Compacted graphite cast iron （CG1） has been the material for high-power diesel engines recently, but its increased strength causes poor machinability. In this study, coated and uncoated carbide tools were used in dr...Compacted graphite cast iron （CG1） has been the material for high-power diesel engines recently, but its increased strength causes poor machinability. In this study, coated and uncoated carbide tools were used in dry milling experiment and FEM simulation to study the machinability of CGI and wear behaviour of tools. The experimental and FEM simulation results show that coated tool has great advantage in dry milling of CGI. SEM and EDS analysis of tool wear indicate the wear morphology and wear mechanism. Adhesive wear is the main mechanism to cause un- coated tool wear, while abrasive wear and delamination wear are the main mechanism to cause coated tool wear. Stress and temperature distribution in FEM simulation help to understand the wear mechanism including the reason for coat- ing peeled off.展开更多
The prediction of the wheel wear is a fundamental problem in heavy haul railway. A numerical methodology is introduced to simulate the wheel wear evolution of heavy haul freight car. The methodology includes the spati...The prediction of the wheel wear is a fundamental problem in heavy haul railway. A numerical methodology is introduced to simulate the wheel wear evolution of heavy haul freight car. The methodology includes the spatial coupling dynamics of vehicle and track, the three-dimensional rolling contact analysis of wheel-rail, the Specht's material wear model, and the strategy for reproducing the actual operation conditions of railway. The freight vehicle is treated as a full 3D rigid multi-body model. Every component is built detailedly and various contact interactions between parts are accurately simulated, taking into account the real clearances. The wheel-rail rolling contact calculation is carried out based on Hertz's theory and Kalker's FASTSIM algorithm. The track model is built based on field measurements. The material loss due to wear is evaluated according to the Specht's model in which the wear coefficient varies with the wear intensity. In order to exactly reproduce the actual operating conditions of railway,dynamic simulations are performed separately for all possible track conditions and running velocities in each iterative step.Dimensionless weight coefficients are introduced that determine the ratios of different cases and are obtained through site survey. For the wheel profile updating, an adaptive step strategy based on the wear depth is introduced, which can effectively improve the reliability and stability of numerical calculation. At last, the wear evolution laws are studied by the numerical model for different wheels of heavy haul freight vehicle running in curves. The results show that the wear of the front wheelset is more serious than that of the rear wheelset for one bogie, and the difference is more obvious for the outer wheels. The wear of the outer wheels is severer than that of the inner wheels. The wear of outer wheels mainly distributes near the flange and the root; while the wear of inner wheels mainly distributes around the nominal rolling circle. For the outer wheel of front wheelset of each bogie, the development of wear is gradually concentrated on the flange and the developing speed increases continually with the increase of traveled distance.展开更多
This paper describes the design of a new kind of miniature abrading sphere, which is magnetically mounted inside a spherical gap and set in rotation pneumatically with air. Large eddy simulation is performed in conjun...This paper describes the design of a new kind of miniature abrading sphere, which is magnetically mounted inside a spherical gap and set in rotation pneumatically with air. Large eddy simulation is performed in conjunction with the compressible Smagorinsky model. Minimal temperature variation allows for the assumption of adiabatic walls. Fluid-solid interaction is modeled using the law of the wall for compressible turbulent flow. A parametric study is done to determine optimal geometric layout while taking physical restrictions into account. The resulting optimal configuration is then examined in detail in order to determine demands to be met by the computerized control of the magnetic bearing as well as to quantify the force available to the abrasion process. Finally, a mathematical relation is given that determines available abrasion force depending on standard volumetric flow rate and rotation frequency. The findings presented here provide a basis for further development of smaller versions of the tool.展开更多
Improving the carrying ability of oil film between slipper and swash plate and reducing the partial abrasion of slipper are important to improve the service life and reliability of axial piston pump.In this paper,a nu...Improving the carrying ability of oil film between slipper and swash plate and reducing the partial abrasion of slipper are important to improve the service life and reliability of axial piston pump.In this paper,a numerical simulation model was developed for slipper/swash-plate friction pair based on the elastohydrodynamic theory.The dynamic micro-motion and pressure distribution of slipper were analyzed and it was pointed out that the tilt of slipper was the main reason for its partial abrasion.The simulations about the slippers with different slopes on the outer edge of the sealing belt showed that the partial abrasion could reduce the carrying ability and increase the leakage of the slipper/swash-plate pair.The proper slope on the inner edge helped to improve the carrying ability and reduce the leakage of slipper.The experimental tests were in accord with the simulation results to a great extent,showing that the simulation model had a high accuracy and could be applied to the design and optimization of slipper,and that the slipper with optimal inner slope provided an encouraging method to improve the efficiency and reliability of axial piston pump.展开更多
Based on the solid-liquid two-phase mixture transportation test, the renormalization group (RNG) k-e turbulent model was utilized to simulate the solid-liquid two-phase turbulent flow in a centrifugal pump. By compari...Based on the solid-liquid two-phase mixture transportation test, the renormalization group (RNG) k-e turbulent model was utilized to simulate the solid-liquid two-phase turbulent flow in a centrifugal pump. By comparing the simulated and experimental results, inner flow features were revealed to improve the abrasion characteristic of the solid-liquid two-phase centrifugal pump. The influence of the solid phase on centrifugal pump abrasive performance is small when the particle volume fraction is less than 2.5%. The aggregation degree of the solid particles is enhanced as the particle diameter increases from 0.1 to 1 mm; however, the mixture density on the pressure side is reduced when the particle diameter increases to 1 mm for the impact of inertia. The wear on the hub is most severe for the shear stress on this position; it is also the largest. The wear characteristic is affected greatly by the parameters of the solid phase. The wear chracteristic can be optimized by decreasing the blade outlet angle. In the modified design, the blade angle is different, whereas the other geometric dimensions remain the same. The improved pump is simulated to contrast with the original pump. The results show that the values of mixture density and shear stress both decrease. The wear condition of the blade is improved to a certain extent.展开更多
基金Supported by National Natural Science Foundation of China (No. 50935001 and No. U0734007)Important National Science and Technology Specific Projects of China (No.,20011ZX04015-031)+1 种基金National High Technology Research and Development Program of China("863"Program, No. 2009AA04Z150)Major State Basic Research Development Program of China ("973"Program, No. 2010CB731703 and No. 2011CB706804)
文摘Compacted graphite cast iron （CG1） has been the material for high-power diesel engines recently, but its increased strength causes poor machinability. In this study, coated and uncoated carbide tools were used in dry milling experiment and FEM simulation to study the machinability of CGI and wear behaviour of tools. The experimental and FEM simulation results show that coated tool has great advantage in dry milling of CGI. SEM and EDS analysis of tool wear indicate the wear morphology and wear mechanism. Adhesive wear is the main mechanism to cause un- coated tool wear, while abrasive wear and delamination wear are the main mechanism to cause coated tool wear. Stress and temperature distribution in FEM simulation help to understand the wear mechanism including the reason for coat- ing peeled off.
基金Project(U1234211)supported of the National Natural Science Foundation of ChinaProject(20120009110020)supported by the Specialized Research Fund for Ph.D. Programs of Foundation of Ministry of Education of ChinaProject(SHGF-11-32)supported the Scientific and Technological Innovation Project of China Shenhua Energy Company Limited
文摘The prediction of the wheel wear is a fundamental problem in heavy haul railway. A numerical methodology is introduced to simulate the wheel wear evolution of heavy haul freight car. The methodology includes the spatial coupling dynamics of vehicle and track, the three-dimensional rolling contact analysis of wheel-rail, the Specht's material wear model, and the strategy for reproducing the actual operation conditions of railway. The freight vehicle is treated as a full 3D rigid multi-body model. Every component is built detailedly and various contact interactions between parts are accurately simulated, taking into account the real clearances. The wheel-rail rolling contact calculation is carried out based on Hertz's theory and Kalker's FASTSIM algorithm. The track model is built based on field measurements. The material loss due to wear is evaluated according to the Specht's model in which the wear coefficient varies with the wear intensity. In order to exactly reproduce the actual operating conditions of railway,dynamic simulations are performed separately for all possible track conditions and running velocities in each iterative step.Dimensionless weight coefficients are introduced that determine the ratios of different cases and are obtained through site survey. For the wheel profile updating, an adaptive step strategy based on the wear depth is introduced, which can effectively improve the reliability and stability of numerical calculation. At last, the wear evolution laws are studied by the numerical model for different wheels of heavy haul freight vehicle running in curves. The results show that the wear of the front wheelset is more serious than that of the rear wheelset for one bogie, and the difference is more obvious for the outer wheels. The wear of the outer wheels is severer than that of the inner wheels. The wear of outer wheels mainly distributes near the flange and the root; while the wear of inner wheels mainly distributes around the nominal rolling circle. For the outer wheel of front wheelset of each bogie, the development of wear is gradually concentrated on the flange and the developing speed increases continually with the increase of traveled distance.
文摘This paper describes the design of a new kind of miniature abrading sphere, which is magnetically mounted inside a spherical gap and set in rotation pneumatically with air. Large eddy simulation is performed in conjunction with the compressible Smagorinsky model. Minimal temperature variation allows for the assumption of adiabatic walls. Fluid-solid interaction is modeled using the law of the wall for compressible turbulent flow. A parametric study is done to determine optimal geometric layout while taking physical restrictions into account. The resulting optimal configuration is then examined in detail in order to determine demands to be met by the computerized control of the magnetic bearing as well as to quantify the force available to the abrasion process. Finally, a mathematical relation is given that determines available abrasion force depending on standard volumetric flow rate and rotation frequency. The findings presented here provide a basis for further development of smaller versions of the tool.
基金supported by the National Natural Science Foundation of China (Grant No. 51075360)the National Key Technology R&D Program of the Twelfth Five-year Plan of China (Grant No. 2011BAF09B03)the Fundamental Research Funds for the Central Universities
文摘Improving the carrying ability of oil film between slipper and swash plate and reducing the partial abrasion of slipper are important to improve the service life and reliability of axial piston pump.In this paper,a numerical simulation model was developed for slipper/swash-plate friction pair based on the elastohydrodynamic theory.The dynamic micro-motion and pressure distribution of slipper were analyzed and it was pointed out that the tilt of slipper was the main reason for its partial abrasion.The simulations about the slippers with different slopes on the outer edge of the sealing belt showed that the partial abrasion could reduce the carrying ability and increase the leakage of the slipper/swash-plate pair.The proper slope on the inner edge helped to improve the carrying ability and reduce the leakage of slipper.The experimental tests were in accord with the simulation results to a great extent,showing that the simulation model had a high accuracy and could be applied to the design and optimization of slipper,and that the slipper with optimal inner slope provided an encouraging method to improve the efficiency and reliability of axial piston pump.
文摘Based on the solid-liquid two-phase mixture transportation test, the renormalization group (RNG) k-e turbulent model was utilized to simulate the solid-liquid two-phase turbulent flow in a centrifugal pump. By comparing the simulated and experimental results, inner flow features were revealed to improve the abrasion characteristic of the solid-liquid two-phase centrifugal pump. The influence of the solid phase on centrifugal pump abrasive performance is small when the particle volume fraction is less than 2.5%. The aggregation degree of the solid particles is enhanced as the particle diameter increases from 0.1 to 1 mm; however, the mixture density on the pressure side is reduced when the particle diameter increases to 1 mm for the impact of inertia. The wear on the hub is most severe for the shear stress on this position; it is also the largest. The wear characteristic is affected greatly by the parameters of the solid phase. The wear chracteristic can be optimized by decreasing the blade outlet angle. In the modified design, the blade angle is different, whereas the other geometric dimensions remain the same. The improved pump is simulated to contrast with the original pump. The results show that the values of mixture density and shear stress both decrease. The wear condition of the blade is improved to a certain extent.
