Assessment of fatigue life of remanufactured impeller based on FEA

doi:10.1007/s11465-016-0394-x

Front. Mech. Eng.

2016, Vol. 11

Issue (3) : 219-226 https://doi.org/10.1007/s11465-016-0394-x

RESEARCH ARTICLE

Assessment of fatigue life of remanufactured impeller based on FEA

Lei XU¹,Huajun CAO^1,^*(

),Hailong LIU¹,Yubo ZHANG²

¹. The State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing 400030, China
². National Key Laboratory for Remanufacturing, Academy of Armored Forces Engineering, Beijing 100072, China

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Abstract

Predicting the fatigue life of remanufactured centrifugal compressor impellers is a critical problem. In this paper, the S-N curve data were obtained by combining experimentation and theory deduction. The load spectrum was compiled by the rain-flow counting method based on the comprehensive consideration of the centrifugal force, residual stress, and aerodynamic loads in the repair region. A fatigue life simulation model was built, and fatigue life was analyzed based on the fatigue cumulative damage rule. Although incapable of providing a high-precision prediction, the simulation results were useful for the analysis of fatigue life impact factors and fatigue fracture areas. Results showed that the load amplitude greatly affected fatigue life, the impeller was protected from running at over-speed, and the predicted fatigue life was satisfied within the next service cycle safely at the rated speed.

Keywords remanufactured impeller fatigue life impeller failures finite element analysis (FEA)

Corresponding Author(s): Huajun CAO

Online First Date: 26 July 2016 Issue Date: 31 August 2016

Cite this article:

Lei XU,Huajun CAO,Hailong LIU, et al. Assessment of fatigue life of remanufactured impeller based on FEA[J]. Front. Mech. Eng., 2016, 11(3): 219-226.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-016-0394-x
https://academic.hep.com.cn/fme/EN/Y2016/V11/I3/219

Tab.1 Chemical composition of FV520B

Tab.2 Mechanical compositions properties of FV520B

Fig.1 Remanufactured impeller

Fig.2 Dynamic-balancing experiment on remanufactured impeller

Fig.3 Full sized model of the remanufactured impeller

Fig.4 Mesh model of the impeller

Fig.5 Procedure of FEA process

Fig.6 Aerodynamic load set

Fig.7 von-Mises stress of the remanufactured impeller

Fig.8 S-N curve of the impeller

Tab.3 Experiment life of specimen [12]

Tab.4 Working speed and laser cladding residual stress

Fig.9 Load in rated speed

Fig.10 Counting process of load cycles in rated speed

Tab.5 Fatigue life simulation and experimental results

Fig.11 Result of simulated analysis on fatigue life in different rotating states

Fig.12 Fatigue life under different maximum residual stresses

Fig.13 Fatigue life nephogram with the maximum residual stress of 488 MPa

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