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Article(id=1241029726232441587, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241029724655383270, articleNumber=null, orderNo=null, doi=10.16579/j.issn.1001.9669.2025.02.005, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1683302400000, receivedDateStr=2023-05-06, revisedDate=1694102400000, revisedDateStr=2023-09-08, acceptedDate=null, acceptedDateStr=null, onlineDate=1773814143951, onlineDateStr=2026-03-18, pubDate=1739548800000, pubDateStr=2025-02-15, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1773814143951, onlineIssueDateStr=2026-03-18, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1773814143951, creator=13701087609, updateTime=1773814143951, updator=13701087609, issue=Issue{id=1241029724655383270, tenantId=1146029695717560320, journalId=1227999626482147330, year='2025', volume='47', issue='2', pageStart='1', pageEnd='158', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1773814143575, creator=13701087609, updateTime=1773840259815, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1241139264176574915, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241029724655383270, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1241139264176574916, tenantId=1146029695717560320, journalId=1227999626482147330, issueId=1241029724655383270, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=37, endPage=43, ext={EN=ArticleExt(id=1241029726475711226, articleId=1241029726232441587, tenantId=1146029695717560320, journalId=1227999626482147330, language=EN, title=Crack failure analysis of low pressure turbine shaft oil passage hole of aero-engine, columnId=1241029725523604201, journalTitle=Journal of Mechanical Strength, columnName=Fatigue∙Damage∙Fracture∙Failure Analysis, runingTitle=null, highlight=null, articleAbstract=

In order to investigate the nature and causes of the cracked passage hole of the low-pressure turbine shaft of aero-engine during the high and low circumference compound fatigue test, the low-pressure turbine shaft crack location was examined in appearance, fracture analysis, surface inspection, metallographic organization, finite element analysis and crack expansion simulation.The results show that the low-pressure turbine shaft passage hole crack failure is a fatigue crack, which is caused by the incomplete removal of the remelting layer after the passage hole is cut by electrical discharge machining,resulting in the existence of part of the unremoved remelting layer and visible microcracks on the internal surface, and the fatigue crack sprouted and crack expansion occurred under the action of large high and low circumferential composite load,thus leading to the passage hole crack failure. The initial crack length is estimated to be between 0.2-0.3 mm by the crack expansion simulation analysis. In order to ensure the processing quality of the through oil hole, considering the poor processing accessibility of this location, it is suggested that special tooling can be designed and the machining technology can be used for processing, on the basis of ensuring the processing, fundamental eliminate the influence of the remelting layer.

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WANG Xuemin, E-mail：
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为探究某型航空发动机低压涡轮轴高低周复合疲劳试验过程中通油孔裂纹故障的性质和原因，对低压涡轮轴裂纹位置进行了外观检查、断口分析、表面检查、金相组织检查、有限元分析和裂纹扩展仿真。结果表明，低压涡轮轴通油孔裂纹故障为疲劳裂纹，其原因为通油孔采用电火花加工后，未完全去除重熔层，导致其内侧表面存在部分未去除的重熔层且有可见微裂纹，在较大的高低周复合载荷作用下萌生疲劳裂纹并发生了裂纹扩展，从而导致通油孔裂纹故障，通过裂纹扩展仿真分析预估初始裂纹长度介于0.2~0.3 mm。为了保证通油孔加工质量，考虑该位置加工可达性较差，建议可设计特殊工装、采用机械加工技术进行加工，在保证加工精度的基础上从根本上杜绝重熔层的影响。

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王学民，男，1992年生，江西赣州人，工程师；主要研究方向为航空发动机结构强度；E-mail：。

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王学民，男，1992年生，江西赣州人，工程师；主要研究方向为航空发动机结构强度；E-mail：。

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王学民，男，1992年生，江西赣州人，工程师；主要研究方向为航空发动机结构强度；E-mail：。

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articleId=1241029726232441587, language=CN, label=图16, caption=不同初始裂纹表面裂纹长度随循环数变化曲线, figureFileSmall=Eaag8BbVSX05uoe8TLn2+Q==, figureFileBig=6lGID/PIa8XnjSaAVV+Oww==, tableContent=null), ArticleFig(id=1241029742711861706, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241029726232441587, language=EN, label=Tab.1, caption=

Number of cycles under 0.1, 0.2, 0.3 mm initial cracks when external surface cracks reach 6.325 mm

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初始裂纹长度
Initial crack length/mm		循环数 Number of cycles
低周
Low-cycle		高周
High-cycle
0.12 3122 570 944
0.22 0592 289 608
0.31 8392 044 968
), ArticleFig(id=1241029742804136396, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241029726232441587, language=CN, label=表1, caption=

外表面裂纹达到6.325 mm时0.1、0.2、0.3 mm初始裂纹下循环数

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初始裂纹长度
Initial crack length/mm		循环数 Number of cycles
低周
Low-cycle		高周
High-cycle
0.12 3122 570 944
0.22 0592 289 608
0.31 8392 044 968
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航空发动机低压涡轮轴通油孔裂纹失效分析
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王学民 1, 2 , 卢绪平 1 , 沈莲 1 , 古远兴 1 , 吴晨 1 , 郭建英 1 , 徐敬沛 1
机械强度 | 疲劳·损伤·断裂·失效分析 2025,47(2): 37-43
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机械强度 | 疲劳·损伤·断裂·失效分析 2025, 47(2): 37-43
航空发动机低压涡轮轴通油孔裂纹失效分析
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王学民1, 2 , 卢绪平1, 沈莲1, 古远兴1, 吴晨1, 郭建英1, 徐敬沛1
作者信息
  • 1.中国航发四川燃气涡轮研究院，成都　610500
  • 2.电子科技大学 机械与电气工程学院，成都　611731

    • 王学民，男，1992年生，江西赣州人，工程师；主要研究方向为航空发动机结构强度；E-mail：。

Crack failure analysis of low pressure turbine shaft oil passage hole of aero-engine
Xuemin WANG1, 2 , Xuping LU1, Lian SHEN1, Yuanxing GU1, Chen WU1, Jianying GUO1, Jingpei XU1
Affiliations
  • 1.AECC Sichuan Gas Turbine Research Establishment, Chengdu 610500, China
  • 2.School of Mechanical and Electrical Engineering, University of Electronic Science and Technology of China, Chengdu 611731, China
出版时间: 2025-02-15 doi: 10.16579/j.issn.1001.9669.2025.02.005
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摘要
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为探究某型航空发动机低压涡轮轴高低周复合疲劳试验过程中通油孔裂纹故障的性质和原因，对低压涡轮轴裂纹位置进行了外观检查、断口分析、表面检查、金相组织检查、有限元分析和裂纹扩展仿真。结果表明，低压涡轮轴通油孔裂纹故障为疲劳裂纹，其原因为通油孔采用电火花加工后，未完全去除重熔层，导致其内侧表面存在部分未去除的重熔层且有可见微裂纹，在较大的高低周复合载荷作用下萌生疲劳裂纹并发生了裂纹扩展，从而导致通油孔裂纹故障，通过裂纹扩展仿真分析预估初始裂纹长度介于0.2~0.3 mm。为了保证通油孔加工质量，考虑该位置加工可达性较差，建议可设计特殊工装、采用机械加工技术进行加工，在保证加工精度的基础上从根本上杜绝重熔层的影响。

低压涡轮轴  /  失效分析  /  重熔层  /  疲劳断裂  /  有限元分析  /  裂纹扩展仿真  /  航空发动机

In order to investigate the nature and causes of the cracked passage hole of the low-pressure turbine shaft of aero-engine during the high and low circumference compound fatigue test, the low-pressure turbine shaft crack location was examined in appearance, fracture analysis, surface inspection, metallographic organization, finite element analysis and crack expansion simulation.The results show that the low-pressure turbine shaft passage hole crack failure is a fatigue crack, which is caused by the incomplete removal of the remelting layer after the passage hole is cut by electrical discharge machining,resulting in the existence of part of the unremoved remelting layer and visible microcracks on the internal surface, and the fatigue crack sprouted and crack expansion occurred under the action of large high and low circumferential composite load,thus leading to the passage hole crack failure. The initial crack length is estimated to be between 0.2-0.3 mm by the crack expansion simulation analysis. In order to ensure the processing quality of the through oil hole, considering the poor processing accessibility of this location, it is suggested that special tooling can be designed and the machining technology can be used for processing, on the basis of ensuring the processing, fundamental eliminate the influence of the remelting layer.

Low pressure turbine shaft  /  Failure analysis  /  Remelting layer  /  Fatigue fracture  /  Finite element analysis  /  Crack expansion simulation  /  Aero-engine
王学民, 卢绪平, 沈莲, 古远兴, 吴晨, 郭建英, 徐敬沛. 航空发动机低压涡轮轴通油孔裂纹失效分析. 机械强度, 2025 , 47 (2) : 37 -43 . DOI: 10.16579/j.issn.1001.9669.2025.02.005
Xuemin WANG, Xuping LU, Lian SHEN, Yuanxing GU, Chen WU, Jianying GUO, Jingpei XU. Crack failure analysis of low pressure turbine shaft oil passage hole of aero-engine[J]. Journal of Mechanical Strength, 2025 , 47 (2) : 37 -43 . DOI: 10.16579/j.issn.1001.9669.2025.02.005
正文
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0　引言
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低压涡轮轴是发动机转子系统中的重要组成部分，主要功能是传递涡轮功率、承受循环载荷和支撑其他零部件[1]。在飞机运行时，低压涡轮轴承受复杂的稳态载荷，包括工作转矩、轴向力、径向力、热应力等；同时，还受到高频的振动转矩和陀螺力矩影响，受力情况比较复杂。一旦发生断裂等故障，会引起发动机、飞行器的严重失效，尤其是对于单发飞行器，将造成机毁人亡的后果[2]。因此，要求低压涡轮轴具备极高的可靠性，其疲劳寿命必须通过试验进行验证[3-6]。针对低压涡轮轴承力特点，对某型航空发动机低压涡轮轴开展了高低周复合疲劳研究性试验，试验加载轴向力、主转矩等低周载荷和振动转矩、弯矩等高周载荷，试验过程中载荷反馈系统出现异常，停车检查发现轴上通油孔位置产生了非预计性裂纹失效。低压涡轮轴采用适用于制造转动零件的优质GH4169材料，通油孔位置的加工工艺流程为电火花加工、人工去除重熔层[7]。
国内学者针对低压涡轮轴进行了诸多研究。骆丽等[8]建立了连续纤维增强轴结构力学模型，结合成熟的细观力学失效边界，可分析轴在扭转载荷下的应力响应并判断轴结构危险位置失效模式；陆艺鑫等[9]搭建了涡轮轴结构分析、可靠性分析和可靠性优化设计的参数化平台，建立了基于自适应协作代理策略的类序列解耦算法；刘丁玮[10]对涡轮轴疲劳失效分析方法进行了总结，引入危险部位数目和疲劳分散系数，建立了使用小子样疲劳寿命试验数据来估计总体疲劳寿命的方法；丁水汀等[11]研究发现，高、低压轴断裂后几十毫秒内最先发生的危害性事件分别是中压压气机喘振、涡轮转子超转和涡轮前温度略微升高，需引起高度重视；习年生等[12]通过涡轮轴断裂失效的宏观和微观特征分析，发现轴裂纹位置位于螺纹槽底，存在较大的应力集中，在大弯曲载荷作用下产生了疲劳断裂。
目前，国内鲜有关于低压涡轮轴中由于表面加工质量问题导致高低周复合疲劳试验过程发生断裂失效方面的报道。本文通过对低压涡轮轴通油孔裂纹位置进行外观检查、断口分析、表面检查和金相组织检查，初步判断裂纹属性，在此基础上进行有限元分析和裂纹扩展仿真，获得具体的失效原因并探究源区初始裂纹深度范围，为消除该类隐患提供了依据。
1　试验检测结果
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1.1　外观检查
低压涡轮轴裂纹产生于长轴段上通油孔位置，目视可见，轴表面裂纹长约7 mm，裂纹延伸方向与轴向呈约45°夹角。其宏观图像如图1所示。
采用体视镜观察轴通油孔边裂纹形貌，发现裂纹贯穿轴壁厚，外表面侧裂纹长度约为6.325 mm，内表面侧裂纹长度约为4.494 mm。孔壁内表面局部可见重熔层形貌（图2中虚线框标注），孔内壁裂纹穿过重熔层区域，重熔层区域以外可见沿孔壁周向加工去除重熔层痕迹，如图2所示。
1.2　断口分析
低压涡轮轴裂纹断口宏观形貌如图3所示。由图3可知，通油孔断口呈灰白色，断面较平坦，没有明显的塑性变形，可见清晰的放射棱线和疲劳弧线；人为打断区有一定起伏，断面基本垂直于轴壁面。孔内壁局部可见重熔层形貌，无明显加工痕迹。根据放射棱线和疲劳弧线的方向初步判断，疲劳起始于孔内壁中间区域。
在扫描电子显微镜下观察，由断口扩展棱线汇聚状态判断，裂纹起始于孔内壁重熔层区域，源区距外表面孔口约6 mm，如图4所示。裂纹起始后朝基体扩展，扩展区可见细密的疲劳条带和二次裂纹等典型疲劳断裂特征，距源区不同位置，疲劳条带宽度变化不大，分布在0.24~0.35 μm，如图5所示。断口瞬断区为典型韧窝特征，由内侧表面向外侧表面方向撕裂，如图6所示。
1.3　表面检查
低压涡轮轴裂纹断口疲劳源区附近和远离源区表面的微观形貌如图7所示。由图7可见电加工痕迹，源区表面为重熔层形貌，孔壁去除重熔层区域有可见孔周向加工痕迹；并且源区附近未见明显的损伤形貌。
1.4　金相组织检查
在裂纹孔截面切片制作金相试样，进行金相组织检测，组织形貌如图8所示。重熔层与基体存在明显分界，重熔层表面存在微裂纹，随机选取多处测量重熔层厚度，最大厚度为20.59 μm。孔边基体显微组织未见异常，平均晶粒度为6.5级，满足标准规定的4级或更细要求。
2　低压涡轮轴疲劳试验仿真及分析
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低压涡轮轴结构如图9所示，有限元仿真模型如图10所示。
低压涡轮轴在某结构静力与疲劳试验器上开展试验，在图9中“载荷加载面”上施加轴向力、弯矩和转矩载荷，在“约束面1”位置约束转动和轴向方向，在“约束面2”位置约束径向和周向。因本试验为研究性试验，载荷大小以发动机实际受载情况为基准调整而来，载荷大小如图11所示。
模拟低压涡轮轴高低周复合疲劳试验状态，施加低周峰值状态的轴向力、转矩和高周峰值状态的振动转矩、弯矩（载荷大小与图11一致）载荷，构建低压涡轮轴有限元模型进行仿真计算分析。低压涡轮轴有限元模型单元类型为10节点四面体单元的SOLID187，节点总数为4 235 981，单元总数为3 568 459，图10（b）中通油孔分网时沿圆周方向分为81份，网格间距约0.25 mm。
图12给出了通油孔位置的有限元仿真结果，X方向为沿低压涡轮轴方向（发动机气流方向），左边云图为3个主应力的矢量方向图，其中第一主应力为黑色箭头，其主要分布在孔0点钟到3点钟、6点钟到9点钟位置；右边云图为第一主应力分布云图，其中应力较大位置有两个，一个在孔边右上方，另一个在孔边左下方，均与图12中X方向约呈45°夹角，且应力较大区域沿孔表面垂直轴表面向孔内延伸。
由图1、图2中表面裂纹位置可知，裂纹延伸方向与发动机轴向约呈45°夹角；同时根据第1.2节断口分析和图3可知，裂纹源区与孔口裂纹位置连线垂直于轴外表面。因此，结合有限元分析结果和裂纹分析情况，试验低压涡轮轴裂纹起源于通油孔大应力区，且为重熔层覆盖区域。
3　裂纹扩展分析
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由金相组织检查和有限元分析可知，裂纹起始位置表面有重熔层，并存在微裂纹和应力集中，在较大的高低周复合应力下往往会萌生疲劳裂纹。本文采用裂纹扩展软件，基于断裂力学理论，对试验状态下裂纹扩展情况进行仿真，探究源区初始裂纹深度范围及其扩展情况。
3.1　应力强度因子计算
应力强度因子是描述裂纹尖端区域应力分布严重程度的指标[13-17]，利用应力强度因子来表达疲劳裂纹扩展数据和预测疲劳裂纹扩展称为“线弹性断裂力学”。实际使用中的疲劳裂纹通常沿着宏观上与主应力垂直的方向扩展，多数情况下，扩展方向垂直于能使裂纹张开的拉伸应力，这种类型的裂纹张开称为“Ⅰ型”[18]，如图13所示，其余“Ⅱ型”“Ⅲ型”裂纹在循环剪切应力作用下发生，但经验表明，在纯剪切载荷作用下产生的小裂纹很快就呈现出向拉伸模型下的疲劳裂纹扩展转变，即“Ⅰ型”裂纹[19]679-702。从低压涡轮轴应力来看，通油孔位置裂纹以“Ⅰ型”裂纹为主。
因低压涡轮轴模型较大，为提高裂纹扩展分析效率，选取通油孔附近部分单元作为裂纹扩展子模型，子模型位于通油孔壁厚位置，如图14所示，子模型与其他部分有限元模型组成完整的低压涡轮轴有限元模型。
仿真分析时，先在Ansys软件中进行有限元计算，计算边界及载荷与第2节一致，获得低压涡轮轴强度计算结果，通油孔位置应力分布情况如图12所示；然后将计算结果导入裂纹扩展软件进行应力强度因子计算和裂纹扩展寿命分析。
图15给出了通油孔上应力强度因子随表面裂纹长度变化的规律。
3.2　裂纹扩展寿命分析
结合裂纹尖端应力强度因子和Paris方程可估算裂纹扩展寿命[19]679-702。Paris方程的定义为
式中，a为裂纹长度；N为循环周次；C、n为Paris方程参数；ΔK为应力强度因子幅值。
在裂纹扩展子模型通油孔中分别预置0.1、0.2、0.3 mm垂直表面的裂纹，分别获得外表面裂纹扩展寿命。图16所示的裂纹扩展计算结果中，按照外表面裂纹达到6.325 mm获得0.1、0.2、0.3 mm初始裂纹下循环数，如表1所示。
根据低压涡轮轴高低周复合疲劳试验结果，试验实际完成的低周循环数为1 872，对应的高周循环数为2 081 664。结合试验结果与表1裂纹扩展仿真结果，可初步预估初始裂纹介于0.2~0.3 mm。
4　故障原因分析和改进建议
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根据试验检测结果、有限元仿真和裂纹扩展分析，对裂纹故障原因进行分析，并提出改进建议。
1）材料正常。通过扫描电子显微镜观察可知，断口附近未见明显冶金缺陷；金相组织检测未见异常。
2）未去除重熔层、有微裂纹。体视镜和金相检测均发现，裂纹孔内壁局部可见重熔层，且重熔层表面存在微裂纹，表明该通油孔未按照加工工艺流程要求彻底打磨去除重熔层。在微裂纹下会加剧表面的缺口敏感性，降低表面的抗疲劳性能[20]。
3）疲劳损伤。由扫描电镜可知，裂纹起源于孔内壁重熔层区域，由有限元仿真可知，该区域应力较大，裂纹萌生起始应力较大；扩展区有细密的疲劳条带和二次裂纹等特征，为典型疲劳断裂失效。根据裂纹扩展分析，初始裂纹长度介于0.2~0.3 mm。
综上所述，低压涡轮轴通油孔内侧表面存在部分重熔层且有可见微裂纹，在较大的高、低周复合载荷应力作用下萌生疲劳裂纹并发生了裂纹扩展，从而导致通油孔裂纹故障。为了保证通油孔加工质量，考虑该位置加工可达性较差，建议可设计特殊工装、采用机械加工技术进行加工，在保证加工精度的基础上从根本上杜绝重熔层的影响。
5　结论
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通过对某型航空发动机低压涡轮轴裂纹位置进行外观检查、断口分析、表面检查、金相组织检查，明确了失效位置及来源，并进一步开展有限元分析和裂纹扩展仿真模拟试验失效过程，获得了初始裂纹对低压涡轮轴通油孔的影响规律。主要结论如下：
1）低压涡轮轴通油孔裂纹性质为疲劳失效，疲劳起始于孔内壁表面，距外表面孔口约6 mm。
2）低压涡轮轴通油孔内侧表面存在部分重熔层且有可见微裂纹，在较大的高、低周复合载荷应力作用下萌生疲劳裂纹并发生了裂纹扩展，从而导致通油孔裂纹故障，预估初始裂纹长度介于0.2~0.3 mm，应改进加工工艺，杜绝轴关键部位产生微裂纹。
3）低压涡轮轴通油孔裂纹的产生与轴的材质无关。
基金
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  • 航空动力基础研究项目
文献
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2025年第47卷第2期
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doi: 10.16579/j.issn.1001.9669.2025.02.005
  • 接收时间：2023-05-06
  • 首发时间：2026-03-18
  • 出版时间：2025-02-15
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  • 收稿日期：2023-05-06
  • 修回日期：2023-09-08
基金
Basic Research Programs in Aerospace Dynamics
航空动力基础研究项目
作者信息
    1.中国航发四川燃气涡轮研究院，成都　610500
    2.电子科技大学 机械与电气工程学院，成都　611731
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2种不同金属材料的力学参数
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Family		 属数
Number of
genus		 种数
Number of
species		 占总种数比例
Percentage of
total species (%)		 属
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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