张晓辉1,2, 谢永胜1,2,曾超1,2,程市1,2,李超1,2

1.内燃机可靠性国家重点实验室，山东潍坊261061;2.潍柴动力股份有限公司，山东潍坊261061

摘要：针对发动机试验过程中出现的旋压皮带轮故障，采用有限元分析方法，对旋压皮带轮进行故障再现仿真，仿真计算结果与实际故障点吻合。根据旋压皮带轮受力变形特点，分析故障原因发现，由于垫块与轴端法兰直径相差3.0 mm，导致旋压皮带轮两侧接触面受压不均，而危险点与轴端法兰同直径。将轴端法兰直径增加3.0 mm，与垫块直径相同。经仿真和市场验证，改进方案有效，表明仿真再现方法满足工程应用要求，对旋压皮带轮设计具有指导意义。

关键词：发动机；旋压皮带轮；故障再现仿真

Abstract:For the spinning pulley failure during engine test, finite element analysis is employed for fault simulation. The calculation results are similar to the actual fault.According to spinning pulley bearing deformation characteristic, it could be found that the block and the shaft end flange diameter is different, the radius is 3.0 mm, which causes spinning pulley on both sides of the contact pressure, and dangerous point with shaft end flange diameter. The diameter of the shaft end flange is increased by 3.0 mm, which is the same as that of the cushion block. The improvement is validated by the market, which proves that the simulation method meets the requirements of engineering application and has guiding significance for the design of spinning pulley.

Keywords:engine; spinning pulley; fault recurrence simulation