10B-threaded hole finite element network model, 11A-bolt thread geometric model, 11B-bolt thread finite element network model, 12A-single thread connection pair geometric, 12B-single thread connection pair finite element network model.
Detailed Description
The invention is described in further detail below with reference to the accompanying drawings:
The sub-model (Submodel) analysis technique involved in the method of the present invention is a CAE simulation method based on the san-valan principle, i.e. if the actual distributed load is replaced by an equivalent load, the stress and strain will only change around the location where the load is applied. It is stated that there is only a stress concentration effect at the load concentration location, and if the sub-model is located far from the stress concentration location, a more accurate calculation result can be obtained in the sub-model.
Compared with the traditional analysis method, the sub-model (Submodel) analysis technology has the great advantages that 1) the traditional analysis method needs to re-model the modified parts and place the parts in the whole analysis model for re-analysis, thereby obtaining the result of the region of interest and having longer preprocessing and calculating time. 2) The sub-model analysis technology (Submodel) can avoid the whole model and only perform local special technical treatment on the concerned part of the model, extracts boundary conditions from the result of the previous complete calculation to calculate, and can reduce or even cancel the complex stress transmission area required in the finite element solid model, thereby obtaining the simulation result of the concerned area, and can rapidly analyze and compare multiple design schemes (such as different fillet radii) of the simulation result, thereby saving a large amount of calculation time and ensuring accurate results.
As shown in fig. 1, a common design structure of a main bearing seat of an engine is shown in the schematic diagram: the main bearing cover 2 is fixed on the main bearing seat 1 of the cylinder body through a left fastening bolt 3A and a right fastening bolt 3B, and meanwhile, the margin height of the upper main bearing bush 4 and the lower main bearing bush 5 is required to be considered in the process of assembly working conditions; the spigot positioning 6A and 6B on the left side and the right side of the main bearing cap are provided with interference, and the pin sleeve type main bearing cap 2 is provided with pin sleeve interference. The main bearing seat 1 is structured to bear the action of the gas explosion pressure of the crankshaft main shaft diameter 7 and the rotational inertia force of the crankshaft system during the running process of the engine. In general, the main bearing block 1 strength analysis as described in the previous background, the finite element mesh model is also basically the same as that of fig. 1, and the cylinder block 1 is the whole geometric model; because of the limitation of modeling and calculation period, the geometric details of the screw teeth of the screw thread pair are not generally considered, and the screw thread pair is bound by adopting TIED types, so that the finite element calculation result at the screw thread has poor precision and is not generally considered. And practice shows that the main bearing seat global finite element model has low optimization sensitivity to the thread, and cannot meet engineering requirements.
Therefore, the invention builds a micron-sized accurate hexahedral threaded connection pair finite element sub-model based on engineering practice. The left side view of FIG. 2 is a cross-sectional view of a main bearing housing threaded connection sub-local geometry model taken from the main bearing housing global geometry model. The middle diagram of fig. 2 is a grid section view of a threaded connection sub finite element sub-model. In order to improve the calculation accuracy, the method adopts hexahedral units with highest simulation accuracy divided in a full manual mode to divide the geometric shape of each screw tooth in detail. The right side of FIG. 2 is an enlarged detail view of a single thread connection pair finite element mesh model 12B; the method adopts micron-level unit size for the finite element grid of the threaded connection auxiliary screw thread, namely the minimum unit width is only 50 mu m. So that the actual working stress of the screw thread can be simulated greatly and accurately. The number of units of the thread pair finite element sub-model reaches 32 ten thousand, and the number of nodes reaches 35 ten thousand; the number is even more than that of the main bearing seat global finite element model (19 ten thousand units and 30 ten thousand nodes). To improve convergence, the mesh nodes of the thread contact pairs are spatially in one-to-one correspondence.
The following describes in detail a method for accurately calculating the reliability of the threaded connection pair of the main bearing seat of the engine based on a flow chart 3 of the method of the invention:
s301, S303, preparing the first edition conceptual design geometric assembly models of the main bearing seat and geometric models of a crankshaft system.
S302, finite element gridding division and modal compression are carried out on the main bearing seat and the crankshaft system by using finite element software, and data information files such as a mass matrix, a rigidity matrix and the like of the main bearing seat and the crankshaft system are extracted.
S305, inputting the mass and rigidity matrix file of S302 and cylinder pressure curves of different engine speeds of S304 into a crank dynamics analysis model.
S306, the calculation result of the main shaft diameter load EHD (Elastic Hydraulic Dynamics elastohydrodynamic) of the crank dynamics is mapped to a grid model of the main shaft bushing.
The steps can be specifically implemented as follows, for example, through AVL-Exrite software crankshaft dynamics EHD (Elasto Hydrodynamic) load analysis, the main bearing stress in all directions under the rated rotation speed working condition is obtained. And selecting a maximum load working point of the main bearing in the Y, Z direction, mapping the main bearing load corresponding to the working point to a finite element model node of the main bearing bush, and taking the maximum load working point as load input of main bearing seat finite element analysis. For structural fatigue calculations, at least four bearing load outputs at operating points in time are typically selected during an engine operating cycle.
S307, a main bearing seat global finite element model is established, bolt assembly axial force S308, bearing bush interference assembly S309, main bearing cap spigot or pin bush interference assembly S310 are applied, and main bearing EHD calculation results of the main bearing bush are input in step S306 in a mapping mode.
S311, S312, the stress and displacement result of the main bearing seat global finite element model is calculated, then the stress and displacement result is input into professional fatigue simulation software, the safety coefficient distribution cloud image of the main bearing seat global finite element model is calculated, and the area with smaller safety coefficient is found.
S313, evaluating whether the main bearing seat structure needs to be subjected to design optimization according to the evaluation standard.
S314, extracting boundary conditions of the threaded connection auxiliary finite element sub-model from the calculation result of the main bearing seat global finite element model in S311, as shown by a 9-broken line frame in FIG. 1.
S315, establishing a micron-sized fine finite element sub-model of the threaded connection pair, and in order to improve the calculation accuracy, the method adopts hexahedron units with highest simulation accuracy which are divided in a full manual mode, as shown in fig. 2, the unit sizes are set to be small enough, the geometric shapes of threads of the threaded pair are divided in detail, and the contact pair types which are closer to the actual small sliding (SMALL SLIDING) contact pair types are set between the hexahedron units. The right side of FIG. 2 is an enlarged detail view of a single thread connection pair finite element mesh model 12B; the method adopts micron-level unit size for the finite element grid of the threaded connection auxiliary screw thread, and the minimum unit width is only 50 mu m. To improve convergence, the mesh nodes of the thread contact pairs are spatially in one-to-one correspondence.
S316, defining a boundary grid node set of the finite element sub-model of the threaded connection pair as displacement driving input, and taking the boundary displacement calculation result of the global finite element model of the main bearing seat in S315 as the boundary condition input of the corresponding load STEP STEP of the finite element sub-model of the threaded connection pair, so as to calculate the stress and displacement result of the finite element sub-model of the threaded connection pair.
S317, comparing the calculated result displacement values of the main bearing seat global finite element model and the threaded connection pair finite element sub-model, and if the difference is smaller than 5%, indicating that the boundary condition of the threaded connection pair finite element sub-model is accurately set and the simulation calculation result is reliable.
S318 and S319 are respectively used for calculating stress (displacement) and fatigue safety coefficients of the threaded connection pair finite element sub-model.
For example, in actual operation, to ensure simulation accuracy, the grid of the threaded connection pair finite element sub-model adopts hexahedral grid cells which are divided by full "manual" and have the highest quality level; the minimum engagement unit size of the thread contact surface is only 50 mu m; to improve the convergence of the computation, the finite element mesh node positions of the thread contact pairs are in one-to-one correspondence. Applying DS_ABAQUS command 'SUBMODEL', taking the boundary (for the interface shown by the 9 dotted line frame in figure 1) displacement calculation result of the main bearing seat global finite element model as node displacement drive, and solving the stress and displacement value of each crankshaft working condition load of the threaded connection pair finite element sub model; and then, applying a TransMAX module of FEMFAT software to calculate the fatigue safety coefficient of the screw teeth of the threaded connection pair finite element sub-model.
Finally, S320 index judgment: if the calculation result of the thread stress and the fatigue safety coefficient of the finite element sub-model of the threaded connection pair cannot meet the judgment standard, the reliability of the threaded connection pair is judged to have risks; the screw thread screwing length, the rigidity of the main bearing cap or the assembly positioning mode, the bolt length, the rigidity of the bolt and the like need to be optimized.
After the applicant adopts the method in the actual design, the improvement effect of the optimization scheme (increasing the rigidity of the main bearing cap, increasing the length of the bolt and the like) is accurately calculated and evaluated: the safety factor of the concerned position (the bottom of the last screwing thread groove of the threaded hole) is improved to 1.16 from 0.91 of the original scheme (the bench test shows that a plurality of penetration cracks occur); the method improves the efficiency by 27.5 percent and meets the design requirement; the engine adopting the optimization scheme is successfully verified by all bench reliability tests, and all the inspection of the main bearing seat of the cylinder body is normal/crack-free.
The method has the advantages of high simulation precision and good engineering applicability, and can effectively guide the design optimization of products; meanwhile, the test verification and manufacturing cost can be reduced, the research and development efficiency is improved, and the project progress is ensured.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure.
Claims (7)
1. A method for analyzing the reliability simulation of a threaded connection pair of a main bearing seat of an engine is characterized by comprising the following steps:
step 1, calculating three-dimensional EHD dynamics of a crankshaft, and coupling the boundary of the EHD dynamics load of the crankshaft to the bearing surface of a main bearing seat;
step 2, calculating the strength and fatigue result of the main bearing seat global finite element model;
Step 3, establishing a threaded connection pair finite element sub-model with fine grid size, and enabling the threaded connection pair finite element sub-model to be consistent with the main bearing seat global finite element model in coordinates; taking the displacement calculation result of each load step of the main bearing seat global finite element model at the boundary of the threaded connection pair finite element sub-model as the driving boundary of the threaded connection pair finite element sub-model, and calculating the accurate stress and displacement of the threaded threads;
Step 4, performing fatigue calculation and reliability evaluation on the stress result of the finite element sub-model of the threaded connection pair;
The built finite element model of the threaded connection pair is of a micron level, and comprises the following steps: dividing geometric feature details of the thread threads by using micron-sized grid size units, and setting the contact pair state of the thread pairs as a small sliding contact pair type; and the coordinates of the threaded connection pair finite element sub-model and the main bearing seat global finite element model are completely consistent.
2. The method for analyzing the reliability simulation of the threaded connection pair of the main bearing seat of the engine according to claim 1, wherein the step 1 includes:
step 1.1, carrying out overall gridding division and modal compression on a main bearing seat and a crankshaft geometric model, extracting mass matrix and rigidity matrix data information of the main bearing seat and the crankshaft geometric model and cylinder pressure curves of different engine speeds, and inputting the mass matrix and the rigidity matrix data information and the cylinder pressure curves into a crankshaft dynamics analysis model;
and 1.2, calculating the load of the main bearing by the dynamics of the crankshaft, and mapping the load of the main bearing to a bearing bush inner surface node of a global finite element model of the main bearing.
3. The simulation analysis method of reliability of a threaded connection pair of a main bearing seat of an engine according to claim 1, wherein step 2 comprises:
step 2.1, constructing a main bearing seat global finite element model;
step 2.2, calculating stress and displacement results of a main bearing seat global finite element model based on bearing load input of crankshaft EHD dynamics;
Step 2.3, calculating a safety coefficient distribution cloud chart according to the stress result of the main bearing seat global finite element model in the step 2.2, and finding out a region with smaller safety coefficient;
And 2.4, judging whether design optimization is needed, if so, returning to the step 1, and carrying out optimization modification on the structure of the main shaft seat.
4. The method for simulating and analyzing the reliability of the threaded connection pair of the main bearing seat of the engine according to claim 3, wherein in the step 2.1, when the global finite element model of the main bearing seat is built, bolt shaft force assembly, bearing bush interference assembly, main bearing cap spigot or pin bush interference assembly are considered, and crankshaft dynamics EHD load mapping is input.
5. The simulation analysis method of reliability of a threaded connection pair of a main bearing seat of an engine according to claim 1, wherein step 3 comprises:
Step 3.1, establishing a threaded connection pair finite element sub-model, and setting boundary grid nodes of the finite element sub-model to define driving nodes;
STEP 3.2, using an input command to input a displacement result of the driving boundary node defined in STEP 3.1 of the main bearing seat global finite element model as a boundary load condition of the threaded connection pair finite element sub-model in a corresponding crankshaft load STEP STEP, so as to calculate stress and displacement results of the threaded connection pair finite element sub-model;
step 3.3, difference judgment: and (4) comparing the calculated result displacement values of the main bearing seat global finite element model and the threaded connection pair finite element sub model at the driving boundary, and if the difference meets the requirement, entering a step (4).
6. The simulation analysis method of reliability of a threaded connection pair of a main bearing seat of an engine according to claim 1, wherein step 4 comprises:
step 4.1, calculating fatigue safety coefficients of the load crankshaft steps based on the stress calculation results of the load crankshaft steps of the threaded connection pair finite element sub-model;
And 4.2, index judgment: if the fatigue safety coefficient calculation result of the threaded connection pair finite element sub-model is lower than the judgment standard, returning to the step 1 to optimize the main bearing structure; if the requirements are met, ending.
7. The simulation analysis method for the reliability of the threaded connection pair of the main bearing seat of the engine according to claim 5, wherein the difference judgment standard in the step 3.3 is that the difference is less than 5%.
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|---|---|---|---|---|
| CN103678749A (en) * | 2012-09-24 | 2014-03-26 | 重庆长安汽车股份有限公司 | Finite element analysis method of automobile pull rod type suspension |
| CN107665286A (en) * | 2017-10-31 | 2018-02-06 | 华晨汽车集团控股有限公司 | One kind is on automobile engine bearings dynamic analysis method |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN103678749A (en) * | 2012-09-24 | 2014-03-26 | 重庆长安汽车股份有限公司 | Finite element analysis method of automobile pull rod type suspension |
| CN107665286A (en) * | 2017-10-31 | 2018-02-06 | 华晨汽车集团控股有限公司 | One kind is on automobile engine bearings dynamic analysis method |
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