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    Surface roughness is one of the reasons for the fracture of crankshaft of high-pressure air compressor

    Surface roughness is one of the reasons for the fracture of crankshaft of high-pressure air compressor Surface roughness is one of the reasons for the fracture of crankshaft of high-pressure air compressor The crankshaft is the most complicated part of the high-pressure air compressor, and its stability is directly related to the stability of the entire aerodynamic system. What we are mainly involved here are the matters that should be considered when designing and manufacturing the crankshaft. According to the finite element analysis of the crankshaft, the crankshaft is mainly subjected to alternating torsion-bending composite stress during normal service. The corner of the transition between the connecting rod neck and the main journal is the area with the highest stress and is the most prone to fatigue fracture. According to the strength check of the crankshaft, if the mechanical properties, surface roughness and installation quality of the material meet the design requirements, the crankshaft still has a long enough fatigue life and no accidental fatigue fracture will occur. Fatigue fracture is very sensitive to cracks, notches, tissue defects, etc., because notches, sharp corners and cracks greatly reduce the stress value required for crack initiation due to stress concentration. Fatigue failure is first selected to start at these local defects, and once the fatigue crack Sprout, in general, further expansion is inevitable. Therefore, different surface roughness has a significant effect on the fatigue strength of the component. The rougher the surface, the lower the fatigue strength. This may be the main reason for the failure of the crankshaft of the high-pressure air compressor at the corner of the crank pin before reaching the design life. The results of physical and chemical analysis of the failed crankshaft also confirmed this: from the macroscopic morphology and microscopic characteristics of the fracture, it can be judged that the fracture of the crankshaft is a typical high-cycle fatigue fracture, and obvious machining residues can be seen at the crack initiation area and nearby areas Under the circumferential notch, the local surface roughness only reaches 12.5 μm, which is far lower than the design requirement of 1.6 μm. When the surface roughness of the material increases from 1.6 μm to 12.5 μm, the allowable fatigue limit of the original crank pin fillet will drop by 50%, and the safety factor will also decrease to 1.126, which is lower than the allowable safety factor, indicating that the crank pin fillet is in use Fatigue damage may occur at any time during the process. Therefore, we give the following suggestions: the original design of the crankshaft meets the strength requirements, and the transition fillet of the crank pin and the main journal is the area of ​​maximum stress and the most prone to fatigue fracture. When other factors are not conducive to the strength of the crankshaft, fracture may occur there. By comparing with the actual fracture behavior, the calculation and analysis results are consistent with the actual situation. Because the surface roughness of the transition fillet does not affect the assembly production of the crankshaft, it is often difficult to attract enough attention in production. Analysis and calculations show that the rounded surface roughness is a direct factor that affects the fatigue performance of the crankshaft, and can even offset some measures to improve the fatigue performance. It should attract enough attention and be strictly controlled. In order to avoid similar crankshaft fracture accidents, the following measures are recommended: (1) Improve machining accuracy, avoid machining damage at corners, and ensure that surface finish meets design requirements; (2) Strictly control the purchase channels and processing and repair processes of equipment parts and components. The main parts must be provided by the manufacturer with an effective test report or certificate of compliance to ensure that key components are effectively controlled during the selection of materials and processing techniques.

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