Simulation analysis of wear characteristics of connecting rod bearing bush based on improved mixed lubrication model

The failure rate of crankpin bearing bush of diesel engine under complex working conditions such as high temperature,dynamic load and variable speed is high.After serious wear,it is easy to deteriorate the stress state of connecting rod body and connecting rod bolt,resulting in serious accidents such as connecting rod fracture and body damage.Based on the mixed lubrication characteristics of connecting rod big endbearing shell of diesel engine under high explosion pressure impact load,an improved mixed lubrication mechanism model is established,which considers the influence of viscoelastic micro deformation of bearing bush material,integrates the full film lubrication model and dry friction model,couples dynamic equation of connecting rod.Then the actual lubrication state of big end bearing shell is simulated numerically.Further,the correctness of the theoretical research results is verified by fault simulation experiments.The results show that the high-frequency impact signal with fixed angle domain characteristics will be generated after the serious wear of bearing bush and the deterioration of lubrication state.The fault feature capture and alarm can be realized through the condition monitoring system,which can be applied to the fault monitoring of connecting rod bearing bush of diesel engine in the future.

Predictions of friction and flash temperature in marine gears based on a 3D line contact mixed lubrication model considering measured surface roughness

Wear and scuffing failures often occur in marine transmission gears due to high friction and flash temperature at the interface between the meshing-teeth.In this paper,a numerical solution procedure was developed for the predictions of transient friction and flash temperature in the marine timing gears during one meshing circle based on the 3D line contact mixed lubrication simulation,which had been verified by comparing the flash temperature with those from Blok’s theory.The effect of machined surface roughness on the mixed lubrication characteristics is studied.The obtained results for several typical gear pairs indicate that gear pair 4-6 exhibits the largest friction and the highest interfacial temperature increase due to severe rough surface asperity contacts,while the polished gear surfaces yield the smallest friction and the lowest interfacial temperature.In addition,the influences of the operating conditions and the gear design parameters on the friction-temperature behaviors are discussed.It is observed that the conditions of heavy load and low rotational velocity usually lead to significantly increased friction and temperature.In the meantime,by optimizing the gear design parameters,such as the modulus and the pressure angle,the performance of interfacial friction and temperature can be significantly improved.

Parametric analysis of mixed lubrication characteristics in work zone of strip rolling

A theoretical model for mixed lubrication with more accurate contact length has been developed based on the average volume flow model and asperity flattening model,and the lubricant volume flow rate and outlet speed ratio are determined by integrating differential equations based on rolling parameters.The lubrication characteristics at the roll-strip interface with different surface roughness,rolling speed,reduction and lubricant viscosity are analyzed respectively.Additionally,the average volume flow rates of lubricant under different rolling conditions are calculated and used to explain the change rule of lubrication characteristics.The developed scheme is able to determine the total pressure,lubricant pressure,film thickness and real contact area at any point within the work zone.The prediction and analysis of mixed lubrication characteristics at the interface is meaningful to better control the surface quality and optimize the rolling process.

A MIXED LUBRICATION MODEL MODIFIED BY SURFACES' FRACTAL CHARACTERISTICS

Fractal characteristics are introduced into solving lubrication problems. Based on the analysis of the relationship between roughness and engineering surfaces' fractal characteristics and by introducing fractal parameters into the mixed lubrication equation, the relationship between flow factors and fractal dimensions is analyzed. The results show that the pressure flow factors' values increase, while the shear flow factor decreases, with the increasing length to width ratio of a representative asperity γ at the same fractal dimension. It can be also found that these factors experience more irregular and significant variations and show the higher resolution and the local optimal and the worst fractal dimensions, by a fractal dimension D , compared with the oil film thickness to roughness ratio h/R q . As an example of application of the model to solve the lubrication of the piston skirt in an engine, the frictional force and the load capacity of the oil film in a cylinder were analyzed. The results reveal that the oil film frictional force and the load capacity fluctuate with increasing fractal dimension, showing big values at the small D and smaller ones and slightly variable in the range of bigger one, at the same crank angle.

Numerical analysis on mixed lubrication performance of journal-thrust coupled microgroove bearings with different bottom shapes

The purpose of the present study is to establish a mixed lubrication model for the journal-thrust coupled microgroove bearings(also referred as coupled bearings)used for the ship shaftless rim-driven thrusters.During the hydrodynamic modelling,the coupling hydrodynamic pressure between the journal bearing and the thrust bearing is considered.The mixed lubrication performances of the microgroove journal-thrust bearing with five different bottom shapes,including rectangle,semi-ellipse,right triangle,isosceles triangle and left triangle,are compared.Based on the numerical results,the optimal microgroove bottom shape of the journal bearing and tilting angle of the thrust pad are determined.Additionally,the comparative analysis shows that the coupled bearing with left triangle microgroove bottom shape exhibits the optimal mixed lubrication performance.The numerical result also indicates that the optimal inclination angle of the thrust bearing pad is 0.01°for the current simulation case.

Theoretical analysis based on a modified mixed-film lubrication model for metal forming processes

An analytical model for metal rolling in the mixed lubrication regime was developed based on Wilson and Chang’s asperity flattening model and Von Mises homogenous deformation model. A more rigorous average Reynolds equation was used to calculate the hydrodynamic pressure. The variations of the yield stress with strain were considered in the model. An efficient iteration procedure was developed to solve the contact area, film thickness and hydrodynamic pressure. The model is more practical with fewer assumption and converges quickly. It is applicable to a wider range of rolling regimes. The calculation results using the model agree well with the literature as well as with measured data from a rolling mill.

Design and Engineering Application of Direct Mixing Lubrication System for Emulsion Pipeline in Secondary Cold Rolling Mill

With the benefit fierce competition in the steel industry market in recent years,double cold reduction products have been developed towards strength improvement and thickness reduction.The traditional cold-rolling lubrication process with a fixed flow rate and concentration cannot solve the problems,which are uncontrollable plate shape and the excessive consumption of lubricating oil.Moreover,based on the analysis of the traditional direct aplication lubrication system of double cold reduction mill,a set of design scheme suitable for the emulsion pipeline direct mixing lubrication system of double cold reduction mill unit was proposed.The design completed the selection of key components,which included the static mixer and atomization nozzle selection,pump and oil pump design selection,pipeline design selection,flow type selection,pressure gauge selection,electronic control cabinet design selection and other eight aspects.Equipment of the emulsion pipeline direct mixing lubrication system of double cold reduction has been developed.Comparing with characteristics of the traditional direct aplication lubrication system,the emulsion pipeline direct mixing lubrication system was better applied to the production practice of a 1220 double cold reduction mill.The consumption of ton of steel was reduced by 9.6%.The rolling energy consumption and fuel consumption comprehensive costs decreased by 10.7%,and the strip steel section thickness difference was reduced by 19.3%.In addition,the plate shape quality defect rate decreased by 25.6%,otherwise creating a large economic benefit for the unit and promoting the application value.

基于MixedEHL啮合齿轮润滑特性研究

为了改善和提高齿轮传动系统综合传动性能和疲劳寿命,以某直齿轮传动为研究对象,运用专业齿轮润滑仿真软件MixedEHL建立啮合齿轮混合润滑有限元仿真模型;对啮合齿轮油膜压力、油膜厚度分布、接触齿面平均粗糙度、接触刚度等啮合齿轮接触面的润滑特性进行仿真分析。仿真结果表明:啮合齿轮油膜压力呈现单波峰的形式,油膜厚度呈现双波峰的形式;在不同方向上,油膜压力和油膜厚度不同;接触齿面平均粗糙度较小,接触刚度呈现先增加再基本保持不变最后减小的趋势;该研究为直齿轮传动混合润滑特性、接触特性的改善提供理论依据。

Plastic-elastic Model for Water-based Lubrication Considering Surface Force

Water-based lubrication is an effective method to achieve superlubricity,which implies a friction coefficient in the order of 10−3 or lower.Recent numerical,analytical,and experimental studies confirm that the surface force effect is crucial for realizing water-based superlubricity.To enhance the contribution of the surface force,soft and plastic materials can be utilized as friction pair materials because of their effect in increasing the contact area.A new numerical model of water-based lubrication that considers the surface force between plastic and elastic materials is developed in this study to investigate the effect of plastic flow in water-based lubrication.Considering the complexity of residual stress accumulation in lubrication problems,a simplified plastic model is proposed,which merely calculates the result of the dry contact solution and avoids repeated calculations of the plastic flow.The results of the two models show good agreement.Plastic deformation reduces the local contact pressure and enhances the function of the surface force,thus resulting in a lower friction coefficient.

Precision loss of ball screw mechanism under sliding-rolling mixed motion behavior

The sliding-rolling mixed motion behavior degrades the ball screw’s precision at different levels.Based on the sliding-rolling mixed motion between ball and screw/nut raceway,the ball screw’s precision loss considering different given axial loading and rotational speed working conditions was investigated.Since creep and lubrication relate to sliding and rolling motion wear,the creep and lubrication characteristics are analyzed under different working conditions.Besides,the precision loss was calculated considering the sole influence of sliding behavior between ball and screw and compared with the results from other current models.Finally,research on precision loss owing to the sliding-rolling mixed motion behavior was realized under given working conditions,and suitable wear tests were carried out.The analytical results of precision loss are in good agreement with the experimental test conclusions,which is conducive to better predicting the law of precision loss in stable wear period.

Molecular dynamics simulation of the Stribeck curve: Boundary lubrication, mixed lubrication, and hydrodynamic lubrication on the atomistic level

Lubricated contact processes are studied using classical molecular dynamics simulations for determining the entire range of the Stribeck curve.Therefore,the lateral movement of two solid bodies at different gap height are studied.In each simulation,a rigid asperity is moved at constant height above a flat iron surface in a lubricating fluid.Both methane and decane are considered as lubricants.The three main lubrication regimes of the Stribeck curve and their transition regions are covered by the study:Boundary lubrication(significant elastic and plastic deformation of the substrate),mixed lubrication(adsorbed fluid layer dominates the process),and hydrodynamic lubrication(shear flow is set up between the surface and the asperity).We find the formation of a tribofilm in which lubricant molecules are immersed into the metal surface—not only in the case of scratching,but also for boundary lubrication and mixed lubrication.The formation of a tribofilm is found to have important consequences for the contact process.Moreover,the two fluids are found to show distinctly different behavior in the three lubrication regimes:For hydrodynamic lubrication(large gap height),decane yields a better tribological performance;for boundary lubrication(small gap height),decane shows a larger friction coefficient than methane,which is due to the different mechanisms observed for the formation of the tribofilm;the mixed lubrication regime can be considered as a transition regime between the two other regimes.Moreover,it is found that the nature of the tribofilm depends on the lubricant:While methane particles substitute substrate atoms sustaining mostly the crystalline structure,the decane molecules distort the substrate surface and an amorphous tribofilm is formed.

Influence of Oil Film Inertia on Piston Skirt Lubrication in High Speed Engine

By an iteration method, the influence of oil film inertia on piston skirt lubrication in a high speed engine is investigated. By alternately solving the Navier-Stocks equations and the Reynolds equation, the new iteration method can trace the variations of velocity field and pressure field with time. Based on this, the mixed-lubrication model suitable for the piston skirt of high engines is proposed. By introducing the inertia coefficient, the new lubrication model includes the inertia term in oil film. The model can be also used to solve for the lubrication performances of a piston skirt in low or medium speed engines and for lubrication problem in general excluding the inertia term of oil film , when the inertia coefficient is put equal to zero. The calculation results show that the influence of oil film inertia on the friction force increases with the ratio of the piston skirt's length to its diameter, the inertia coefficient and the eccentricities of the lower and the upper piston skirt, with other conditions kept constant, while the influence of it on the load capacity of oil film is small.

粗糙度和轴向运动对艉轴承混合润滑性能的影响

针对大型船舶航行过程中出现船体变形时艉轴承的磨损状态异常这一问题,本文探究磨损表面粗糙度变化和轴向运动对于艉轴承混合润滑性能的影响,建立了耦合轴向运动和表面粗糙度的混合润滑模型,通过数值模拟得到轴承润滑特征的分布,分析轴向运动和粗糙度对轴承混合润滑特性的影响,并对该润滑模型进行验证。计算结果表明:在轴向运动和轴颈倾斜耦合作用下,油膜厚度沿轴向方向非线性减小,油膜压力和接触压力在局部出现峰值,轴瓦在局部出现较大变形;轴向速度增加会加强动压润滑效应,轴向运动对润滑特性的影响程度随着倾角的增大而增加;粗糙度越大承载能力越强,同时接触情况越严重,会加速轴承的局部磨损。

混合润滑状态下非高斯表面法向接触刚度研究

为了揭示混合润滑状态下表面形貌特征对接触特性的影响,针对微凸体高度非高斯分布粗糙表面在法向静载荷作用下的固-液接触问题展开研究。固-液接触结合面包括微凸体的固体接触和润滑介质的流体接触。对于固体接触部分,基于弹塑性固体力学对非高斯等效粗糙表面接触展开接触特性分析,建立了考虑微凸体弹塑性变形的非高斯粗糙表面法向接触刚度计算模型;对于流体接触部分,提出了一种考虑微凸体峰度/偏度分布影响的密闭油坑接触模型。通过仿真分析,揭示了法向压力、非高斯表面粗糙度参数及润滑油黏度系数对混合润滑固-液结合面法向接触刚度的影响规律,并对比分析了无润滑介质的固-固结合面和存在润滑介质时的固-液结合面法向接触刚度。研究表明:固-液和固-固结合面法向接触刚度均随着法向载荷的增大呈非线性增大,且固-液结合面相对固-固结合面的接触刚度略大;润滑介质黏度越大,接触刚度越大;非高斯分布的峰度和偏度对混合润滑结合面接触刚度具有显著影响,相对于零偏度分布的高斯分布表面,呈负偏度分布的非高斯表面通常具有较大的接触刚度;在轻载时,峰度对接触刚度的影响不容忽视。因此,通过改变接触表面峰度/偏度、增大法向载荷、提高润滑介质黏度,可有效改善混合润滑状态固-液结合面法向接触刚度。

油水气混合的数字化微量润滑装置

微量润滑装置对油水气量的准确控制及其雾化效果,将直接影响切削冷却效果,进而影响零件加工质量。为改善微量润滑装置的辅助切削效果,研制了一种具有油水气混合的数字化微量润滑装置,有效改善了润滑油雾喷射的连续性和均匀性。基于微量润滑雾化技术,设计开发了数字化微量润滑装置,搭建铣削工艺实验平台,测试新型微量润滑装置的辅助切削效果。结果表明,所研制的油水气混合的数字化微量润滑装置能够明显提高油雾质量和辅助切削效果。

考虑表面粗糙度与空化效应的组合密封润滑分析

为了研究表面粗糙度及空化效应对压裂泵柱塞密封副密封性能的影响,基于稳态Reynolds方程,建立了粗糙峰和空化效应影响下组合密封的弹流润滑数值模型.在数值模拟基础上,采用有限体积法求解稳态Reynolds方程,研究了密封副在表面粗糙度影响下的油膜厚度、油膜压力、油膜流速分布规律,以及不同的往复速度和滑环表面粗糙度对密封性能的影响.结果表明,外行程流体动压效应微弱,油膜在空气侧附近会出现空化现象;较高的往复速度有利于减小泄漏量及摩擦阻力;滑环表面粗糙度从0.8μm增加到1.8μm时,净泄漏量与外行程摩擦力分别升高了180.4%和11.17%.因此,在工作过程中应设置较高的往复速度和使用较低粗糙度的滑环以提高密封性能.

燃油介质作动器往复密封摩擦热效应及磨损特性分析

发动机矢量推力作动器采用燃油作为传动介质,燃油的低黏度将使作动器密封接触面处于不良润滑条件,密封件摩擦磨损问题突出。针对燃油介质作动器不同压力、作动速度及油液温度的工作环境,建立往复密封热弹流混合润滑数值仿真模型,分析往复密封接触面摩擦热效应对油膜行为的影响,确定热分析边界条件,计算密封系统的瞬态温度分布。根据热分析结果,对油液黏度及密封区域内的油膜厚度进行修正,考虑密封件润滑条件探究摩擦热效应对密封性能与磨损特性的作用机理,分析不同工况条件对油膜厚度、摩擦力和磨损深度分布的影响,为设计高性能航空密封件奠定理论基础。

脂润滑弧齿锥齿轮热弹流润滑与效率研究

基于油动重载四旋翼无人机的特殊应用条件,研究了无人机齿轮箱内脂润滑弧齿锥齿轮的润滑状态及啮合效率.推导了适用于弧齿锥齿轮的脂润滑雷诺方程,采用计算油膜剪切力和微凸体接触摩擦力组成的复合摩擦系数代替摩擦系数经验公式的方法,研究了在无人机各种工况下的齿面润滑情况和啮合效率.结果表明,本研究中提出的考虑粗糙度的脂润滑雷诺方程能够很好预测文献中的试验结果;弧齿锥齿轮的齿面较为复杂,不能用油润滑的中心油膜厚度算法近似估计脂润滑弧齿锥齿轮整个齿面上的润滑状态;1个啮合周期内的齿面摩擦系数在节点处最大;低转速情况下,齿面将进入混合润滑状态;1个啮合周期内啮合效率的变化与啮合位置密切相关,在啮入点处效率最低;在转速不变的前提下,润滑脂黏度越高,效率损失越大.

G13Cr4Mo4Ni4V轴承钢重载滚动接触疲劳损伤演化及失效行为研究

G13Cr4Mo4Ni4V高温轴承钢在航发主轴轴承中广泛应用,具有优异的接触疲劳强度.采用球棒式疲劳试验机研究其在重载润滑条件下的滚动接触疲劳(RCF)损伤演化及失效行为.通过对测试棒接触轨迹三维形貌的测量,结合混合弹流润滑分析,获取了接触区润滑行为的演变规律及其对表层和近表层疲劳失效行为的影响.通过对次表层材料微观结构组分和组织形貌的分析,研究了材料组织结构的累积损伤行为,探讨了微区润滑行为与近表层夹杂和次表层材料累积损伤之间的映射关系.研究结果表明:接触轨迹表面磨损、微点蚀和塑性变形造成接触表面润滑状态变化,润滑状态变化、近表层夹杂和次表层材料组织结构累积损伤之间的竞争机制和相互作用是造成不同疲劳失效形式的主要因素.该研究中首次对G13Cr4Mo4Ni4V轴承钢疲劳损伤演化及失效行为进行了详细分析,为轴承制造筛选材料和工艺提供数据.

考虑瓦块磨损的可倾瓦径向轴承-转子系统动态特性研究

针对含有瓦块磨损故障的可倾瓦径向轴承-转子系统润滑和振动特性耦合建模问题,考虑了瓦块磨损、转子与瓦块平摆振动和轴承混合润滑的影响,提出了可倾瓦径向轴承-转子系统的混合润滑动力学模型,研究了不同磨损率下转子振动特性和轴承润滑性能的动态响应,探明了转子偏心量、转速和预载荷系数等参数与磨损率的耦合作用对轴承-转子系统动态特性的影响。结果表明:转子在磨损瓦块位置的振动位移和振动加速度随磨损率的增加而增大;与无磨损轴承相比,磨损轴承的转子加速度峰值频率会额外激起转频的偶次倍频;多瓦块磨损会导致转子振动响应和轴承油膜压力显著增大。该研究结果可为可倾瓦径向轴承-转子系统的状态监测及故障识别提供理论参考依据。