Velocity-Incorporated Wear Model of Rolling Guide Shoe Material Selection

To ensure an accurate selection of rolling guide shoe materials,an analysis of the intricate relationship between linear speed and wear is imperative.Finite element simulations and experimental measurements are employed to evaluate four distinct types of materials:polyurethane,rubber,polytetrafluoroethylene(PTFE),and nylon.The speed-index of each material is measured,serving as a preparation for subsequent analysis.Furthermore,the velocity-wear factor is determined,providing insights into the resilience and durability of the material across varying speeds.Additionally,a wear model tailored specifically for viscoelastic bodies is explored,which is pivotal in understanding the wear mechanisms within the material.Leveraging this model,wear predictions are made under higher speed conditions,facilitating the choice of material for rolling guide shoes.To validate the accuracy of the model,the predicted degree of wear is compared with experimental data,ensuring its alignment with both theoretical principles and real-world performance.This comprehensive analysis has verified the effectiveness of the model in the selection of materials under high-speed conditions,thereby offering confidence in its reliability and ensuring optimal performance.

Establishment of wear model and life prediction of drum of hot rolling coiler

For the drum of hot rolling coiler is prone to be easily destroyed, the type of MMU-5G abrasion tester was applied to revealing the friction and wear behavior. The morphology observation by scanning electron microscope (SEM) demonstrates the wear mechanism of the drum, and the test data of the influence coefficient of the normal pressure, relative sliding speed and surface lubrication conditions acted on the linear rate of the wear could be obtained by the regression method. A calculation model, which considers the factors of the structure of the drum, coiling tension and coiling strip specifications, was established by the combination method to predict the wear life of the drum. Then the practical production data was applied into this model and the analysis result was in good accordance with that of actual production.

3D finite element analysis of a two-surface wear model in fretting tests

This article aims at developing a computationally efficient framework to simulate the erosion of two contact surfaces in three-dimensional(3D),depending on the body resistance.The framework involves finite element(FE)resolution of a fretting problem,wear computation via a non-local criterion including a wear distribution parameter(WDP),as well as updating of the geometry and automatic remeshing.Its originality is based on the capability to capture the damage on each surface and obtain local and global results for a quantitative and qualitative analysis.Numerical simulations are carried out for two 3D contact specimens with different values of WDP.The results highlight the importance of correctly modelling wear:One-surface wear model is sufficient from a global point of view(wear volume),or whenever the wear resistance for a body is much higher than that of another one,whereas a 3D two-surface wear model is essential to capturing local effects(contact pressure,wear footprint,etc.)related to the difference in wear resistance of the bodies.

The effectiveness of different wear indicators in quantifying wear on railway wheels of freight wagons

Railway infrastructure relies on the dynamic interaction between wheels and rails;thus,assessing wheel wear is a critical aspect of maintenance and safety.This paper focuses on the wheel-rail wear indicator T-gamma(Tγ).Amidst its use,it becomes apparent that Tγ,while valuable,fails to provide a comprehensive reflection of the actual material removal and actual contact format,which means that using only Tγas a target for optimization of profiles is not ideal.In this work,three different freight wagons are evaluated:a meter-gauge and a broad-gauge heavy haul vehicles from South American railways,and a standard-gauge freight vehicle operated in Europe,with different axle loads and dissimilar new wheel/rail profiles.These vehicles are subjected to comprehensive multibody simulations on various tracks.The simulations aimed to elucidate the intricate relationship between different wear indicators:Tγ,wear index,material removal,and maximum wear depth,under diverse curves,non-compensated lateral accelerations(A_(nc)),and speeds.Some findings showed a correlation of 0.96 between Tγand wear depth and 0.82 between wear index and material removed for the outer wheel.From the results,the Tγis better than the wear index to be used when analyzing wear depth while the wear index is more suited to foresee the material lost.The results also show the low influence of A_(nc)on wear index and Tγ.By considering these factors together,the study aims to improve the understanding of wheel-rail wear by selecting the best wear analysis approaches based on the effectiveness of each parameter.

Tribological properties and wear prediction model of TiC particles reinforced Ni-base alloy composite coatings

TiC particles reinforced Ni-based alloy composite coatings were prepared on 7005 aluminum alloy by plasma spray. The effects of load, speed and temperature on the tribological behavior and mechanisms of the composite coatings under dry friction were researched. The wear prediction model of the composite coatings was established based on the least square support vector machine (LS-SVM). The results show that the composite coatings exhibit smaller friction coefficients and wear losses than the Ni-based alloy coatings under different friction conditions. The predicting time of the LS-SVM model is only 12.93%of that of the BP-ANN model, and the predicting accuracies on friction coefficients and wear losses of the former are increased by 58.74%and 41.87%compared with the latter. The LS-SVM model can effectively predict the tribological behavior of the TiCP/Ni-base alloy composite coatings under dry friction.

A Review on Fretting Wear Mechanisms,Models and Numerical Analyses

Fretting wear is a material damage in contact surfaces due to micro relative displacement between them.It causes some general problems in industrial applications,such as loosening of fasteners or sticking in components supposed to move relative to each other.Fretting wear is a complicated problem involving material properties of tribosystem and working conditions of them.Due to these various factors,researchers have studied the process of fretting wear by experiments and numerical modelling methods.This paper reviews recent literature on the numerical modelling method of fretting wear.After a briefly introduction on the mechanism of fretting wear,numerical models,which are critical issues for fretting wear modelling,are reviewed.The paper is concluded by highlighting possible research topics for future work.

Numerical Model of Ultra-High Molecular Weight Polyethylene Abrasive Wear Tests

Ultra-high molecular weight polyethylene (UHMWPE) has been used in orthopedics as one of the materials for artificial joints in knee, hip and spine prostheses, most of the implanted joints are designed so that the metal of the prosthesis is articulate against a polymeric material, however the main problems is the average life time of the UHMWPE due to wear, and the particles generated by the friction of the metal on the articulation of the polymer are the most common inducer of osteolysis, generating a loosening of the implant leading to an imminent failure resulting in the total replacement of the prosthesis. In this investigation a numerical model of abrasive wear was made using the classic Archard wear equation applied to dynamic simulation of finite element analysis (FEA) of the micro-abrasion test using a subroutine written in Fortran language linked to the finite element software to predict the rate of wear. The results of the numerical model were compared with tests of abrasive wear in the laboratory, obtaining a margin of error below 5%,concluding that the numerical model is feasible for the prediction of the rate of wear and could be applied in knowing the life cycle of joint prostheses or for the tribological analysis in industrial machinery or cutting tools. The wear coefficient (K) was obtained from the grinding tests depending on the depth of stroke of the crater, which was analyzed by 3D profilometry to obtain the wear rate and the wear constant.

Prediction of Wearing of Cutting Tools Using Real Time Machining Parameters and Temperature Using Rayleigh-Ham Method

Wear of cutting tools is a big concern for industrial manufacturers, because of their acquisition cost as well as the impact on the production lines when they are unavailable. Law of wear is very important in determining cutting tools lifespan, but most of the existing models don’t take into account the cutting temperature. In this work, the theoretical and experimental results of a dynamic study of metal machining against cutting temperature of a treated steel of grade S235JR with a high-speed steel tool are provided. This study is based on the analysis of two complementary approaches, an experimental approach with the measurement of the temperature and on the other hand, an approach using modeling. Based on unifactorial and multifactorial tests (speed of cut, feed, and depth of cut), this study allowed the highlighting of the influence of the cutting temperature on the machining time. To achieve this objective, two specific approaches have been selected. The first was to measure the temperature of the cutting tool and the second was to determine the wear law using Rayleigh-Ham dimensional analysis method. This study permitted the determination of a law that integrates the cutting temperature in the calculations of the lifespan of the tools during machining.

基于赫兹接触模型的发动机封严涂层碰磨力计算与优化

目的提高航空发动机的推进效率,在压气机机匣上喷涂可以减少叶尖径向间隙的封严涂层。叶尖与涂层之间的碰磨力会导致涂层脱落,且会击伤叶片,需要对碰磨力进行分析。方法采用大气等离子喷涂技术制备4种不同硬度的AlSi-PHB(聚苯酯)封严涂层,通过表面硬度测试、弹性模量测试和高速碰磨试验,分别评价封严涂层的硬度、弹性模量,以及在高速碰磨过程中不同工况下涂层受到的碰磨力;基于赫兹接触模型对叶尖与涂层之间的碰磨力进行计算,通过激光共聚焦显微镜和扫描电子显微镜对碰磨后的涂层和叶尖进行分析,同时根据接触面形态特征和温度特征对赫兹模型进行优化。结果碰磨力与涂层的硬度、叶尖转速、叶尖切入速率有关,复杂的接触表面形貌和摩擦升温会导致理论计算值与实验值之间出现偏差。结论通过优化叶尖和涂层的接触系数,同时考虑摩擦升温对涂层弹性模量的影响,可将不同工况下碰磨力计算值与测量值之间的偏差控制在1%~11%,这项研究对于指导航空发动机封严涂层的设计具有重要意义。

沙粒质量分数对油气混输泵过流部件磨损的影响

为研究沙粒质量分数对油气混输泵过流部件磨损的影响规律,基于DPM模型对油气混输泵内部的沙粒运动进行数值计算,并采用Finnie磨蚀模型计算油气混输泵过流部件的磨蚀率.研究结果表明:在沙粒质量分数较小时,沙粒与流体介质混合均匀;随着沙粒质量分数的增大,增压单元内的沙粒局部质量浓度显著增大,沙粒集中在叶轮压力面及导叶流道中部;沙粒质量分数增大会使磨损区域和磨损率急剧增大;在叶轮域中,磨损首先发生在压力面出口处,吸力面则在进口外缘发生点状和条状磨损;在导叶域中,压力面的磨损主要发生在外缘处,吸力面的磨损主要发生在进口轮毂处;从定量分析看,叶轮叶片表面的磨蚀率普遍大于导叶叶片表面的磨蚀率,磨损最严重的位置为叶轮叶片进口靠近轮毂处.研究结果可为改善油气混输泵抗磨损性能以及提高油气混输泵实际运行寿命提供一定参考依据.

砂卵石地层盾构刀具磨损预测模型及刀具参数敏感性分析

[目的]砂卵石地层中的石英颗粒体积分数较高,会导致盾构刀具磨损严重,影响施工进度及工期。建立盾构刀具磨损预测模型来预测盾构刀具的磨损量,是确保盾构法施工高效安全进行的重要环节。因此,有必要研究刀具磨损预测模型,并进行刀具参数敏感性分析。[方法]分析了砂卵石地层对盾构刀具的研磨性;介绍了砂卵石地层盾构刀具的切削机理;建立了考虑微观磨损特征的盾构刀具磨损预测模型,并对刀具参数进行敏感性分析。[结果及结论]不均匀系数、特征粒径与材料的磨损量正相关;塑性去除磨损、脆性去除磨损和黏着磨损的体积分数分别为61.4%、30.8%、7.8%,塑性去除磨损和脆性去除磨损占比较大;磨损系数随着不均匀系数和特征粒径的增大而增大,盾构刀具的磨损量整体随着刀具刃角的减小而减小。盾构刀具的磨损主要由磨粒磨损和黏着磨损造成。

实测轮轨蠕滑曲线对钢轨磨耗影响分析

轮轨蠕滑曲线会影响轮轨动态相互作用,进而影响钢轨磨耗,为研究实测轮轨蠕滑曲线对钢轨磨耗的影响,首先,基于最小二乘法获得适用于Polach模型和修改FASTSIM算法的参数,模拟40~400 km/h行车速度范围内的实测蠕滑曲线;随后,在SIMPACK软件中建立车辆系统动力学模型,并通过Polach模型测得实测蠕滑曲线;最后,采用Kik-Piotrowski模型和修改的FASTSIM算法进行轮轨非赫兹滚动接触计算,并结合USFD磨耗模型预测钢轨磨耗,对比了理想与实测蠕滑曲线条件下钢轨磨耗的差异.研究表明:理想蠕滑曲线条件下钢轨磨耗深度明显大于实测蠕滑曲线下的结果,随着车辆通过次数的增加,理想条件下钢轨磨耗分布范围更大,内外轨磨耗分布范围分别为实测蠕滑曲线的1.5倍和1.3倍;摩擦系数和磨耗率显著影响钢轨磨耗大小及磨耗分布情况,故在车辆动力学仿真和钢轨磨耗计算中有必要考虑实测轮轨蠕滑曲线;形成了确定实测蠕滑曲线参数的前处理程序,可服务于车辆动力学仿真和钢轨磨耗计算,可以有效指导现场进行钢轨打磨等养护维修工作.

皮质悬吊装置和股骨间微动磨损有限元分析

研究了皮质悬吊装置的钛板和股骨表面的皮质骨承受交变载荷发生的微动行为.基于钛/皮质骨材料建立了球/平面微动磨损有限元模型,通过与Hertz接触理论和已有试验结果进行对比,验证了有限元方法的正确性;同时研究了位移幅值、摩擦系数和法向力对钛球/皮质骨接触面间微动磨损行为的影响.最后把已验证的模型和方法用于研究前交叉韧带(ACL)重建手术中的皮质悬吊装置和股骨间的微动磨损情况.发现随着微动位移幅值从2μm增大至10μm,磨损状态由部分滑移向完全滑移转变,最大磨损深度由0.195μm逐渐增大至14.13μm,磨损体积由5.69×10^(4)μm^(3)增大至1.41×10^(6)μm^(3);在位移幅值为5和10μm时,磨损深度、磨损面积和磨损体积都表现出随摩擦系数增大而减小的趋势;在位移幅值为5μm时,磨损深度随法向力的增加逐渐减小,在位移幅值为10μm时,磨损深度随法向力的增加逐渐增大.通过研究交变载荷下皮质悬吊装置/皮质骨微动磨损模型的微动磨损行为发现:磨损深度最大值在皮质骨隧道孔边缘的应力最大值处,并且与球/平面微动磨损模型预测趋势相同,可以通过增加皮质悬吊装置和皮质骨隧道孔边缘接触面间的摩擦系数来提高皮质骨的抗微动磨损能力,提高ACL重建手术成功率.

主成分分析和灰色模型组合的身管多点烧蚀磨损量预测

身管是火炮类武器的关键零件,对其烧蚀磨损量进行预测,有助于保持火炮作战效能。针对火炮身管沿轴向各点烧蚀磨损量需分别建立数学模型进行预测问题,提出一种组合烧蚀磨损量预测方法。采用主成分分析(principal component analysis,PCA)方法对身管多点烧蚀磨损量进行数据空间降维,提取反映烧蚀磨损量变化的主成分,利用灰色模型对主成分进行多步预测,通过PCA逆运算获得身管内膛多点烧蚀磨损量预测值。结果表明,在历史数据较少的条件下,通过选择合适的预测步数可获得较为准确的预测值,为身管内膛多点烧蚀磨损量的预测提供了一种新的有效途径。

电气化铁路弓网系统摩擦磨损性能研究进展

针对电气化铁路弓网正常和异常状态的接触副,分析受电弓滑板磨耗周期内的摩擦磨损性能差异性,特别是受电弓滑板的磨耗率和磨耗型面的差异性,包括:发生异常磨损时受电弓滑板磨损率数倍甚至数十倍的增长差异,以及局部偏磨、波浪型磨耗和贯穿性凹坑等磨耗型面差异;着重归纳不同弓网系统载流摩擦磨损试验台的特点及异同,总结磨耗检测接触式测量方法与非接触式测量方法的优劣;分析弓网系统结构及参数、列车运行参数、弓网系统载流参数及外界环境等因素的影响,归纳总结弓网载流摩擦磨损特性的演变规律.在此基础上,综合分析弓网系统磨耗机理分析模型和数据拟合模型的研究现状和进展,并给出弓网系统载流摩擦磨损性能在后续研究中所需重点关注的研究方向和发展趋势,包括:弓网摩擦副的真实服役工况在实验室条件下的等效模拟;弓网磨耗性能的在线高精度检测;复杂气候条件及多物理场耦合作用下弓网磨耗性能的仿真和优化;结合大数据和智能算法的弓网磨耗预测,以及智能运维策略和全生命周期的能力保持技术等.

基于轴箱垂向振动加速度的地铁车轮失圆状态诊断方法

首先,建立卷积神经网络、深度置信网络、支持向量机和以一维卷积神经网络全连接层特征为输入的支持向量机模型(1DCNN-SVM),对比上述模型在地铁车轮失圆状态分类识别上的效果;其次,利用代理模型构建轴箱垂向加速度均方根与车速和多边形磨耗幅值之间的映射关系;最后,通过智能优化算法逆向求解幅值,对比不同代理模型和智能优化算法在多边形磨耗幅值识别上的适用性。研究结果表明:1DCNN-SVM模型在正常、低阶多边形、高阶多边形、随机非圆车轮4类典型的车轮不圆度状态分类识别中取得99.82%的准确性,相比另外3种分类方法,其泛化性能和强化学习能力都具有明显的优势。在车轮多边形磨耗幅值识别方面,基于克里金模型(KSM)和粒子群算法(PSO)的波深识别模型具有更好的预测稳定性和时效性。

316L不锈钢表面激光熔覆Ni60合金涂层几何尺寸预测及组织性能分析

通过分析激光熔覆过程中金属颗粒、基体与激光束之间的相互作用,建立单层单道涂层几何尺寸理论预测模型。基于316L不锈钢表面激光熔覆Ni60合金涂层的实验结果,采用多元回归分析拟合出修正系数与工艺参数的回归方程,在理论预测模型的基础上引入修正系数,获得单层单道涂层几何尺寸修正预测模型,并在激光功率、扫描速度和送粉速率分别为1 750 W、3.5 mm/s和0.099 g/s的条件下进行验证实验。结果表明:熔宽、熔高和熔深的修正预测值与实验值的平均相对误差分别为0.85%、2.47%和6.05%,修正预测模型的预测精度较理论预测模型明显提高。激光熔覆验证实验表明修正预测模型具有可行性。Ni60合金涂层富含硬质相,其硬度可达316L不锈钢基体的3.4倍,磨损率约为基体的50%,强化效果显著。

基于FIR-Stacking的刀具磨损预测

针对铣刀加工工件时传感器信号存在噪声、单一传统机器学习模型预测效果不理想的问题,提出一种基于自适应FIR滤波器和Stacking集成模型的刀具磨损预测方法。首先,采用自适应FIR滤波器去噪,计算时域、频域和时频域常用统计量作为信号特征,并对同一信号的多源信号特征进行拼接,经Pearson相关系数筛选保留相关系数大于0.2的特征;最后,以LightGBM、支持向量回归(support vector regression,SVR)、多层感知机(multilayer perceptron,MLP)作为基模型,Lasso作为元模型,构建Stacking集成模型进行刀具磨损预测。使用铣削加工数据集进行验证,结果表明该方法可有效提高预测准确性。

刀具磨损和变摩擦系数对切削力的影响

刀具磨损和摩擦系数对切削力、表面质量有显著影响。为进一步研究刀具磨损和摩擦系数对切削力的影响规律,提出了同时考虑刀具磨损和变摩擦系数的切削力模型。首先分析了刀具磨损对刃口半径的影响规律,指出随刀具磨损增加,刃口半径增加;其次明确了刀具磨损及刃口半径对最小切削厚度的影响规律,认为最小切削厚度随刀具磨损、刃口半径的增加而增加。进一步用单晶金刚石刀具切削铝合金,并在切削深度、进给速度、刀具刃口半径、刀具磨损宽度以及恒定摩擦系数与变摩擦系数等方面进行了对比。研究表明,随切削深度、进给速度增加,法向切削力与切向切削力增加;随刃口半径从150 nm增加到450 nm,切向力增加了1.13倍,法向力增加了2.12倍;随刀具磨损宽度从0增加到0.55μm,切向力增加了1倍,法向力增加了约7倍;恒定摩擦系数切削力最大误差高达41%,变摩擦系数切削力最大误差在11%以内。因此,同时考虑了刀具磨损与变摩擦系数的切削模型与实际切削过程更加吻合。

天然气水合物试采多相输送的弯管段防护研究

天然气水合物浆液中混杂的泥砂颗粒在低流速管段容易产生堆积阻塞,在高流速管段经常发生冲蚀磨损,目前国内外针对以液体为连续相流动的气液固多相流冲蚀研究较少。为此,以欧拉(Euler)气泡流模型与离散相模型(DPM)耦合的多相流数学模型为理论基础,对多相流中气液相间分布及管壁冲蚀磨损进行了数值模拟,开展了冲蚀磨损试验并提出耐磨防护方案。研究结果表明:可以从减弱弯管段湍流剪切作用、颗粒对弯管内壁的直接碰撞及减少动能传递进行防护设计;15°楔形垫层对应的最大冲蚀速率减幅74.55%,在1.0~2.2 m/s的流速范围内防护效果更明显;陶瓷涂垫层防护对冲蚀-腐蚀交互作用有明显的抑制效果。研究结论可为管道输送工程防护措施的制定提供技术参考。