Research on Fatigue Crack Propagation Characteristics of Vacuum Switch Transmission System
Dong Huajun1, Li Dongheng1, Li Jinjin2, Ding Gengxin1, Cheng Yonglei1
1. School of Mechanical Engineering Dalian Jiaotong University Dalian 116028 China; 2. School of Automation and Electrical Engineering Dalian Jiaotong University Dalian 116028 China
Abstract：Fatigue failure of key structures under cyclic loading is one of the factors leading to the inability of vacuum switches. However, the failure mechanism under the combined effects of impact and constant load remains unclear. Traditional safety life assessment methods, which rely on the unrealistic assumption of defect-free materials, are limited in their applicability. Therefore, this paper proposes a numerical simulation method for the damage process that couples an impulse load with the time-varying strain of a mechanical structure. By constructing a crack-propagation model of the key structure of the vacuum switch, the fatigue failure mechanism of the connecting plate is elucidated, and the structure's weakness is optimized. First, a dynamic characteristics calculation model of a 12 kV vacuum switch is established in ADAMS, and the mechanism's closing motion characteristics are analyzed. Then, the impact behavior of the vacuum switch transmission structure is simulated using LS-DYNA, and the critical stress region is identified. To calculate the residual life of the vacuum switch transmission mechanism, a fracture mechanics approach is employed to analyze crack propagation in the connecting plate structure, and the evolution of crack propagation to fracture under impact loading is simulated. Finally, according to the stress distribution and failure mode of the vacuum switch transmission system, an anti-damage design scheme for the connecting plate is proposed. The simulation results of the dynamic model indicate that the maximum stress in the transmission connecting plate structure occurs at the upper part of the fixed pin, with a value of approximately 239 MPa. Therefore, mechanical damage is likely to occur at this position. The fatigue crack propagation results on the connecting plate structure show that the fatigue crack of the transmission connecting plate belongs to the open crack. When the crack propagation reaches 11 mm, the critical size is reached; the connecting plate structure then fails rapidly under cyclic loading, with a failure period of only 57 cycles. Therefore, to avoid sudden failure of the connecting plate, the fatigue crack growth in the connecting plate structure should be controlled to remain below 11 mm. When the crack size approaches 11 mm, the connecting plate should be repaired promptly. The following conclusions can be drawn. (1) The critical crack length increases with the increase in the height of the connecting plate. However, the crack-propagation path is essentially unchanged. In addition, in the stage of rapid propagation, the increase in the height of the connecting plate does not reduce the stress intensity factor at the fatigue crack tip. Therefore, increasing the height of the connecting plate can improve the overall fatigue life of the structure but cannot effectively prevent the rapid propagation of cracks. (2) When the crack passes through the stiffeners, the morphology of the crack front changes, and the crack propagation speed near the stiffener is slower than that away from the stiffener. Therefore, orienting the stiffeners along the direction of crack propagation can improve the distribution of the stress intensity factor at the crack tip and delay the crack propagation.
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2026, Vol. 41 
