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对某重载车辆悬挂系统断裂压簧进行了宏/微观断口形貌观察、理化检测、工艺分析和服役环境综合分析,找出了该压簧发生断裂的原因。研究发现,由于采用了支撑圈与第一工作圈相接触的设计形式,服役中两圈接触、碰撞导致磨损,从而使簧丝磷化膜和漆层脱落,造成簧丝表面腐蚀并形成腐蚀坑。腐蚀坑引起的应力集中诱发了疲劳裂纹萌生,并在最大主应力作用下沿垂直主应力方向不断扩展,最终导致压簧的正应力断裂。最后提出了避免发生此类失效的建议。
The macro / micro fracture appearance observation, physical and chemical detection, process analysis and service environment comprehensive analysis were carried out on the rupture compression spring of a heavy haul vehicle suspension system to find out the cause of the rupture of the compression spring. The study found that due to the support ring with the first working ring in contact with the design form, service contact in two laps, resulting in collision wear and tear, so that the spring wire phosphate coating and paint off, causing the spring wire surface corrosion and the formation of corrosion pit . Stress concentration induced by corrosion pits induces fatigue crack initiation and expands along the direction of the principal principal stress under the action of the maximum principal stress, finally resulting in the normal stress fracture of the compression spring. Finally, a suggestion was put forward to avoid such a failure.