摘要
城市处置危险废物是国家解决危险废物问题的重点项目,开展闸板断裂失效分析研究,不仅为危险废物处置行业进行产品设计提供了基础数据,而且打破了国外设备在国内的垄断。研发出替代进口的核心零部件可以降低危废处置企业的维护成本。首先分析固体泵闸板断裂失效产生的裂纹,对断口进行宏观形貌观察、材料化学成分测定、力学性能检测、硬度测量、金相分析、SEM形貌分析,在闸板的横向、纵向剖面和裂纹源处凹坑均呈现显微疏松特征,然后根据断口基本形态判定是由于残余内应力造成断裂失效,再基于有限元仿真研究论证材料强度是否满足设计要求,得出应力集中位置螺纹处和圆弧刃处是易发生断裂的位置。最后优化设计机械结构和热处理工艺,采用去机械加工应力、深冷和多次回火工艺,新闸板能够完全满足性能需求,工程应用中再未发生闸板断裂失效问题。
Urban disposal of hazardous waste is a key project for the country to solve the problem of hazardous waste.Conducting analysis and research on gate fracture failure not only provides basic data for product design in the hazardous waste disposal industry,but also breaks the monopoly of foreign equipment in China.Developing core components to replace imports can reduce maintenance costs for hazardous waste disposal enterprises.This project first analyzes the cracks of fracture failure of solid pump gate plates.Macroscopic morphology observation,material chemical element determination,mechanical properties,hardness measurement,metallographic analysis,and SEM morphology analysis are carried out on the fracture surface.The transverse and longitudinal sections of the gate plate and the pits at the grain source show obvious loose characteristics.Then,based on the basic morphology of the fracture surface,it is determined that the fracture failure was caused by residual internal stress.Based on finite element simulation research to demonstrate whether the material strength meets the design requirements.At the same time,it is found that the stress concentration position at the thread and the circular arc edge are the locations where fracture is prone to occur.Finally,the mechanical structure and heat treatment process were optimized,and the new gate was able to fully meet performance requirements by using stress reduction,deep cooling,and multiple tempering processes.No gate fracture failure occurred in engineering applications.
作者
郭光明
GUO Guangming(Beijing Academy Science and Technology,Intelligent Equipment Research Institute,Beijing 100061,China)
基金
北京市科学技术研究院财政资助项目(24CB008-02)。