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The aircraft’s inlet structure is connected to the engine sleeve using countersunk rivets. During maintenance,fatigue fractures were discovered in some rivets. It suggests that the inadequate perpendicularity of rivet holes during manufacturing causes the rivet misalignment, reducing the load-bearing capacity, and leading to fatigue fractures under aircraft vibrations. The finite element simulation was used to study the effect of inclined rivet holes on the load-bearing capacity,simulation results show that inclined holes cause uneven stress distribution across the rivet section. The higher the tilt angle,the higher the maximum stress and the more uneven stress distribution on the rivet head section. Fatigue tests under axial loads at different tilt angles demonstrated a reduction in the rivet’s fatigue life due to the hole inclination. The study concludes that non-compliance with perpendicularity standards during hole fabrication results in uneven stress distribution, decreasing load-bearing capacity. Therefore, the strict control over rivet hole perpendicularity during the aircraft manufacturing is crucial to ensure structural reliability.

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MENG Qingxun, E-mail:
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飞机进气道结构与发动机套筒之间使用沉头铆钉连接,在检修中发现部分铆钉发生疲劳断裂问题,分析认为制造过程中因铆钉孔垂直度不合格导致铆钉偏斜,造成铆钉承载能力降低,受机身振动影响引发疲劳断裂。通过有限元仿真方法研究铆钉孔倾斜对铆钉承载能力的影响,结果表明,铆钉孔倾斜会造成铆钉截面应力分布不均,且倾斜角度越大,铆钉头截面的铆钉最大应力和应力分布不均匀程度越高。不同倾斜角度下的铆钉轴向载荷疲劳试验表明,铆钉孔倾斜会造成轴向交变载荷下铆钉疲劳寿命的缩减。研究结果表明,制孔及锪窝工艺中铆钉孔垂直度不合格会造成铆钉截面内应力分布不均,降低铆钉承载能力,在飞机制造过程中应严格控制铆钉孔垂直度,以确保铆接结构的可靠性。

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孟庆勋,男,1989年生,吉林松原人,博士,副教授,硕士研究生导师;主要研究方向为飞行器智能装配技术;E-mail:
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李传钊,男,2000年生,山东德州人,硕士研究生;主要研究方向为飞行器装配工艺;E-mail:

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李传钊,男,2000年生,山东德州人,硕士研究生;主要研究方向为飞行器装配工艺;E-mail:

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keyword=制孔垂直度), Keyword(id=1228282205064065937, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1228282195668824648, language=CN, orderNo=3, keyword=应力分布), Keyword(id=1228282205152146327, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1228282195668824648, language=CN, orderNo=4, keyword=疲劳寿命), Keyword(id=1228282205244421020, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1228282195668824648, language=CN, orderNo=5, keyword=有限元仿真)], refs=[Reference(id=1228282210697015447, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1228282195668824648, doi=null, pmid=null, pmcid=null, year=2023, volume=66, issue=1, pageStart=26, pageEnd=37, url=null, language=null, rfNumber=[1], rfOrder=0, authorNames=曹增强, 张铭豪, 谭学才, journalName=航空制造技术, refType=null, unstructuredReference=曹增强,张铭豪,谭学才,等.航空复合材料结构铆接技术综述[J].航空制造技术202366(1):26-37., articleTitle=航空复合材料结构铆接技术综述, refAbstract=null), Reference(id=1228282210780901531, 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Material properties

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参数Parameter2A102B06TC2
弹性模量
Modulus of elasticity/MPa
69 00065 262109 706
密度Density/(kg/m3)2 8002 7004 500
泊松比Poisson ratio0.310.3680.324
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材料属性

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参数Parameter2A102B06TC2
弹性模量
Modulus of elasticity/MPa
69 00065 262109 706
密度Density/(kg/m3)2 8002 7004 500
泊松比Poisson ratio0.310.3680.324
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J-C model parameters of 2A10 aluminum alloy

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A/MPaB/MPaCnm
297338.20.0150.341
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2A10铝合金J-C模型参数

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A/MPaB/MPaCnm
297338.20.0150.341
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制孔垂直度对轴向振动载荷下铆钉承载能力的影响研究
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李传钊 1 , 张辉 2 , 潘新 2 , 刘学儒 3 , 孟庆勋 1, 2
机械强度 | 实验研究·测试技术 2025,47(10): 105-113
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机械强度 | 实验研究·测试技术 2025, 47(10): 105-113
制孔垂直度对轴向振动载荷下铆钉承载能力的影响研究
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李传钊1 , 张辉2, 潘新2, 刘学儒3, 孟庆勋1, 2
作者信息
  • 1.沈阳航空航天大学 航空宇航学院,沈阳 110136
  • 2.沈阳飞机工业(集团)有限公司,沈阳 110034
  • 3.沈阳航空航天大学 民用航空学院,沈阳 110136
  • 李传钊,男,2000年生,山东德州人,硕士研究生;主要研究方向为飞行器装配工艺;E-mail:

通讯作者:

孟庆勋,男,1989年生,吉林松原人,博士,副教授,硕士研究生导师;主要研究方向为飞行器智能装配技术;E-mail:
Research on influences of drilling verticality on bearing capacity of rivets under the axial vibration load
Chuanzhao LI1 , Hui ZHANG2, Xin PAN2, Xueru LIU3, Qingxun MENG1, 2
Affiliations
  • 1.School of Aeronautics and Astronautics, Shenyang Aerospace University, Shenyang 110136, China
  • 2.Shenyang Aircraft Industry (Group) Co., Ltd., Shenyang 110034, China
  • 3.School of Civil Aviation, Shenyang Aerospace University, Shenyang 110136, China
出版时间: 2025-10-15 doi: 10.16579/j.issn.1001.9669.2025.10.012
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飞机进气道结构与发动机套筒之间使用沉头铆钉连接,在检修中发现部分铆钉发生疲劳断裂问题,分析认为制造过程中因铆钉孔垂直度不合格导致铆钉偏斜,造成铆钉承载能力降低,受机身振动影响引发疲劳断裂。通过有限元仿真方法研究铆钉孔倾斜对铆钉承载能力的影响,结果表明,铆钉孔倾斜会造成铆钉截面应力分布不均,且倾斜角度越大,铆钉头截面的铆钉最大应力和应力分布不均匀程度越高。不同倾斜角度下的铆钉轴向载荷疲劳试验表明,铆钉孔倾斜会造成轴向交变载荷下铆钉疲劳寿命的缩减。研究结果表明,制孔及锪窝工艺中铆钉孔垂直度不合格会造成铆钉截面内应力分布不均,降低铆钉承载能力,在飞机制造过程中应严格控制铆钉孔垂直度,以确保铆接结构的可靠性。

铆钉  /  制孔垂直度  /  应力分布  /  疲劳寿命  /  有限元仿真

The aircraft’s inlet structure is connected to the engine sleeve using countersunk rivets. During maintenance,fatigue fractures were discovered in some rivets. It suggests that the inadequate perpendicularity of rivet holes during manufacturing causes the rivet misalignment, reducing the load-bearing capacity, and leading to fatigue fractures under aircraft vibrations. The finite element simulation was used to study the effect of inclined rivet holes on the load-bearing capacity,simulation results show that inclined holes cause uneven stress distribution across the rivet section. The higher the tilt angle,the higher the maximum stress and the more uneven stress distribution on the rivet head section. Fatigue tests under axial loads at different tilt angles demonstrated a reduction in the rivet’s fatigue life due to the hole inclination. The study concludes that non-compliance with perpendicularity standards during hole fabrication results in uneven stress distribution, decreasing load-bearing capacity. Therefore, the strict control over rivet hole perpendicularity during the aircraft manufacturing is crucial to ensure structural reliability.

Rivet  /  Drilling verticality  /  Stress distribution  /  Fatigue life  /  Finite element simulation
李传钊, 张辉, 潘新, 刘学儒, 孟庆勋. 制孔垂直度对轴向振动载荷下铆钉承载能力的影响研究. 机械强度, 2025 , 47 (10) : 105 -113 . DOI: 10.16579/j.issn.1001.9669.2025.10.012
Chuanzhao LI, Hui ZHANG, Xin PAN, Xueru LIU, Qingxun MENG. Research on influences of drilling verticality on bearing capacity of rivets under the axial vibration load[J]. Journal of Mechanical Strength, 2025 , 47 (10) : 105 -113 . DOI: 10.16579/j.issn.1001.9669.2025.10.012
铆钉连接以其良好的机械性能和较强的环境适应性等优点在航空航天制造领域应用十分广泛[1]。在众多铆接形式中,沉头铆钉相比于普通铆钉表面平整度更高,因此气动阻力较低,更加适合在有气流通过的区域使用,但沉头铆钉的制孔工序较多,制孔质量较难控制,制孔与铆接的过程中容易产生质量问题[2]
影响铆接质量的因素有很多,如孔垂直度、铆接干涉量、孔同轴度、铆接夹层间隙等[3]。SUN等[4]通过疲劳试验的方法研究了垂直度偏差对碳纤维增强塑料(Carbon Fibre Reinforced Plastics, CFRP)接头疲劳性能的影响,证明垂直度偏差会降低接头的高周疲劳寿命。KORBEL[5]通过控制铆接过程中的生产变量,研究了安装工艺对薄板铆接搭接接头残余应力、夹紧力和疲劳性能的影响。LI等[6]通过数值分析和试验的方法研究了配合公差对CFRP/铝合金单搭接盲铆接接头承载能力的影响。徐茂青[7]结合有限元分析与试验,研究了连接孔垂直度误差对复合材料双钉单剪连接性能的影响,分析了垂直度误差中倾斜角度和倾斜方向对钉载分配的影响。CHISHTI等[8]研究了沉头铆钉孔的锪窝深度、铆接间隙等对复合材料结构接头强度及疲劳寿命的影响。赵琪等[9]通过有限元分析配合试验验证的方法,研究了制孔垂直度对螺栓连接强度的影响规律。高航等[10]使用极限承载强度、弦刚度、2%偏移承载强度为指标研究了连接孔的倾斜角度、倾斜方向以及螺栓转矩对接头承载性能的影响规律。LIU等[11]的研究表明,随着孔倾斜程度的增加,复合材料单搭接双螺栓结构的连接强度逐渐下降
上述研究成果表明,制孔质量的下降影响连接结构的承载能力。但上述研究多数关注于制孔偏差对于被连接件强度的影响,缺少对连接件自身受载情况的分析。本文研究了制孔垂直度偏差对铆钉承载能力的影响,基于在发动机运行条件下采集到的真实振动载荷谱,通过有限元方法模拟铆接区域受载情况,得到倾斜角度与铆钉截面应力分布的关系,并通过振动疲劳试验,研究了铆钉孔垂直度对振动疲劳寿命的影响,为飞机铆装现场优化制孔工艺参数,进一步规范工艺流程提供了理论依据。
飞机进气道内筒蒙皮与发动机套筒之间由两排交错的铆钉连接而成,在飞行过程中,发动机振动产生的部分载荷会影响到该铆接区域,振动环境容易引起铆钉连接处的松动、滑移甚至断裂,给飞行安全带来隐患。如图1所示,从航向方向来看,该铆接区域前方为铝合金材质的进气道内筒蒙皮,进气道内筒蒙皮的前端与机身隔框通过铆钉连接;后方为钛合金套筒,套筒与发动机转接段之间采用过渡配合。发动机在运行过程中会产生振动载荷,大部分振动载荷经由螺栓等连接件传递到机身,但仍有部分振动载荷会通过套筒传递到其与进气道蒙皮的铆接区域,成为影响该铆接区域的主要外部载荷。飞机的紧固件及其连接结构在复杂交变载荷作用下容易产生疲劳断裂问题[12],因此本文参考了真实测得的机身振动载荷,为铆接结构仿真分析和疲劳试验制定合适的外部激励载荷。
孔垂直度误差是一种制造缺陷,外观上表现为沉头铆钉的窝孔倾斜,垂直度较差的铆钉孔会在承受载荷时在孔周区域造成不均匀的应力分布,影响铆接结构的连接性能[13-15]。沉头铆钉孔的制孔工艺包括制孔、铰孔、锪窝、去毛刺等,在进气道铆接叠层结构制孔工作中,受操作空间限制,大部分的制孔-锪窝工序由工人持风钻手工完成,制孔质量缺乏同一性,容易产生垂直度偏差等问题。本文通过有限元仿真的方法,在仿真模型中调整铆钉的倾斜方向与角度,对比不同倾斜角度下铆钉的受力情况,探究铆钉倾斜对其承载能力的影响。之后分别对倾斜铆钉和竖直铆钉连接的试验件进行轴向振动疲劳试验,研究垂直度偏差对铆钉疲劳寿命的影响及其机制并给出结论。
发动机在运行阶段存在振动问题,铆接区域作为发动机套筒与进气道的连接区域,承受着传递部分载荷的作用。需要经过加速度测量的方法确定振动载荷的量级与方向,作为仿真分析载荷设置的依据[16]。加速度测量如图2所示,使用三轴加速度传感器对发动机在不同转速下铆接区域的时域加速度信息进行测量,测量位置为保证发动机运行安全的情况下操作可达的套筒内侧铆钉旁,振动加速度信号经过信号放大器由数据采集器采集。
加速度传感器的方向设定如下:x为顺航向气流方向,y为发动机进气道径向方向,z为进气道圆周切向方向。图3为测量点在xy、z 3个方向的加速度值。由图3可知,随着发动机转速的变化,xyz 3个方向上的振动加速度变化趋势一致,沿y方向的最大加速度为199 m/s2xz方向最大加速度分别为41、40 m/s2y方向的振动加速度显著高于xz方向,因此在随后的仿真分析中重点关注铆钉沿轴向的载荷。根据断裂铆钉形貌分析可知,断裂形式为低应力高周疲劳断裂,因此认为铆钉断裂原因为铆钉长期承受周期性轴向振动载荷,在钉头应力集中处出现裂纹,随后裂纹逐渐扩展,最终完全失效断裂。
选取y方向上发动机转速为100%时的部分时域信号进行分析。调整时域坐标轴尺度分析加速度信息,在耦合了发动机和机体振动的环境下,铆接区域的加速度信号无周期性规律,为典型的随机振动,无法直接进行频率、振幅等振动特性的提取。
使用载荷分析软件Siemens LMS tecware对该时域加速度信号进行功率谱密度(Power Spectral Density, PSD)分析,得到图4所示的功率谱密度示意图。该信号的主要频率区间为2 750~3 750 Hz,在1 000~1 250 Hz也有少量分布。仿真载荷选取的原则是在铆钉产生最大加速度的工况下频率最为集中的振动状态。根据以上分析及图4所示结果,最终选用3 100 Hz作为仿真计算载荷的加载频率。
铆接区域结构整体尺寸过大,在有限元分析中对计算机要求较高,计算时间过长。经分析,铆接区域中两排铆钉交错排列,每排中相邻两颗铆钉之间弧长为40 mm,具有明显的重复性规律,因此采用提取等效结构的方法进行仿真模型的构建。选用包含5颗铆钉的区域,并隐去被连接件的多余结构,作为用于仿真的等效几何结构,如图5所示。圆环曲率较小,5颗铆钉覆盖的区域与平面较为接近,因此近似为平面结构以便于计算。选用中间铆钉作为研究对象,该结构可隔绝边缘铆钉的边际效应影响,保证中间铆钉所承受载荷的对称性和一致性。分别设置铆接区域宽度为25 mm;铆钉距边缘为9 mm;两排铆钉间距为7 mm。按照铆接区域的真实结构尺寸进行边界条件设置。由图5可知,进气道内筒蒙皮外侧被机身隔框约束,根据隔框在该区域的相对位置在仿真模型中施加约束条件;套筒与发动机嵌套,承受来自发动机的振动载荷,因此在套筒中间位置施加载荷。将仿真载荷设置为y方向上施加载荷大小为100 N、频率为3 100 Hz的周期性载荷。
调整不同模型中中间铆钉孔的倾斜角度与方向,以便研究钉孔倾斜对铆钉承载能力的影响。
图6(a)为正常的竖直铆钉;图6(b)为中间铆钉孔绕x轴正方向倾斜3°的模型;图6(c)为绕z轴负方向倾斜3°,图6(d)为绕z轴正方向倾斜3°。对倾斜方向不同的铆钉进行仿真计算,目的是排除载荷加载位置对仿真的影响,证明影响铆钉应力分布的因素仅为铆钉倾斜。
为了研究倾斜角度对铆钉承载能力的影响,分别设置中间连接孔的倾斜角度为0°、1°、2°和3°,根据仿真结果分析铆钉头根部应力分布随倾斜角度变化的规律。
模型由蒙皮、套筒、铆钉以及模拟铆接过程的冲头构成,蒙皮厚度为1.8 mm,材质为2B06铝合金;套筒厚度为2 mm,材质为TC2钛合金;铆钉与冲头材料为2A10铝合金。材料力学性能如表1所示。
仿真涉及铆钉的塑性成形,仿真中2A10铝合金材料采用Johnson-Cook(J-C)模型。J-C模型常用于材料准静态条件下的塑性变形,对于铆接成形仿真来说较为合适。J-C材料强度模型的表达式为
式中,Re为材料屈服应力;A为材料准静态屈服强度;ε为塑性应变;Bn均为应变硬化影响系数;C为应变率敏感指数;m为材料温度的敏感系数;为应变率;为参考的应变率;T0为材料熔点;T为材料瞬时温度;Tr为室温。
在Abaqus软件材料属性设置中选择J-C准则,对ABCnm 5个参数进行设置,相关参数值如表2所示[17]
其他仿真设置如下:
1)变形设置:铆钉及被铆接件为变形体,两侧冲头为刚体。
2)网格划分:使用C3D8R六面体网格对模型进行划分。定义进气道内筒蒙皮和发动机套筒的近似全局网格种子尺寸为0.3 mm,进气道内筒蒙皮划分了153 781个网格,发动机套筒的网格数为193 338;为了更精准地分析铆钉的受载情况,设置铆钉网格种子尺寸为0.12 mm,每颗铆钉划分49 488个网格。网格划分后的装配体如图7(a)所示。
3)相互作用属性设置:在铆钉与板材、两侧冲头之间,板材与板材之间设置为通用接触,法向方向为硬接触,切向设置为摩擦因数为0.3的罚摩擦接触,如图7(b)所示。
4)分析步设置:为了模拟铆钉铆接及后续受载后铆钉的受力情况,在仿真中设置了3个分析步,分别模拟铆钉铆接,冲头撤出以及加载的过程,每个分析步均设置为显式动力学分析。在分析步①中,设置上侧冲头向下位移0.5 mm。下侧冲头向上位移3 mm,图7(c)为直钉模型的位移边界条件设置,图7(d)为斜钉模型的位移边界条件设置;随后在分析步②中为上、下两侧冲头设置远离铆钉的位移,撤出铆模,避免其在加载过程中与铆钉产生干涉;在分析步③中施加载荷幅值为100 N的周期性载荷,载荷的幅值曲线如图8所示。3个分析步的初始状态如图9所示。采用分析步③最后时刻的仿真结果作为结果分析,此时铆钉承受的载荷最大。
不同倾斜方向下铆钉头根问截面的应力分布,如图10所示。首先,对垂直铆钉进行分析,由图10(a)可知,在y方向视图下,铆钉钉头根部的应力分布较为均匀,最大应力出现在接近表层的区域,最大应力值为254 MPa,最小应力点出现在钉杆的正中间。由图10(b)可知,铆钉孔向左倾斜3°,垂直于铆钉轴线平面内的应力呈明显非对称分布,最大应力集中在铆钉沉头倾斜的方向,应力集中区域的最大应力值为288.2 MPa,明显大于非倾斜钉的情况,最小应力点同样偏离了铆钉中心。由图10(c)图10(d)可知,铆钉孔分别向前、后倾斜3°,其应力分布同样呈现非对称形式,2种情况下最大应力均集中在铆钉头倾斜方向。向前倾斜情况下的最大应力值为289.2 MPa,向后倾斜情况下的最大应力值为281.8 MPa,两者均明显大于竖直铆钉的情况。铆钉孔向不同方向倾斜所引起的最大应力值差异仅为几兆帕。此结果可证明,铆钉截面应力分布不均仅与铆钉孔倾斜方向有关,排除仿真的边界条件和载荷设置对铆钉截面应力分布的影响。
对倾斜角度不同的仿真结果进行分析,沿经过铆钉轴线的平面将铆钉剖开,以便观察截面的应力分布。沉头铆钉钉头与钉杆的过渡区域位于2个被连接件接触的区域,直接承受振动带来的轴向载荷,因此钉头根部应力水平高于其他位置,易形成应力集中,成为疲劳断裂的源区。图11(a)为正常的非倾斜铆钉应力分布情况,铆钉轴线两侧应力呈对称分布,无明显的应力集中。图11(b)~图11(d)分别为1°、2°、3°倾斜的铆钉,可见铆钉轴线两侧应力呈明显的非对称分布,各铆钉在图11展示的视图中左侧应力水平较高,且随着倾斜度数增加,应力集中程度也逐渐升高。该结果表明,铆钉倾斜角度越大,越容易在钉头与钉杆的过渡区域形成应力集中现象。应力集中处在振动环境下容易产生微裂纹,进而成为裂纹扩展的源区,裂纹在振动载荷下继续扩展,导致铆钉整体断裂[18]
分别提取倾斜角度为0°、1°、2°、3°的铆钉钉头根部截面最大应力,如图12所示。由图12可知,随着倾斜角度增加,最大应力逐渐增大。倾斜度过大的铆钉更容易在钉头根部形成应力集中,造成初始损伤,成为疲劳断裂的起裂源,在振动载荷的作用下扩展为裂纹,最终造成断裂,影响飞行安全。
在Abaqus软件后处理模块中提取不同倾斜角度的模型中钉头根部截面上距圆心3.8 mm的圆周上的节点Mises应力信息,绘制在图13所示的雷达图上。图13中,周向刻度为各节点编号,轴向刻度为该节点Mises应力值。图13中,紫色线为铆钉孔垂直情况下的应力数据,其应力分布均匀性较好,随着倾斜角度的增加,应力分布均匀度变差,高应力区域更容易集中在同一侧,容易引发裂纹的萌生,进而造成铆钉承载能力的降低。
为研究垂直度缺陷对铆钉疲劳寿命的影响,设计铆接结构受轴向振动载荷的疲劳试验。准备图14所示的试验件。上板模拟进气道蒙皮,材料为2B06铝合金,厚度为1.8 mm;下板模拟发动机套筒,材料为TC2钛合金,厚度为2 mm;铆钉为HB8065-4×9 mm 90°沉头半冠状铆钉[19],材质为2A10铝合金。试验件各部件的材料及铆钉孔之间的位置关系均与飞机的真实结构保持一致。分别制作中间铆钉孔垂直和倾斜3°的试验件,a组试验件中间铆钉垂直于板平面,b组试验件中间铆钉向左侧倾斜,进行对比试验。
使用电磁振动试验机进行振动试验。设计图15所示的振动试验夹具。试验件的一端由螺栓固定在夹具上,模拟机身隔框对进气道内蒙皮的约束作用;另一端通过专用夹具连接特定质量的配重,用于在振动中为试验件提供载荷。
设置振动台模式为垂直振动,在振动试验中,每1次循环可分为4步,每1步中振动台与试验件以及配重的运动状态各有不同。图16为振动试验各部件的运动状态。假设1次振动循环开始时振动台拥有向下的运动趋势,如图16(a)所示,此时台面开始向下移动,配重块在自身重力作用下也随之向下移动。图16(b)中,振动台面移动至最低点,配重随试验件与夹具也移动至最低点,之后进入第3步。如图16(c)所示,振动台在移动至最低点后开始向上移动,而配重块由于自身质量较大,在惯性作用下仍有保持原有运动状态的趋势,所以配重块的移动滞后于振动台与夹具,从而在试验件的铆钉处造成了轴向拉力,实现了在振动中为铆钉提供轴向周期性拉伸载荷的目的。最后,图16(d)中,台面移动至最高点,配重块在试验件的拉伸作用下也开始向上移动,之后再回到图16(a)所示状态,进行下一周期的循环。配重块为铆钉提供周期性的拉伸载荷,模拟发动机运行过程中产生的轴向振动载荷作用在铆钉上的效果。
在振动试验的1次循环中,配重的振动滞后于振动台,试验件中铆钉的拉伸载荷来源于配重与振动台的相位差,在两者振动加速度差别最大时,铆钉的拉伸载荷最大。进行振动试验时,以高功率模式下配重存在垂直方向上的位移为标准进行振动台参数的设置,对试验件进行轴向振动载荷加载,直至铆钉头发生断裂失效。
首先进行倾斜铆钉试验件的振动试验,试验结果中,b组试验件中间部位的倾斜铆钉发生疲劳断裂,此时振动试验机记录的试验时长为584 642 s,等效循环次数为4 092 494。之后替换为a组试验件进行试验,在相同的振动参数及载荷下,振动时长超过1 000 000 s时,a组试验件上的铆钉仍未发生断裂。试验结果表明,在相同振动载荷条件下,存在制孔垂直度缺陷的铆钉疲劳寿命低于垂直度较好的铆钉。
倾斜铆钉疲劳断口形貌与仿真应力图的对比如图17所示。图17(a)标示了振动试验中的铆钉倾斜方向;图17(b)为断裂铆钉的断裂形貌,可明显观察到断口左侧为疲劳断裂的源区,中间部分为扩展区,右侧为瞬断区,断口形貌符合疲劳断裂的一般特征[20]图17(c)所示为与试验件铆钉倾斜方向相同的有限元仿真结果,可见铆钉截面应力分布不均,左侧存在应力集中现象,与振动试验中铆钉疲劳断裂的源区位置一致。综合有限元仿真结果与振动试验结论可认为,存在垂直度缺陷的铆钉疲劳寿命不佳的原因为在拉伸载荷下铆钉沉头与钉杆过渡处应力分布不均匀,在应力集中处形成初始裂纹,随后裂纹在载荷作用下继续扩展,最终造成铆钉断裂。
通过有限元仿真结合试验的方法研究了制孔垂直度对受轴向载荷作用下的铆钉承载能力的影响,以铆钉头根部截面应力分布均匀程度、最大应力值为指标,对不同钉孔倾斜角度下铆钉受载情况进行仿真,并进行了铆钉疲劳振动试验,得出以下主要结论:
1)铆钉孔倾斜会引发铆钉截面内应力分布不均匀。对具有不同倾斜方向钉孔的仿真模型进行有限元计算,结果表明,钉孔倾斜会引发铆钉头根部截面的应力不均匀,造成一侧应力集中。
2)随着钉孔倾斜角度的增大,铆钉截面的最大应力增大,应力分布均匀程度降低。在仿真中分别设置钉孔倾斜角度为0°、1°、2°、3°的模型,结果表明,铆钉头根部截面最大应力值逐渐升高,且应力分布均匀程度逐渐降低,高应力区域更容易集中在同一侧,造成铆钉承载能力的降低。
3)钉孔垂直度不合格会降低铆钉承受轴向载荷时的疲劳寿命。设计铆接结构受轴向振动载荷下的铆钉疲劳试验,试验结果显示,具有倾斜铆钉孔的试件的循环次数低于铆钉孔垂直的试验件,断裂铆钉的初始裂纹位置与仿真中应力集中区域一致。因此,在制孔及锪窝时应严格控制钉孔垂直度误差,避免发生铆钉断裂事故,影响铆接结构可靠性。
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2025年第47卷第10期
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doi: 10.16579/j.issn.1001.9669.2025.10.012
  • 接收时间:2024-01-19
  • 首发时间:2026-02-11
  • 出版时间:2025-10-15
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  • 收稿日期:2024-01-19
  • 修回日期:2024-03-14
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    1.沈阳航空航天大学 航空宇航学院,沈阳 110136
    2.沈阳飞机工业(集团)有限公司,沈阳 110034
    3.沈阳航空航天大学 民用航空学院,沈阳 110136

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孟庆勋,男,1989年生,吉林松原人,博士,副教授,硕士研究生导师;主要研究方向为飞行器智能装配技术;E-mail:
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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