Abstract: In order to realize the measurement of stress distribution and the prediction of connection force of interference fit, an ultrasonic measurement system and calibration device were established based on the principle of ultrasonic pulse reflection method. Firstly, the influencing factors of the reflection coefficient were analyzed by the calibration device. Then, the stress distribution of three types of interference (6μm, 12μm, and 18μm) was measured by the ultrasonic measuring system, and the connection force was predicted based on the measurement results. Finally, the prediction results were verified by extrusion experiments. The research indicates that couplant, the size and texture direction of roughness, and covered boundary are the key factors affecting the measurement accuracy. The error analysis model of the covered boundary can realize the prediction and compensation of measurement error. The measured stress distribution can effectively reflect the contact state and defects between the mating surfaces, and the relative error of the connection force is less than 16%. Therefore, the analytical method and measuring device established in this paper can achieve accurate measurement of stress distribution and reliable prediction of connection force, which provides technical support for reliable evaluation of the connection quality of interference fit. In addition, the research methods in this paper have universal applicability, and it is of great significance to achieve the measurement of stress between different mating surfaces.

Key words: Interference fit;Stress distribution;Connection force;Ultrasonic measurement;Influencing factors;Error analysis model

摘要： 为了实现过盈配合应力分布的测量和连接力预测，以超声波脉冲反射法原理为基础，建立了超声测量系统及标定装置。首先，利用标定装置对反射系数的影响因素进行了分析。然后，用所搭建的超声测量系统测量了3种过盈量（6μm，12μm和18μm）的应力分布，并根据测量结果实现了连接力的预测。最后，通过压出实验对预测结果进行了验证。研究表明，耦合剂、粗糙度的大小和纹理方向及覆型边界是影响测量精度的关键因素。本文建立的覆型边界误差分析模型可以实现测量误差的预测及补偿。应力分布测量结果能够有效反应配合面间的接触状态及缺陷，连接力的相对误差小于16%。因此，本文所建立的分析方法和测量系统可以实现应力分布的准确测量与连接力的可靠预测，并为过盈组件配合质量与连接力的可靠评估提供了技术支撑。此外，本文的研究方法具有普遍的适用性，对实现不同接触面间应力的测量具有一定的指导意义。

关键词: 过盈配合;应力分布;连接力;超声测量;影响因素;误差分析模型