Failure analysis on copper bars of traction motor key component

doi:10.13251/j.issn.0254-6051.2023.08.042

Abstract

Abstract: Many accidents of the motor rotor copper guide bar fracture occurred in service for the 5GEB32B1 type traction motor of HXN5 locomotive. The fracture causes were analyzed, and the corresponding improvement measures were proposed by means of chemical composition test, metallographic examination, tensile test and fracture morphology analysis. The results show that the chemical composition, microstructure and properties of the copper all meet the requirements of relevant standards, and the fracture mechanisms are fatigue fracture and creep fracture. Obvious fatigue striations are observed on the broken copper bars, and the temperature around the copper bar and throughout the whole motor raises caused by the copper bars rubbing violently with the spindle after fracture, which further causes the guide bars to creep under various loads at high temperature and for a long time.

Key words: copper bar, failure analysis, fatigue fracture, creep rupture

CLC Number:

U264.1

Lu Jiping, Yang Chuan, Cui Guodong, Ma Ji, Zhang Chengsong, Guo Qiyang, Chen Dazhi. Failure analysis on copper bars of traction motor key component[J]. Heat Treatment of Metals, 2023, 48(8): 260-264.

References

[1]安国庆, 刘教民, 郭立炜, 等. 利用相关性基波消去法诊断电机转子断条故障[J]. 电机与控制学报, 2011, 15(3): 69-73.
An Guoqing, Liu Jiaoming, Guo Liwei, et al. Diagnosing rotor broken bar fault in motor by using correlation fundamental component filtering method[J]. Electric Machines and Control, 2011, 15(3): 69-73.
[2]李舜酩, 郭海东, 李殿荣. 振动信号处理方法综述[J]. 仪器仪表学报, 2013, 34(8): 1907-1913.
Li Shunming, Guo Haidong, Li Dianrong. Review of vibration signal processing methods[J]. Chinese Journal of Scientific Instrument, 2013, 34(8): 1907-1913.
[3]许伯强, 孙丽玲, 李和明. 基于多重信号分类与模式搜索算法的笼型异步电动机转子断条故障检测新方法[J]. 中国电机工程学报, 2012, 32(9): 93-99.
Xu Boqiang, Sun Liling, Li Heming. A detection method for broken rotor bar fault in induction motors based on multiple signal classification and pattern search algorithm[J]. Proceedings of the CSEE, 2012, 32(9): 93-99.
[4]周尤利, 汤胜华. 电机导条及其制备方法: 201510035091.7, 中国[P]. 2015-01-23.
[5]Kim Y K, Park S H, Lee K A. Effect of post-heat treatment on the thermophysical and compressive mechanical properties of Cu-Ni-Sn alloymanufactured by selective laser melting[J]. Materials Characterization, 2020, 162: 110194.
[6]李岳桥. 热处理工艺对铜镍锡合金力学性能和微观组织的影响[D]. 太原: 中北大学, 2021.
[7]浦玉萍, 肖汉成, 吕广庶. Cu₇₅Ni₉Sn₂P₁₄非晶合金热稳定性的研究[J]. 钢铁研究学报, 2000, 12(3): 55-58.
Pu Yuping, Xiao Hancheng, Lü Guangshu. Research of thermal stability of Cu-base amorphous alloy[J]. Journal of Iron and Steel Research, 2000, 12(3): 55-58.
[8]Li J, Sun Q, Zhang Z P, et al. Theoretical estimation to the cyclic yield strength and fatigue limit for alloy steels[J]. Mechanics Research Communications, 2009, 36(3): 316-321.
[9]束德林. 工程材料力学性能[M]. 3版. 北京: 机械工业出版社, 2004.
[10]洛阳铜加工厂中心试验室金相组. 铜及铜合金金相图谱[M]. 北京: 冶金工业出版社, 1983.

[1]	Chen Shengchao, Chen Yesheng, Rong Zeyu, Wang Hongwei, Xu Hongxiang, Zhao Shaofu, Guo Jingqiang. Cracking failure analysis on high-speed intermediate shaft gear [J]. Heat Treatment of Metals, 2023, 48(7): 287-291.
[2]	Xu Zhigang, Yang Yang, Yang Zhongna, Yao Xiaojiang, Qin Caihui, Wang Haipeng, Liu Liang. Effect of surface strengthening on microstructure and properties of C17200 beryllium bronze substrate for logging while drilling equipment [J]. Heat Treatment of Metals, 2023, 48(6): 107-113.
[3]	Wang Hao, Fu Neng, Feng Kangtun. Failure analysis on cracking of 7A09 aluminum alloy outer cylinder parts [J]. Heat Treatment of Metals, 2023, 48(5): 298-302.
[4]	Wang Cuiying, Yang Youcai, Ke Meiwu, Chu Xiaofei, Wang Wei. Failure analysis of 7A04 aluminum alloy shell [J]. Heat Treatment of Metals, 2023, 48(4): 298-302.
[5]	Chen Jilin, Zhang Yuming, Meng Yi, Yan Cong, Lin Peng. Failure analysis of fatigue fracture of engine cylinder head bolts [J]. Heat Treatment of Metals, 2023, 48(2): 308-313.
[6]	Jiao Li, Shang Haikun, He Jianfeng, Wang Guoliang, Feng Tao, Wang Jia, Hu Yutao. Failure analysis on piston connecting rod mechanism of diesel engine [J]. Heat Treatment of Metals, 2022, 47(7): 277-282.
[7]	Li Tianfu, Qu Shen, Dong Chen, Zhang Zhefeng. Failure analysis on spindle bearing of numerical control machine tool [J]. Heat Treatment of Metals, 2022, 47(4): 258-262.
[8]	Nie Xiaolong, Gao Jiaqiang, Meng Kairen, Wang Junyi, Liu Xinkuan. Fracture failure analysis of 60Si2Mn spring steel [J]. Heat Treatment of Metals, 2021, 46(8): 246-249.
[9]	Yang Jinping, Song Guobin, Dong Yongjun, Cui Chong, Duan Wenfeng, Shi Quanqiang, Shan Yiyin. Microstructure and properties of a gas turbine blade after long-term service [J]. Heat Treatment of Metals, 2021, 46(6): 213-220.
[10]	Zhao Xin'e. Cracking analysis of 8418 steel barrel used for aluminum-melting [J]. Heat Treatment of Metals, 2021, 46(6): 236-239.
[11]	Tan Xiaomeng, Tian Feng, Qiao Xin, Guo Xin'ai. Cracking failure analysis on a high speed shaft of belt conveyor reducer [J]. Heat Treatment of Metals, 2021, 46(6): 253-255.
[12]	Huang Xin, Zhou Jiguang, Fang Zhixiao, Wu Wei, Wen Yonghong. Fracture cause analysis of 30CrMnSiA steel bolt for motor fixing [J]. Heat Treatment of Metals, 2021, 46(5): 253-258.
[13]	Gao Zhiyu, He Wei, Jing Xiukun, Fan Xianjin, Wang Yingxin, Bai Jiang, Wang Daliang. Failure analysis and heat treatment process optimization of Cr12MoV steel blanking die [J]. Heat Treatment of Metals, 2021, 46(3): 206-212.
[14]	Li Jiahua, Li Ping, Sun Song, Xie Hui, Zeng Yin. Fracture failure analysis of stainless steel tie rod joint [J]. Heat Treatment of Metals, 2021, 46(3): 218-222.
[15]	Yu Haihua, Yan Haiyan, Zhang Jingtong, Wang Yukui, Huang Zhiyong, Wu Jianxin, Wei Zhenwei. Failure analysis of 30CrMnSiA steel countersunk bolt [J]. Heat Treatment of Metals, 2021, 46(3): 223-228.