磨削烧伤、化瓦对残余应力及可靠性影响的分析与研究

Analysis and Study on the Effects of Grinding Burns and Tiles on Residual Stress and Reliability

摘要: 残余应力、微观组织及形貌等表面完整性是影响柴油机关键轴类零件服役性能的核心因素。本文针对柴油机轴类零件制造或服役过程中的表面完整性问题，运用宏观观测、残余应力检测、硬度测试、扫描电镜等手段，系统探究了残余应力形成机制及其对零件失效行为的影响，结果表明磨削烧伤和化瓦缺陷会引起表面残余应力值显著降低，进而促使疲劳裂纹在应力集中区域优先萌生，通过X射线残余应力测试及扫描电子显微镜(SEM)断口分析揭示了残余应力分布与柴油机轴类零件裂纹萌生的关联性，可为柴油机重要轴类件生产制造及可靠性分析研究提供检测借鉴和参考。

Abstract: The surface integrity of residual stress, microstructure, and morphology are the core factors affecting the service performance of key shaft components in diesel engines. This article focuses on the surface integrity issues in the manufacturing or service process of diesel engine shaft parts. By using macroscopic observation, residual stress detection, hardness testing, scanning electron microscopy and other methods, the mechanism of residual stress formation and its influence on the failure behavior of the parts are systematically explored. The results showed that grinding burns and tile defects can significantly reduce the surface residual stress values, thereby promoting the preferential initiation of fatigue cracks in stress concentration areas. The correlation between residual stress distribution and crack initiation in diesel engine shaft parts was revealed through X-ray residual stress testing and scanning electron microscopy fracture analysis, which can provide detection reference and guidance for the production and reliability analysis of important shaft parts in diesel engines.