A membrane disc coupling analogue and a method of designing the same

Abstract

This invention relates to the field of fatigue strength testing technology for moving parts, and discloses a diaphragm disc coupling simulation component and its design method. The diaphragm disc coupling simulation component includes: a diaphragm disc, comprising a central portion and an edge portion connected to each other; the central portion is annular, and the edge portion extends around the entire circumference of the central portion, with multiple connecting holes spaced circumferentially on the edge portion; a connecting shaft, comprising a connecting portion and a clamping portion connected to each other; the connecting portion is connected to the middle of the central portion, and the clamping portion is located on one axial side of the central portion. The diaphragm disc coupling simulation component and its design method of this invention reduce testing costs, simplify the testing process, are easy to operate, have a mature and reliable testing scheme, and improve economic efficiency.

Description

Technical Field

[0001] This invention relates to the field of fatigue strength testing technology for moving parts, specifically to a diaphragm disc coupling simulator and its design method. Background Technology

[0002] A diaphragm coupling is a mechanical component used to connect shafts and rotates with them during transmission. Its main function is to transmit motion and power between different shafts or parts, making it a high-performance flexible coupling. Fatigue failure is the primary cause of failure in diaphragm couplings; therefore, fatigue strength testing is crucial for their practical application. However, conducting fatigue tests using actual diaphragm coupling components is costly, complex, and difficult to perform. Summary of the Invention

[0003] In view of this, the present invention provides a diaphragm coupling simulation component and its design method to solve the problems of high cost, complex testing methods, and difficult operation in fatigue strength testing of diaphragm coupling structures.

[0004] In a first aspect, the present invention provides a diaphragm disc coupling simulation component, comprising: a diaphragm disc, including a central portion and an edge portion connected to each other; the central portion is annular, the edge portion extends around the entire circumference of the central portion, and the edge portion is provided with a plurality of connecting holes spaced apart circumferentially; a connecting shaft, including a connecting portion and a clamping portion connected to each other; the connecting portion is connected to the middle portion of the central portion, and the clamping portion is located on one axial side of the central portion.

[0005] In one alternative embodiment, the axial sides of the central portion are recessed within the edge portion; along the axial direction of the central portion, at least a portion of the connecting portion protrudes from the side of the central portion away from the clamping portion.

[0006] In one alternative embodiment, the membrane disc further includes a first transition portion and a second transition portion; the first transition portion is connected between the center portion and the edge portion, and the second transition portion is connected between the center portion and the connecting portion; the second transition portion is provided with an annular protrusion extending around an axis, the annular protrusion being located on the side of the second transition portion away from the clamping portion.

[0007] In one alternative embodiment, the diaphragm coupling simulator further includes a first fastener, the clamping portion having a threaded section, and the first fastener being threadedly connected to the threaded section.

[0008] In one alternative embodiment, the diaphragm disc coupling simulator further includes a plurality of second fasteners, which are respectively inserted into a plurality of connection holes. The second fasteners are used to fix the diaphragm disc coupling simulator to the external structure.

[0009] Secondly, the present invention also provides a design method for a diaphragm disc coupling simulation component, used to obtain the diaphragm disc coupling simulation component as described above, comprising the following steps: Step 1: Determine the structural characteristics of the test piece and determine the load conditions of the test piece under actual working conditions; Step 2: Based on the structural characteristics of the test piece and the load conditions under actual working conditions, establish a three-dimensional model and a finite element model of an initial diaphragm disc coupling simulation component containing the structural characteristics of the test piece, and use linear elastic constitutive modeling to calculate and obtain the stress field of the initial diaphragm disc coupling simulation component under actual working condition load; Step 3: Compare the stress field of the initial diaphragm disc coupling simulation component under actual working condition load with the stress state of the test piece under actual working conditions to determine the initial diaphragm disc coupling simulation component. Whether it meets the design requirements; if not, optimize the characteristic structure of the initial diaphragm coupling simulation component until it meets the requirements; Step 4: After completing Step 3, design the clamping structure based on the finally obtained initial diaphragm coupling simulation component to obtain the three-dimensional model of the diaphragm coupling simulation component; Step 5: Establish a finite element model based on the three-dimensional model of the diaphragm coupling simulation component to obtain the stress field of the diaphragm coupling simulation component under actual working conditions and compare it with the stress state of the test piece under actual working conditions to ensure that each part of the diaphragm coupling simulation component can meet the test requirements; Step 6: After completing Step 5, obtain the diaphragm coupling simulation component based on the finally obtained three-dimensional model of the diaphragm coupling simulation component and the structural characteristics of the test piece.

[0010] In one optional embodiment, in step 1, the structural features of the test piece include its geometry, dimensions, material parameters, cold and hot working processes, heat treatment state, and surface roughness; the load conditions of the test piece under actual working conditions include the environmental conditions, load magnitude, and load type of the test piece under actual service conditions.

[0011] In one optional implementation, in step 2, the following are identified based on the stress field of the initial diaphragm coupling simulator under actual working load: the deformation mode of the initial diaphragm coupling simulator containing the structural features of the test piece; the critical location of the initial diaphragm coupling simulator, where the critical location refers to the location of the maximum principal stress; the geometric features of the critical location; the distribution of the maximum principal stress at the critical location; and the stress distribution at the diaphragm of the initial diaphragm coupling simulator.

[0012] In an optional implementation, step 3 further includes: determining the working load type and basic mechanical model of the initial diaphragm coupling simulation component, and optimizing the initial diaphragm coupling simulation component based on the determined working load type and basic mechanical model.

[0013] In an optional embodiment, before step 6, the method further includes: determining the test load of the diaphragm coupling simulator, which includes determining the maximum test load and the minimum test load; wherein, the loading load is determined by finite element calculation, and the maximum test load of the diaphragm coupling simulator is obtained by adjusting the load size in the finite element to make the maximum local principal stress of the diaphragm coupling simulator equal to the maximum principal stress of the critical part; and the minimum local stress of the diaphragm coupling simulator is calculated according to the local stress ratio of the test piece, and the minimum test load of the diaphragm coupling simulator is determined by combining the finite element calculation method.

[0014] The technical solution of this invention provides a diaphragm coupling simulator comprising a diaphragm disc and a connecting shaft, which incorporates the actual structural features of the diaphragm coupling structure. By using the simulator to replace the actual diaphragm coupling structure for fatigue strength testing, testing costs are reduced and economic efficiency is improved. Furthermore, this solution utilizes the connecting holes on the diaphragm disc and the clamping parts on the connecting shaft to mount it onto the testing equipment, converting the torsional and angular offset loads during the service life of the diaphragm coupling structure into uniaxial tensile loads. This simplifies the testing process, makes operation simple, and ensures a mature and reliable testing scheme, further improving economic efficiency. Attached Figure Description

[0015] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0016] Figure 1 This is a front view of a diaphragm disc coupling simulation component according to an embodiment of the present invention;

[0017] Figure 2 for Figure 1 Sectional view of AA;

[0018] Figure 3 for Figure 2 A magnified view of part I;

[0019] Figure 4 This is a top view of a diaphragm disc coupling simulation component according to an embodiment of the present invention;

[0020] Figure 5 This is a flowchart illustrating a design method for a diaphragm coupling simulation component according to an embodiment of the present invention.

[0021] Figure 6 This is a three-dimensional model of a diaphragm disc coupling simulation component according to an embodiment of the present invention;

[0022] Figure 7 This is a stress distribution cloud diagram of a diaphragm coupling simulation component according to an embodiment of the present invention.

[0023] Explanation of reference numerals in the attached figures:

[0024] 1. Membrane disc; 11. Center section; 12. Edge section; 13. Connecting hole; 14. First transition section; 15. Second transition section; 151. Annular protrusion;

[0025] 2. Connecting shaft; 21. Connecting part; 22. Clamping part; 221. Threaded section. Detailed Implementation

[0026] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] A diaphragm coupling is a mechanical component used to connect shafts and rotates with them during transmission. Its main function is to transmit motion and power between different shafts or parts. Diaphragm couplings not only enhance the flexibility of machinery, allowing for small axial and angular misalignments to a certain extent, but also improve the vibration characteristics of rotating components, acting as a buffer and vibration isolation device. It is a high-performance flexible coupling. Diaphragm couplings offer advantages such as no lubrication required, no maintenance, strong offset resistance, simple structure, light weight, and long service life. They also combine high speed, high power, and large deflection capabilities, making them widely used in aerospace, shipbuilding, and other fields.

[0028] As a flexible coupling, the diaphragm disc in the diaphragm disc coupling structure bears periodic loads, and the main form of structural failure is fatigue failure. Therefore, fatigue strength research is a major part of the strength research of diaphragm disc coupling structures. However, conducting fatigue tests using actual diaphragm disc coupling structures is costly, and the testing methods are complex and difficult to operate.

[0029] Based on this, the present invention provides a diaphragm coupling simulation component and its design method to solve the problems of high cost, complex testing methods, and difficult operation in diaphragm coupling structural fatigue strength testing.

[0030] The following is combined with Figures 1 to 7 The following describes embodiments of the present invention.

[0031] According to embodiments of the present invention, in one aspect, a diaphragm disc coupling simulation component is provided, such as... Figures 1-4 As shown, the diaphragm disc coupling simulation component includes a diaphragm disc 1 and a connecting shaft 2. The diaphragm disc 1 includes a connected central portion 11 and an edge portion 12. The central portion 11 is annular, and the edge portion 12 extends around the entire circumference of the central portion 11, with multiple connecting holes 13 spaced circumferentially around the edge portion 12. The connecting shaft 2 includes a connected connecting portion 21 and a clamping portion 22. The connecting portion 21 is connected to the middle of the central portion 11, and the clamping portion 22 is located on one axial side of the central portion 11.

[0032] In this embodiment, the diaphragm coupling simulator includes a diaphragm disk 1 and a connecting shaft 2. It incorporates the actual structural features of the diaphragm coupling structure. By using the simulator to replace the actual diaphragm coupling structure for fatigue strength testing, testing costs are reduced and economic efficiency is improved. Furthermore, by using the connecting hole 13 on the diaphragm disk 1 and the clamping part 22 on the connecting shaft 2 to mount it onto the testing equipment, the torsional and angular offset loads during the service life of the diaphragm coupling structure are converted into uniaxial tensile loads. This simplifies the testing process, makes operation simple, and ensures a mature and reliable testing scheme, further improving economic efficiency.

[0033] Understandably, the present invention does not specifically limit the number of connecting holes 13. The connecting holes 13 can be set to two, three, four, five, six or other numbers; preferably, multiple connecting holes 13 are evenly spaced around the edge portion 12 in the circumferential direction.

[0034] The present invention does not specifically limit the forming method of the diaphragm disk 1 and the connecting shaft 2, as long as it can be close to or the same as the stress state of the actual diaphragm disk coupling structure. For example, the diaphragm disk 1 and the connecting shaft 2 can be integrally formed.

[0035] In some embodiments, the axial sides of the central portion 11 are recessed within the edge portion 12, meaning the thickness of the central portion 11 is less than the thickness of the edge portion 12. This maximizes the stress in the central portion 11 of the diaphragm disk 1, gradually decreasing towards the direction away from the connecting shaft 2. Understandably, the thicknesses of the central portion 11 and the edge portion 12 refer to their axial dimensions. Furthermore, along the axial direction of the central portion 11, at least a portion of the connecting portion 21 protrudes from the side of the central portion 11 away from the clamping portion 22, making the diaphragm disk coupling simulation more closely resemble the stress state of a real diaphragm disk coupling structure, thus improving the reliability of the test.

[0036] For example, the connecting portion 21 and the clamping portion 22 are coaxially arranged, and both are coaxially arranged with the center portion 11 and the edge portion 12. That is, the center portion 11, the edge portion 12, the connecting portion 21, and the clamping portion 22 are on the same axis.

[0037] Exemplarily, the clamping portion 22 can be constructed as a cylinder, preferably a truncated cylinder. Exemplarily, the clamping portion 22 includes a connected cylindrical segment and a frustum-shaped segment. Exemplarily, the cross-sectional dimension of the axial connecting portion 21 is larger than the cross-sectional dimension of the clamping portion 22. Exemplarily, the connecting portion 21 and the clamping portion 22 can be integrally formed.

[0038] In some embodiments, the diaphragm disk 1 further includes a first transition portion 14 and a second transition portion 15. The first transition portion 14 connects the central portion 11 and the edge portion 12, and the second transition portion 15 connects the central portion 11 and the connecting portion 21. The second transition portion 15 has an annular protrusion 151 extending around an axis, located on the side of the second transition portion 15 away from the clamping portion 22. The annular protrusion 151 further optimizes the stress state of the diaphragm disk coupling simulation component, ensuring that its critical portion is formed on the central portion 11, thus conforming to the structure of a real diaphragm disk coupling.

[0039] Understandably, both the first transition portion 14 and the second transition portion 15 are arc-shaped structures, which can be formed by rounding the corners. Specifically, the thickness of the first transition portion 14 gradually decreases from the edge portion 12 towards the center portion 11; the thickness of the second transition portion 15 gradually decreases from the connecting portion 21 towards the center portion 11, in order to further ensure that the stress in the center portion 11 of the diaphragm disk 1 is maximized, and gradually decreases in the direction away from the connecting shaft 2.

[0040] Understandably, the position of the annular protrusion 151 can be adaptively adjusted according to the actual stress state of the diaphragm disc coupling simulation component, so as to match the stress state of the real diaphragm disc coupling structure. In some embodiments not shown, the annular protrusion 151 may also be provided on the side of the second transition portion 15 near the clamping portion 22.

[0041] Furthermore, in some embodiments, the diaphragm coupling simulator further includes a first fastener, with a threaded section 221 on the clamping portion 22, and the first fastener is threadedly connected to the threaded section 221. Exemplarily, the nominal size of the threaded section 221 can be M12, and the length range of the threaded section 221, i.e., the axial dimension, can be 20-40 mm, preferably 30 mm, to prevent later transmission failure. Exemplarily, the first fastener can be a counternut, with a nominal size of M12 and a thickness of 3-10 mm, preferably 5 mm, to ensure accurate load transmission. It is understood that the threaded section 221 and the counternut can also be set to other sizes, and their specific dimensions depend on the actual size of the diaphragm coupling simulator.

[0042] In some embodiments, the diaphragm disc coupling simulator further includes a plurality of second fasteners, each passing through a plurality of connecting holes 13. These second fasteners are used to fix the diaphragm disc coupling simulator to an external structure. Exemplarily, the connecting holes 13 may be evenly spaced in six places around the edge 12, with six corresponding second fasteners. Exemplarily, the second fasteners may be matching bolts and nuts, with a nominal size of M8. The nuts may be self-locking nuts to ensure the reliability of the bolted connection, making the maximum principal stress of the diaphragm disc coupling simulator equal to, similar to, and similarly distributed as the maximum principal stress at the critical location of the actual diaphragm disc coupling structure. Understandably, the number of connecting holes 13 and second fasteners may also be different, and the bolts and nuts may also be of other nominal sizes, as long as the maximum principal stress of the diaphragm disc coupling simulator is equal to, similar to, and similarly distributed as the maximum principal stress at the critical location of the actual diaphragm disc coupling structure.

[0043] According to an embodiment of the present invention, in another aspect, a method for designing a diaphragm disc coupling simulator is also provided, for obtaining the diaphragm disc coupling simulator as described above. Specifically, as... Figure 5 As shown, the design method of this diaphragm disc coupling simulation component specifically includes the following steps:

[0044] Step 1: Determine the structural characteristics of the test piece and the load conditions of the test piece under actual working conditions. Specifically, the test piece refers to a real diaphragm coupling structure that requires fatigue strength testing.

[0045] Step 2: Based on the structural characteristics of the test piece and the load conditions under actual working conditions, establish a three-dimensional model and a finite element model of the initial diaphragm disc coupling simulation component, incorporating the structural characteristics of the test piece. Using linear elastic constitutive modeling, calculate and obtain the stress field of the initial diaphragm disc coupling simulation component under actual working load conditions. The initial diaphragm disc coupling simulation component must at least include the structural characteristics of the root portion of the diaphragm disc profile of the test piece, i.e., the central portion 11 of the diaphragm disc 1 and the structural characteristics of the connection between the central portion 11 and the connecting shaft 2.

[0046] Step 3: Compare the stress field of the initial diaphragm coupling simulation component under actual working load with the stress state of the test piece under actual working conditions to determine whether the initial diaphragm coupling simulation component meets the design requirements; if it does not meet the requirements, optimize the characteristic structure of the initial diaphragm coupling simulation component until it meets the requirements; if it does meet the requirements, proceed directly to the next step.

[0047] Step 4: After completing Step 3, based on the initial diaphragm coupling simulation obtained, design a clamping structure to obtain a three-dimensional model of the diaphragm coupling simulation; wherein, the clamping structure can be the aforementioned connecting hole 13, threaded section 221, first fastener and second fastener.

[0048] Step 5: Establish a finite element model based on the three-dimensional model of the diaphragm coupling simulation component, obtain the stress field of the diaphragm coupling simulation component under actual working conditions and load, and compare it with the stress state of the test piece under actual working conditions to ensure that each part of the diaphragm coupling simulation component can meet the test requirements and avoid local optimization results.

[0049] Step 6: After completing Step 5, obtain the diaphragm disc coupling simulation component based on the three-dimensional model of the final obtained diaphragm disc coupling simulation component and the structural characteristics of the test component.

[0050] The design method for the diaphragm coupling simulator of this invention reduces testing costs, simplifies the testing process, and makes operation simple and reliable. Furthermore, the design method of this invention retains the local features of the actual diaphragm coupling structure (i.e., the root of the diaphragm disc surface). The local geometry not only reflects the machining processes and techniques but also determines the local stress distribution characteristics and stress state. By retaining the local geometry, the stress distribution and stress state of the critical parts of the actual structural component can be reflected more directly and conveniently, ensuring that the working state of the diaphragm coupling simulator is consistent with the actual diaphragm coupling structure, reducing the number of optimization attempts and improving design efficiency.

[0051] Furthermore, in some embodiments, in step 1, the structural features of the test piece include the geometry, size, material parameters, cold and hot working processes, heat treatment state, and surface roughness of the test piece; the load conditions of the test piece under actual working conditions include the environmental conditions, load magnitude, and load type of the test piece under actual service conditions.

[0052] The material parameters include at least the material grade, elastic modulus, Poisson's ratio, tensile strength, and yield strength. These parameters can be obtained through material performance testing or by consulting material handbooks. Since this experiment is a room temperature test, only the room temperature performance parameters of the material used need to be obtained. Hot and cold forming processes refer to the cold and hot forming processes of materials. Hot forming processes specifically refer to processing processes performed above the material's recrystallization temperature, such as casting, hot forging, rolling, and welding. Cold forming processes specifically refer to processing processes performed below the material's recrystallization temperature, such as cold rolling, machining, and electrochemical machining.

[0053] In step 6, a diaphragm coupling simulator is manufactured using the actual material grade, cold and hot working processes, heat treatment state, and surface roughness of the test piece obtained in step 1. The surface condition of the structural component is also a major factor controlling fatigue behavior. In this embodiment, by considering the surface condition of the real structural component, the diaphragm coupling simulator is made to have the same material, hot working process, and surface roughness as the real diaphragm coupling structure. This ensures that the fatigue life, strength behavior, and control factors of the real diaphragm coupling structure are fully reflected during the test, thereby improving the reliability of the test.

[0054] In some embodiments, in step 2, a 3D model of the initial diaphragm coupling simulation component can be established using 3D modeling software such as UG. Then, software such as Hypermesh is used to mesh this 3D model with hexahedral meshes. Attention must be paid to the mesh quality of key parts of the simulation component during meshing to ensure the accuracy of subsequent calculations. Based on this mesh model, loads are applied using software such as Abaqus to obtain the stress field of the initial diaphragm coupling simulation component under actual working conditions, i.e., the stress distribution cloud map, thus obtaining the stress situation and the location of the maximum principal stress.

[0055] Specifically, at least the following components can be identified based on the stress field of the initial diaphragm coupling simulator under actual operating loads:

[0056] 1) Deformation mode of the initial diaphragm disc coupling simulation component, including the structural features of the test piece;

[0057] 2) The critical location of the initial diaphragm disc coupling simulation component, where the maximum principal stress is located;

[0058] 3) Geometric characteristics of the hazardous area;

[0059] 4) Distribution of maximum principal stress in critical areas;

[0060] 5) Stress distribution at the diaphragm of the initial diaphragm coupling simulation component.

[0061] In this embodiment, by identifying the deformation mode, critical parts, geometric features of the critical parts, maximum principal stress distribution, and stress distribution of the diaphragm disc surface of the initial diaphragm disc coupling simulator, it is possible to make an actual comparison with the relevant features of the test piece, thereby ensuring the reliability of the design of the diaphragm disc coupling simulator.

[0062] In step 3, based on the identification results of step 2, if the location of the maximum principal stress distribution of the initial diaphragm coupling simulator is not located in the critical area or on diaphragm 1, or if there is excessive stress, or if there is a significant difference between the stress distribution and that of the test piece under actual service conditions, then it does not meet the design requirements and the characteristic structure of the initial diaphragm coupling simulator needs to be re-optimized. After iterative optimization calculations, an optimal diaphragm coupling simulator is determined.

[0063] Specifically, based on the finite element calculation results in step 2, observe the stress distribution cloud map to determine whether the location of the maximum principal stress is in a critical part of the initial diaphragm disc coupling simulation component, and the stress distribution on diaphragm disc 1 of the initial diaphragm disc coupling simulation component. If the maximum principal stress is located far from the critical part, the structural design scheme of the simulation component needs to be reconsidered. Secondly, if the stress distribution on the diaphragm disc is too large, the size and shape characteristics of the diaphragm disc also need to be reconsidered. Adjust and optimize the three-dimensional model of the initial diaphragm disc coupling simulation component. This optimization includes adjusting the size of diaphragm disc 1 and the position of characteristic structures, and adding transition fillets (i.e., the first transition part 14 and the second transition part 15) to alleviate stress concentration at areas prone to stress concentration. Finally, mesh the optimized three-dimensional model and perform finite element calculations, re-observe the stress distribution cloud map, and finally confirm an optimal three-dimensional model of the initial diaphragm disc coupling simulation component.

[0064] In some embodiments, step 3 further includes: determining the working load type and basic mechanical model of the initial diaphragm coupling simulation component, and optimizing the initial diaphragm coupling simulation component based on the determined working load type and basic mechanical model. For example, the working load type of the initial diaphragm coupling simulation component is bending load caused by axial and angular offsets; the basic mechanical model of the initial diaphragm coupling simulation component is a cantilever beam.

[0065] Step 4 specifically includes the design of the clamping method and dimensions of the clamping part for the initial diaphragm coupling simulation component, in order to finally obtain a diaphragm coupling simulation component with a clamping structure. Key factors to consider in this clamping structure include the length of the clamping end and the clamping method. The length of the clamping end is initially determined based on the clamping length range of the fatigue testing machine, and then adjusted appropriately according to the required fixing method. Based on experimental experience, a preliminary clamping method with threaded connection as the main load transfer mechanism is designed, using 2 / 3 of the length of the clamping part 22 as the thread length, and a second fastener is installed in the connecting hole 13, resulting in a preliminary clamping scheme.

[0066] In some embodiments, after step 4, the method further includes: determining whether the clamping structure of the diaphragm coupling simulation component meets the requirements of the test equipment; if it does, proceeding to the next step; if not, optimizing the clamping structure. In this step, the clamping scheme initially designed in step 4 is analyzed. This analysis includes determining the clamping length, ensuring it conforms to the clamping length of the fatigue testing machine, and applying boundary conditions as close as possible to the actual clamping in the finite element calculation. The results obtained are required to be basically consistent with the final results in step 3. Furthermore, considering that the upper thread may loosen during cyclic loading, the length of the threaded section 221 needs to be increased, and a counter nut needs to be added to prevent inaccurate experimental results caused by loosening during thread load transmission. Since applying preload alone may not be sufficient to meet the test requirements for the second fastener within the connecting hole 13, a bolt with a self-locking nut is considered for fixation to improve the reliability of the bolt connection and ensure the accuracy of the test results.

[0067] In step 5, the final finite element calculation is performed on the final determined diaphragm coupling simulation component. Boundary conditions are applied according to the actual clamping method, and the final stress distribution is observed. It is confirmed again that the stress state of each part of the simulation component meets the design requirements of the simulation component, and finally a diaphragm coupling simulation component that meets the project requirements is obtained.

[0068] In some embodiments, before step 6, the method further includes: determining the test load of the diaphragm coupling simulator, which includes a maximum test load and a minimum test load. Specifically, the loading load is determined using finite element analysis (FEM). By adjusting the load magnitude in the FEM, the maximum local principal stress of the diaphragm coupling simulator is made equal to the maximum principal stress at the critical location to obtain the maximum test load of the diaphragm coupling simulator. The minimum local stress of the diaphragm coupling simulator is calculated based on the local stress ratio of the test piece. Combined with the FEM calculation method, the minimum test load of the diaphragm coupling simulator is determined.

[0069] In some embodiments, step 6 specifically includes drawing an engineering drawing of the diaphragm disc coupling simulation component based on the final obtained three-dimensional model of the diaphragm disc coupling simulation component and the structural features of the test piece, and annotating and explaining the drawing according to the actual material grade, cold and hot working processes, heat treatment state, and surface roughness of the test piece. The actual structural component of the diaphragm disc coupling simulation component is then manufactured using the obtained engineering drawing.

[0070] The design process of this invention will be specifically explained below using the design of a diaphragm coupling simulator in a helicopter transmission system as an example.

[0071] Step 1: Determine the load conditions for the test piece, i.e., the actual diaphragm disc coupling structure, during service: angular offset of 1.5° (0.02618 radians), torque of 510 N·m, and rotational speed of 6000 r / min (628.3 rad / s). The material of the actual diaphragm disc coupling structure is determined to be TC4 titanium alloy, conforming to the standard "GJB 2218A-2008 Specification for Titanium and Titanium Alloy Bars and Forgings for Aviation". The material's hot working process is hot forging followed by annealing at 750℃ for 2 hours. The geometry is a thin-walled disc-type component, with transition fillet radii of R5 and R6 at the first transition section 14 and the second transition section 15 of the diaphragm disc 1. The cold working process is milling the plane, rough turning, rough milling, and ball end milling. Since the material has already undergone heat treatment, its machining does not require heat treatment; only cooling during machining is necessary, and the surface roughness is guaranteed to be Ra1.6.

[0072] Step 2: Based on the conditions determined in Step 1, a 3D model and a finite element model of the simulated diaphragm coupling structure with real structural features are established using 3D modeling software. A linear elastic constitutive model (elastic modulus E = 120 GPa, Poisson's ratio ν = 0.34) is used to calculate the stress field of the simulated diaphragm coupling structure under actual working load. The following are identified: 1) The initial deformation mode of the simulated diaphragm coupling is torsion with angular displacement; 2) The critical location of the initial simulated diaphragm coupling, i.e., the location of the maximum principal stress, is at the center (point 11); 3) The geometric characteristics of the critical location; 4) The specific location and magnitude of the maximum principal stress at the critical location, with a maximum principal stress of 320 MPa; 5) The stress distribution at diaphragm disc 1 shows that the stress is greatest at the center (point 11), and the stress gradually decreases with the radial direction.

[0073] Step 3: Based on the finite element calculation results from Step 2, the stress distribution was analyzed. It was found that the maximum principal stress did not occur in the central part 11, therefore this simulation component did not meet the design requirements. Therefore, through structural optimization, an annular protrusion 151 was provided on the side of the second transition part 15 away from the clamping part 22, so that the critical part of the diaphragm coupling simulation component was located on the side away from the clamping part 22. After calculation confirmation, this design approach was found to be feasible, and thus, after optimization, the following was obtained: Figure 6 The three-dimensional model shown is obtained through linear elastic analysis as follows. Figure 7 The stress distribution cloud map shown.

[0074] Step 4: Based on the final result of Step 3, design the clamping structure. The clamping part 22 is bolted, and a threaded section 221 with a nominal size of M12 and a length of 30mm is provided at the clamping part 22 to prevent later transmission failure; a counter nut with a nominal size of M12 and a thickness of 5mm is added to ensure the accuracy of load transmission. Six connecting holes 13 are provided, and six second fasteners are respectively set in the six connecting holes 13. The second fasteners include matching bolts and nuts, both with a nominal size of M8. The nuts are self-locking nuts to ensure the reliability of the bolted connection.

[0075] Step 5: Using the finite element model and calculations, the stress field of the diaphragm coupling simulator under actual operating load is obtained by applying a load condition close to the real service scenario (axial displacement of 0.14 mm). This is then compared with the test specimen. If the maximum stress of the diaphragm coupling simulator is equal to the maximum principal stress at the critical location of the test specimen, the stress state is similar, and the maximum principal stress distribution is similar, then proceed to the next step; otherwise, further optimization of the characteristic structure of the diaphragm coupling simulator is required.

[0076] Step 6: Based on the diaphragm coupling simulation obtained after Step 5, produce engineering drawings for the diaphragm coupling simulation. Specify the material parameters, cold and hot processing techniques, and surface condition of the diaphragm coupling simulation based on the structural characteristics of the test piece. The actual structural component of the diaphragm coupling simulation is then manufactured according to the engineering drawings.

[0077] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A design method for a diaphragm disc coupling simulation component, characterized in that, Used to obtain a diaphragm disc coupling simulation component, the diaphragm disc coupling simulation component includes: The membrane disk (1) includes a central part (11) and an edge part (12) connected to each other; the central part (11) is annular, the edge part (12) extends around the central part (11) around the entire circumference, and the edge part (12) is provided with a plurality of connecting holes (13) at circumferential intervals. The connecting shaft (2) includes a connecting part (21) and a clamping part (22) connected to each other; the connecting part (21) is connected to the middle part of the central part (11), and the clamping part (22) is located on one side of the axial direction of the central part (11); The central portion (11) is recessed into the edge portion (12) on both axial sides; Along the axial direction of the central portion (11), at least a portion of the structure of the connecting portion (21) protrudes from the side of the central portion (11) away from the clamping portion (22); The diaphragm coupling simulation component also includes a first fastener, and the clamping part (22) is provided with a threaded section (221), and the first fastener is threadedly connected to the threaded section (221); The diaphragm coupling simulation component also includes a plurality of second fasteners, which are respectively inserted into the plurality of connecting holes (13). The second fasteners are used to fix the diaphragm coupling simulation component to the external structure. The method includes the following steps: Step 1: Determine the structural characteristics of the test piece and the load conditions of the test piece under actual working conditions; Step 2: Based on the structural characteristics of the test piece and the load conditions under actual working conditions, establish a three-dimensional model and a finite element model of the initial diaphragm coupling simulation piece containing the structural characteristics of the test piece. Using linear elastic constitutive model, calculate and obtain the stress field of the initial diaphragm coupling simulation piece under actual working load conditions. Step 3: Compare the stress field of the initial diaphragm coupling simulation component under actual working load with the stress state of the test piece under actual working conditions to determine whether the initial diaphragm coupling simulation component meets the design requirements; if not, optimize the characteristic structure of the initial diaphragm coupling simulation component until it meets the requirements. Step 4: After completing Step 3, based on the initial diaphragm coupling simulation component finally obtained, design a clamping structure, which consists of a connecting hole (13), a threaded section (221), a first fastener, and a second fastener, to obtain a three-dimensional model of the diaphragm coupling simulation component. Step 5: Establish a finite element model based on the three-dimensional model of the diaphragm coupling simulation component, obtain the stress field of the diaphragm coupling simulation component under actual working conditions and load, and compare it with the stress state of the test piece under actual working conditions to ensure that each part of the diaphragm coupling simulation component can meet the test requirements. Step 6: After completing step 5, based on the three-dimensional model of the diaphragm coupling simulation component and the structural features of the test piece, obtain the diaphragm coupling simulation component.

2. The design method of the diaphragm disc coupling simulation component according to claim 1, characterized in that, The membrane disc (1) further includes a first transition portion (14) and a second transition portion (15); the first transition portion (14) is connected between the center portion (11) and the edge portion (12), and the second transition portion (15) is connected between the center portion (11) and the connecting portion (21); the second transition portion (15) is provided with an annular protrusion (151) extending around the axis, and the annular protrusion (151) is located on the side of the second transition portion (15) away from the clamping portion (22).

3. The design method of the diaphragm disc coupling simulation component according to claim 1, characterized in that, In step 1, the structural features of the test piece include its geometry, dimensions, material parameters, cold and hot working processes, heat treatment state, and surface roughness. The load conditions of the test specimen under actual working conditions include the environmental conditions, load magnitude, and load type of the test specimen under actual service conditions.

4. The design method of the diaphragm disc coupling simulation component according to claim 1 or 3, characterized in that, In step 2, the stress field of the initial diaphragm disc coupling simulation component under actual operating load is identified: The deformation mode of the initial diaphragm disc coupling simulation component, including the structural feature portion of the test piece; The dangerous part of the initial diaphragm disc coupling simulation component refers to the location of the maximum principal stress. The geometric features of the dangerous area; The maximum principal stress distribution at the critical location; The stress distribution at the diaphragm of the initial diaphragm coupling simulation component.

5. The design method of the diaphragm disc coupling simulation component according to claim 4, characterized in that, Step 3 further includes: determining the working load type and basic mechanical model of the initial diaphragm coupling simulation component, and optimizing the initial diaphragm coupling simulation component based on the determined working load type and basic mechanical model.

6. The design method of the diaphragm disc coupling simulation component according to claim 5, characterized in that, Before step 6, the method further includes the step of: determining the test load of the diaphragm coupling simulator, which includes the maximum test load and the minimum test load; The loading load is determined using finite element method (FEM) calculations. By adjusting the load magnitude in the FEM, the maximum local principal stress of the diaphragm coupling simulator is made equal to the maximum principal stress of the critical part, thereby obtaining the maximum test load of the diaphragm coupling simulator. The minimum local stress of the diaphragm coupling simulator is calculated based on the local stress ratio of the test piece. Combined with the FEM calculation method, the minimum test load of the diaphragm coupling simulator is determined.

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