飞机铝合金卡箍失效分析与装配过程优化

苗春贺; 朱凤高; 张伟伟; 吕志召; 鲍珣; 刘朋飞; 张平

doi:10.7643/issn.1672-9242.2026.06.005

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装备环境工程 ›› 2026, Vol. 23 ›› Issue (6) : 56-71. DOI: 10.7643/issn.1672-9242.2026.06.005

航空航天装备

飞机铝合金卡箍失效分析与装配过程优化

苗春贺, 朱凤高, 张伟伟, 吕志召, 鲍珣, 刘朋飞, 张平

作者信息 +

Failure Analysis and Optimization on Assembly Process of Aircraft Aluminum Alloy Clamps

MIAO Chunhe, ZHU Fenggao, ZHANG Weiwei, LYU Zhizhao, BAO Xun, LIU Pengfei, ZHANG Ping

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文章历史 +

摘要

目的确定卡箍断裂原因,对导致其变形失效的主要装配过程进行识别与优化。方法采用宏微观显微及理化分析,明确卡箍失效模式。同时,采用应变监测试验和有限元仿真方法,对卡箍夹压、掰开、安装与分解等主要装配过程进行分析,获取卡箍变形情况,并对影响变形的主要装配过程进行优化。结果通过分析卡箍失效断面的宏微观形貌,确定卡箍为疲劳失效,且断裂为沿着厚度方向由内表面向外表面扩展。在卡箍的夹压、安装和掰开过程中,箍带中部均会产生较大的塑性变形。其中,夹压过程的卡箍变形最大达0.018,残余塑性应变约为0.008 6。当夹持位置变为夹持上下接耳时,夹压过程不会产生塑性变形。卡箍接耳开口距离为13 mm左右时,可以在保证线束安装的同时尽可能降低卡箍塑性变形。接耳尺寸增加至10 mm时,接耳R角区域无应力集中,避免R角区域失效。结论通过优化卡箍的夹持位置、开口距离和接耳尺寸,可以有效降低和控制卡箍塑性变形。

Abstract

The study aims to determine the cause of clamp fracture and identify and optimize the main assembly processes leading to its deformation failure. Macro and micro microscopic analysis was used to clarify the failure mode of the clamp. Meanwhile, strain monitoring tests and finite element simulation methods were employed to analyze the main assembly processes of clamp clamping, opening, installation, and disassembly, obtain information on clamp deformation, and optimize the main assembly processes affecting deformation. By analyzing the macro and micro morphologies of the clamp's fracture surface, it was confirmed that the clamp failed due to fatigue, with fracture extending from the inner surface to the outer surface along the thickness direction. During the clamping, installation, and opening processes of the clamp, significant plastic deformation occurred in the middle of the clamp band. During the clamping process, the maximum deformation of the clamp reached 0.018, with a residual plastic strain of approximately 0.008 6. When the clamping position was changed to the upper and lower lugs, no plastic deformation occurred during the clamping process. When the clamp opening distance was around 13 mm, it was possible to minimize clamp plastic deformation while ensuring wire harness installation. When the lug size was increased to 10 mm, there was no stress concentration in the R-angle area of the lug, avoiding failure in the R-angle area. By optimizing the clamping position and opening distance of the clamp, plastic deformation of the clamp can be effectively reduced and controlled.

导出引用

苗春贺, 朱凤高, 张伟伟, 吕志召, 鲍珣, 刘朋飞, 张平. 飞机铝合金卡箍失效分析与装配过程优化[J]. 装备环境工程. 2026, 23(6): 56-71 https://doi.org/10.7643/issn.1672-9242.2026.06.005

MIAO Chunhe, ZHU Fenggao, ZHANG Weiwei, LYU Zhizhao, BAO Xun, LIU Pengfei, ZHANG Ping. Failure Analysis and Optimization on Assembly Process of Aircraft Aluminum Alloy Clamps[J]. Equipment Environmental Engineering. 2026, 23(6): 56-71 https://doi.org/10.7643/issn.1672-9242.2026.06.005

中图分类号： V250.3

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