Research on fatigue crack propagation and fracture failure analysis of piston rod

IF 4.4 2区工程技术 Q1 ENGINEERING, MECHANICAL

Engineering Failure Analysis Pub Date : 2025-03-11 DOI:10.1016/j.engfailanal.2025.109523

Zhen Chen , Nengpeng Chen , Qiaomu Wang , Qingjie Ran , Chaocheng Wei , Jun Tang , Junhai Long , Yuling Zhang

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引用次数: 0

Abstract

The reciprocating compressors in underground gas storage (UGS) run under high temperature and high pressure for a long time, which leads to the piston rod bearing complex alternating load, easy to generate fatigue cracks and spread, and eventually lead to fracture failure, which seriously affects the safe operation of UGS. In this paper, the causes of piston rod fracture failure under actual operating conditions are studied by numerical simulation and test. Firstly, a finite element model is established based on the actual cyclic load of the piston rod, which is used as the boundary condition for crack propagation analysis. The crack propagation model is established by adaptive meshing method, and the stress intensity factor leading to crack propagation is determined by M−integral method. According to the fracture toughness of the piston rod material, the fracture failure occurs when the crack propagation length is 29.599 mm, and the fatigue crack propagation life extends with the decrease of the speed or the increase of the exhaust pressure. Secondly, the fracture morphology of the piston rod is analyzed, and the fracture type is determined to be fatigue fracture, and the crack source starts at the transition corner of the surface, which confirms the accuracy of the numerical simulation results. Long-term alternating load leads to stress concentration and initial crack. Metallographic analysis shows that excessive inclusion, abnormal organization and the presence of Se element are the main factors leading to fatigue fracture of the piston rod. The research results provide valuable insights and theoretical basis for fatigue failure problem and fatigue optimization design of piston rod, and have practical engineering guidance significance.

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来源期刊

Engineering Failure Analysis 工程技术-材料科学：表征与测试

CiteScore

7.70

自引率

20.00%

发文量

956

审稿时长

47 days

期刊介绍： Engineering Failure Analysis publishes research papers describing the analysis of engineering failures and related studies. Papers relating to the structure, properties and behaviour of engineering materials are encouraged, particularly those which also involve the detailed application of materials parameters to problems in engineering structures, components and design. In addition to the area of materials engineering, the interacting fields of mechanical, manufacturing, aeronautical, civil, chemical, corrosion and design engineering are considered relevant. Activity should be directed at analysing engineering failures and carrying out research to help reduce the incidences of failures and to extend the operating horizons of engineering materials. Emphasis is placed on the mechanical properties of materials and their behaviour when influenced by structure, process and environment. Metallic, polymeric, ceramic and natural materials are all included and the application of these materials to real engineering situations should be emphasised. The use of a case-study based approach is also encouraged. Engineering Failure Analysis provides essential reference material and critical feedback into the design process thereby contributing to the prevention of engineering failures in the future. All submissions will be subject to peer review from leading experts in the field.