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Life analysis method for products based on failure behavior models
ZHA Guoqing , JING Hailong , CHEN Yunxia , KANG Rui
School of Reliability and Systems Engineering, Beijing University of Aeronautics and Astronautics, Beijing 100083, China
Received: 2015-11-11; Accepted: 2015-12-06; Published online: 2016-01-21
Corresponding author. Tel.:010-82338909,E-mail:chenyunxia@buaa.edu.cn
Abstract: With the situation that traditional reliability engineering methods cannot meet the demand of design and analysis for the products with high reliability and long life index, this paper considers the uncertainty of inner and outside factors which cause the life dispersion, and on the basis of product functional models or digital prototype models, with the failure behavior model of products, a method is proposed to conduct the life analysis for products with long life index. The dispersion of inner and outside parameters can be expressed by the probability density function and obtained by analyzing the actual use and production conditions. Thus the life characteristics of products obtained with this method can remedy the disadvantage that the reliability prediction method based on physics of failure cannot reflect the actual normal use conditions of the products.
Key words: failure behavior model     mechanism analysis     wear-out failure mechanism     life analysis     physics of failure

1 产品寿命分析方法 1.1 原理与流程

 图 1 产品寿命分析原理与流程 Fig. 1 Principle and process of life analysis for products
1.2 机理分析流程

 图 2 机理分析流程 Fig. 2 Process of mechanism analysis
1.3 故障行为分析方法

MTTF的计算是利用故障行为模型，综合考虑产品内因参数和外因参数的分散性，对产品的寿命指标进行预计。指标计算的原理如式(1)所示:

 (1)

 (2)

 图 3 MTTF分析步骤 Fig. 3 Analysis procedure of MTTF

1) 建立故障行为模型

 (3)

2) 内因特征参数提取

3) 环境特征参数提取

4) 按照式(1)或式(2)计算产品的MTTF

1.4 分析用例生成方法

 (4)

 (5)

 (6)
1.5 机理敏感性分析方法

 (7)
 (8)

 (9)

 (10)

1) 建立故障行为模型，如式(3)或式(7)所示。

2) 通过环境特征提取的方法，获得表征产品实际工作条件的环境应力分布，记为p(E)。

3) 按照p(E)随机生成m组环境条件，分别按照式(8)确定每一种环境条件下的敏感机理。称敏感机理次数最多的故障机理即为主机理。

4) 在通过分析确定主机理或薄弱环节之后，应该针对主机理或者薄弱环境，进行相应的设计改进，从而提高产品的可靠性水平。

2 案例分析

 序号 薄弱环节单元 主机理 1 滑履、卡盘 磨损 2 转子 疲劳 3 内轴、传动轴 接触疲劳 4 弹簧 应力松弛 5 四氟塑料圈 老化   

 (11)
 (12)
 (13)

 序号 参数 数值 1 F/N 34.1 2 R1/mm 5.15 3 R2/mm 7.2 4 R3/mm 5.5 5 hmax/mm 1 6 f 0.075 7 H/MPa 500 8 I/(10-7kg·m2) 1.927 9 μ/(Pa·s) 0.006 63 10 R/mm 21.5 11 n/(r·min-1) 4 000 12 t0/s 20 13 h0/mm 0.085

 序号 薄弱环节单元 主机理 模型名称 寿命/h 1 滑履、卡盘 磨损 滑履-卡盘磨损寿命计算模型 1 413 2 转子 疲劳 名义应力(时域法)寿命计算模型 1 742 3 内轴、传动轴 接触疲劳 渐开线花键接触疲劳寿命计算模型 5 512 4 弹簧 应力松弛 弹簧应力松弛寿命计算模型 3 200 5 四氟塑料圈 老化 塑料老化寿命计算模型 4 786     

 序号 单元名称 机理 模型名称 寿命均值/h 寿命区间/h 1 滑履、卡盘 磨损 滑履-卡盘磨损寿命计算模型 1 413 [1 236，1 606] 2 转子 疲劳 名义应力(时域法)寿命计算模型 1 742 [1 533，2 054] 3 内轴、传动轴 接触疲劳 渐开线花键接触疲劳寿命计算模型 5 512 [5 021，6 102] 4 弹簧 应力松弛 弹簧应力松弛寿命计算模型 3 200 [2 713，3 518] 5 四氟塑料圈 老化 塑料老化寿命计算模型 4 786 [4 205，5 432]      

3 结 论

1) 在产品功能模型或数字样机模型的基础上，系统地提出了一种基于故障行为模型的产品寿命分析方法，为具有长寿命指标产品的设计改进提供了技术支撑。

2) 给出了综合考虑内因和外因分散性的故障行为分析方法，内因参数与外因参数的分散性分别用相应的概率密度函数来表示，并且从实际使用情况和生产条件的估计得到，为准确评估产品在正常使用工况下的故障行为提供了方法支撑。

3) 提出了机理敏感性的分析方法，确定了产品的寿命薄弱环节和敏感机理，为具有长寿命指标产品的设计改进指明了方向。

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#### 文章信息

ZHA Guoqing, JING Hailong, CHEN Yunxia, KANG Rui

Life analysis method for products based on failure behavior models

Journal of Beijing University of Aeronautics and Astronsutics, 2016, 42(11): 2371-2377
http://dx.doi.org/10.13700/j.bh.1001-5965.2015.0739