RESEARCH ARTICLE

Enhancing fatigue life of cylinder-crown integrated structure by optimizing dimension

  • Weiwei ZHANG ,
  • Xiaosong WANG ,
  • Zhongren WANG ,
  • Shijian YUAN
Expand
  • School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150090, China

Received date: 30 Dec 2014

Accepted date: 25 Jan 2015

Published date: 01 Apr 2015

Copyright

2014 Higher Education Press and Springer-Verlag Berlin Heidelberg

Abstract

Cylinder-crown integrated hydraulic press (CCIHP) is a new press structure. The hemispherical hydraulic cylinder also functions as a main portion of crown, which has lower weight and higher section modulus compared with the conventional hydraulic cylinder and press crown. As a result, the material strength capacity is better utilized. During the engineering design of cylinder-crown integrated structure, in order to increase the fatigue life, structural optimization on the basis of the adaptive macro genetic algorithms (AMGA) is first conducted to both reduce weight and decrease peak stress. It is shown that the magnitude of the maximum principal stress is decreased by 28.6%, and simultaneously the total weight is reduced by 4.4%. Subsequently, strain-controlled fatigue test is carried out, and the stress-strain hysteresis loops and cyclic hardening curve are obtained. Based on linear fit, the fatigue properties are calculated and used for the fatigue life prediction. It is shown that the predicted fatigue life is significantly increased from 157000 to 1070000 cycles after structural optimization. Finally, according to the optimization design, a 6300 kN CCIHP has been manufactured, and priority application has been also suggested.

Cite this article

Weiwei ZHANG , Xiaosong WANG , Zhongren WANG , Shijian YUAN . Enhancing fatigue life of cylinder-crown integrated structure by optimizing dimension[J]. Frontiers of Mechanical Engineering, 2015 , 10(1) : 102 -110 . DOI: 10.1007/s11465-015-0329-y

Acknowledgments

This paper was financially supported by the High-end CNC Machine Tools and Basic Manufacturing Equipment Technology Major Project (Grant No. 2011ZX04001-011). The authors would like to take this opportunity to express their sincere appreciation.
1
Geleji A. Forge Equipment, Rolling Mills and Accessories. Budapest: Akadémiai Kiadó, 1967

2
Mueller E. Hydraulic Forging Presses. Berlin: Springer, 1969

3
Altan T, Boulger F W, Becker J R, Forging Equipment, Materials and Practices. Columbus: Metals and Ceramics Information Center, 1973

4
Davis J R, Semiatin S L, American Society for Metals. ASM Metals Handbook, Volume 14: Forging and Forming. 9th ed. Ohio: ASM International, 1988

5
Altan T, Tekkaya E. Sheet Metal Forming: Fundamentals, Volume 1. Ohio: ASM International, 2012

6
Schuler Gmb H. Metal Forming Handbook. Berlin: Springer, 1998

7
Altan T, Ngaile G, Shen G S. Cold and Hot Forging: Fundamentals and Applications. Ohio: ASM International, 2004

8
Wang Z, Yuan S, Wang X, China Patent, 20100502688.5, 2011-<month>02</month>-<day>16</day> (in Chinese)

9
Zhang W, Wang Z, Wang X, Strength calculation of thick-walled hemispherical hydraulic cylinder and comparative analysis with cylindrical hydraulic cylinder. Chinese Journal of Mechanical Engineering, 2012, 48(24): 50–54 (in Chinese)

DOI

10
Zhang W, Wang X, Yuan S, Design and manufacturing of the cylinder-beam integrated hydraulic press. Applied Mechanics and Materials, 2013, 397–400: 157–161

DOI

11
Zhang W, Wang X, Wang Z, Mechanical analysis on the cylinder-crown integrated hydraulic press with a hemispherical cylinder. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering and Science, 2015, 229(3): 407–416

DOI

12
Zhang W, Wang X, Wang Z, Structural optimization of cylinder-crown integrated hydraulic press with hemispherical hydraulic cylinder. Procedia Engineering, 2014, 81: 1663–1668

DOI

13
Yu X. Design and Application of Hydraulic Press. Beijing: China Machine Press, 2009 (in Chinese)

14
Wu S. 150MN Hydraulic Press. Beijing: National Defense Industry Press, 2012 (in Chinese)

15
Williams C R , Lee Y L, Rilly J T. A practical method for statistical analysis of strain-life fatigue data. International Journal of Fatigue, 2003, 25(5): 427–436

DOI

Outlines

/