Material selection and structural strength analysis of power cord tension torsion testing machine

　　Power cord tension and torsion testing machineIt is a key equipment for testing the tensile and torsional performance of wires and cables, and its material selection and structural strength directly affect the testing accuracy, equipment life, and operational safety. Scientific and rational material and structural design is the core to ensure the stable operation of the testing machine.

1、 Material selection: Performance matching and durability guarantee

1. High strength requirements for load-bearing components:

As the main body of the equipment, the rack needs to withstand tensile, torsional, and vibration loads. It is usually made of Q345B low-alloy high-strength steel, which has a yield strength of ≥ 250MPa after quenching and tempering treatment to ensure long-term use without deformation; The frame connectors are made of 42CrMo alloy steel, and the surface hardness (HRC50~55) is improved by carburizing and quenching to enhance wear resistance.

2. Functional adaptation of fixtures and transmission components:

The fixture is in direct contact with the power cord, and both clamping force and insulation layer protection need to be taken into account. The clamping surface is made of Cr12MoV tool steel (hardness HRC58~62), with surface polishing or titanium plating treatment to reduce scratches on the cable; The transmission gear is made of 20CrMnTi carburizing steel, with a tooth surface hardness of HRC55~60 and a core that maintains toughness and can withstand high-frequency torsional loads.

3. Corrosion resistance and lightweight design:

In a high humidity laboratory environment, the equipment surface needs to be sprayed with epoxy zinc rich primer and polyurethane topcoat to isolate water and oxygen corrosion; Some non load bearing components (such as shells and brackets) are made of 6061-T6 aluminum alloy, with a density only one-third of steel, which can reduce weight and cost while meeting the basic strength requirements (tensile strength ≥ 270MPa).

2、 Structural strength analysis: optimizing design to cope with complex working conditions

1. Static and fatigue simulation verification:

By simulating the stress distribution during full load testing through finite element analysis (FEA), the focus is on verifying stress concentration areas such as the root of the fixture and the transition fillet of the transmission shaft, ensuring that larger stress values are below 80% of the material yield strength (safety factor ≥ 1.5). In the dynamic simulation, adjust the gear engagement clearance (0.02~0.05mm) and the shafting support stiffness to avoid fatigue cracks caused by resonance.

2. Modular structure enhances stability:

The rack adopts a combination design of "cross shaped beam+reinforcing rib" to disperse and concentrate the load; Add counterweights to the base (with a mass ratio of ≥ 20%) to lower the center of gravity and reduce vibration interference. The fixture and host adopt a hydraulic locking quick release structure, which not only ensures clamping force (≥ 5kN) but also facilitates the replacement of fixtures of different specifications, adapting to the testing needs of multiple scenarios.

3、 Durability enhancement and maintenance optimization

Key components such as transmission shafts and fixtures must undergo 100000 fatigue tests to verify no plastic deformation; The lubrication system adopts a centralized oil supply design, seals the bearing seat to reduce oil pollution of cables, and extends the maintenance cycle to six months per time.

　　Power cord tension and torsion testing machineThe material and structural design should aim for "high strength, fatigue resistance, and easy maintenance". The combination of scientific material selection and simulation optimization can significantly improve equipment accuracy and lifespan, providing reliable guarantees for quality control of wires and cables.