汽车管带式散热器蠕变-疲劳确信可靠性的建模与分析

doi:10.3969/j.issn.1674-8484.2022.01.016

汽车安全与节能学报 ›› 2022, Vol. 13 ›› Issue (1): 157-167.DOI: 10.3969/j.issn.1674-8484.2022.01.016

汽车管带式散热器蠕变-疲劳确信可靠性的建模与分析

张湘霄(), 杨选虎, 李晓阳(), 李梅珺

1.北京航空航天大学可靠性与系统工程学院，北京100191，中国
2.贵航股份永红散热器公司，贵阳550025，中国

收稿日期:2021-05-24 修回日期:2021-10-08 出版日期:2022-03-31 发布日期:2022-04-02
通讯作者: 李晓阳
作者简介:*李晓阳,研究员。E-mail：leexy@buaa.edu.cn。
张湘霄(1998–),女(汉族),山东,硕士研究生。E-mail:xiangxiaozhang@buaa.edu.cn。
基金资助:
国家自然基金资助项目(51775020)

Creep-fatigue reliability modeling and analysis for automotive tubular radiators

ZHANG Xiangxiao(), YANG Xuanhu, LI Xiaoyang(), LI Meijun

1. School of Reliability and Systems Engineering, Beihang University, Beijing 100191, China
2. Guihang Yonghong Cooler Company Shares, Guiyang 550025, China

Received:2021-05-24 Revised:2021-10-08 Online:2022-03-31 Published:2022-04-02
Contact: LI Xiaoyang

摘要/Abstract

摘要：

为汽车发动机管带式散热器的设计、制造、使用、维护,从可靠性原理出发,基于不确定理论,提出了一种散热器蠕变-疲劳可靠性建模与分析方法,分析该类散热器的可靠性。基于功能性能和失效分析,确定关键失效机理和性能参数; 构建关键性能参数与其物理属性、外界条件、时间及失效判据的因果关系;量化其中不确定性,构建可靠性模型。用AA3003铝合金散热器对本方法进行验证,并发现将外界条件变异系数降低至5%后,散热器可靠度提高了0.1。结果表明：本方法刻画了汽车散热器可靠性的因果规律和不确定性的影响;降低外界条件的变异系数,可提高散热器的可靠度。

关键词: 汽车散热器, 蠕变疲劳, 可靠性科学原理, 累积损伤, 不确定性

Abstract:

A creep-fatigue reliability modeling and an analysis method were proposed for automobile engine tubular belt radiators based on the reliability science principle and the uncertainty theory to analyze the radiator reliability for the radiators’ design, manufacture, operation and maintenance. Key failure mechanisms and performance parameters were determined based on functional performances and failure analysis, with constructing the causal relationship between key performance parameters, and their physical attributes, external conditions, time and failure criteria to quantify the uncertainty by using the uncertainty theory and the reliability model. An AA3003 aluminum alloy radiator was used to verify the proposed method, when the variation coefficient of external conditions is reduced to 5%, the radiator reliability increases by 0.1. The results show that the method describes the causal law and the uncertainty effect on the automotive radiator reliability, in addition, reducing the variation coefficient of external conditions improves the radiator reliability.

Key words: automotive radiator, creep-fatigue, reliability science principle, cumulative damage, uncertainty

中图分类号:

TB114.3

张湘霄, 杨选虎, 李晓阳, 李梅珺. 汽车管带式散热器蠕变-疲劳确信可靠性的建模与分析[J]. 汽车安全与节能学报, 2022, 13(1): 157-167.

ZHANG Xiangxiao, YANG Xuanhu, LI Xiaoyang, LI Meijun. Creep-fatigue reliability modeling and analysis for automotive tubular radiators[J]. Journal of Automotive Safety and Energy, 2022, 13(1): 157-167.

图/表 17

图1 管带式散热器蠕变-疲劳可靠性建模框架

图2 管带式双流程散热器结构图

热膨胀系数	2.32×10^-5 K^-1
弹性模量	69 GPa
屈服强度	145 MPa
液相线温度	654 ℃

表1 铝合金材料参数[28]

芯子尺寸	641 mm×419 mm×26 mm
芯体正面面积	0.26 m²
散热管厚度	0.25 mm

表2 散热器几何尺寸

图3 管带式散热器失效位置与形貌

图4 温度、压强波形图

图5 散热管与主片模型

图6 ANSYS应力仿真结果

图7 散热管根部低周应力波形图

σ_a / MPa	寿命数据N_au
54.2	6 309
52.5	19 953
49.1	63 096
46.8	316 228
44.2	1 000 000
40.6	12 589 254
38.2	199 526 231

表3 90~120 ℃下散热器应力幅值-寿命数据[2]

未知参数	估计结果	未知参数	估计结果
e_H	1 326.371	σ_B	3.929
σ_H	17.089	e_β	27.229
e_r	13.405	σ_β	1.361
σ_r	0.669	e_q	0.932
e_B	78.574	σ_q	0.015

表4 未知参数估计结果

N_ru	APE/%	N_ru	APE/%
27 583	2.56	11 753 708	2.17
70 047	3.99	40 912 212	1.63
498 558	0.31	109 594 000	3.46
2 041 830	3.81	平均值	2.56

表5 期望寿命Nru预测结果

图8 散热器可靠度随循环载荷及循环条件变化

图9 降低材料参数变异系数后散热器可靠度随循环载荷变化

图10 降低应力载荷变异系数后散热器可靠度随循环载荷变化

图11 参数不同变异系数下裕量退化曲线

图12 散热器最大应力-循环次数-可靠度曲面

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汽车管带式散热器蠕变-疲劳确信可靠性的建模与分析

Creep-fatigue reliability modeling and analysis for automotive tubular radiators

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