考虑轧制界面粗糙形貌的轧机辊系非线性振动特性研究

轧制界面的粗糙形貌可导致界面行为的根本变化,极大地影响着轧机辊系的动力学响应行为。考虑轧制界面粗糙形貌的影响,建立了轧机辊系系统的非线性垂直振动动力学模型,计算了具有不同粗糙形貌轧制界面的轧机辊系系统非线性刚度特性和固有频率特性,并与采用Duffing振子描述界面刚度的传统轧机模型进行了对比。采用多尺度法求解了考虑界面粗糙形貌影响的轧机系统主共振幅频特性方程,并推导了系统受迫振动响应的跳跃频率和跳跃幅值表达式,分析了轧制界面粗糙形貌、激励载荷、非线性刚度率和阻尼对轧机辊系系统动力学响应特性的影响,为抑制轧机振动提供有效的理论参考。

粗糙表面形貌对电蚀的影响

以名义线接触副轴承和齿轮为研究对象,用分形方法模拟三维粗糙表面,建立由一个粗糙表面与一个光滑刚性平面接触的简单模型和由2个粗糙表面接触的复杂模型,建立粗糙表面的矩形斑点接触电阻计算模型和电流密度计算模型,从接触电阻和电流密度2个角度来考虑粗糙表面形貌对电蚀的影响.分析接触载荷和分形参数对实际接触面积、接触电阻和电流密度的影响;在恒定载荷下,研究接触电阻和电流密度与粗糙度之间的定量关系.结果表明,从接触电阻或电流密度方面,增加轴承和齿轮表面间的接触载荷和减小表面粗糙度可以防止电蚀的发生,因此接触电阻和电流密度一样可以用来作为电蚀发生的判据.在实际应用中,主动设计最佳的接触载荷大小以及最佳的表面粗糙度可以防止电蚀的发生,并且在研究粗糙表面接触问题时应采用复杂的接触模型.所提出的计算方法可以分析表面电蚀失效.

粗糙表面微型气体轴承润滑性能及其转子动力学特性研究

微型气体轴承-转子系统作为微型旋转机械实现功能转换的重要部件,表面粗糙形貌、薄膜润滑性能及转子动力学特性是影响整体设备可靠运转的关键因素.利用Boltzmann稀薄效应模型修正可压缩气体动压润滑Reynolds方程,通过分形理论表征微型轴承表面的粗糙轮廓,研究了气体稀薄效应和表面粗糙度耦合作用下微型轴承的静动态性能.并利用有限元法建立粗糙表面微型气体轴承-转子系统的动力学模型,得到转子系统固有特性和轴心轨迹的变化规律.结果表明:表面粗糙度效应提高了轴承的承载能力和动态刚度系数,在较大轴承数时增加幅度更明显.由于稀薄效应降低了轴承的直接刚度系数,转子振幅随气膜稀薄程度的增加而增大,表面粗糙峰的增加会降低转子系统的固有频率.

2A12铝合金在EXCO溶液中腐蚀损伤形貌演化分析

目的探索2A12铝合金在EXCO溶液中腐蚀损伤形貌的演化规律。方法开展实验室内2A12铝合金的加速腐蚀实验。为实现表面粗糙度与腐蚀损伤相关性的定量研究,首先采用3D扫描成像仪对实验样品进行扫描,取得样品微观几何特征,实现表面粗糙度值的数字化定量表征。观察样品在EXCO溶液中腐蚀损伤的发生发展过程、腐蚀形貌的演化过程,测量腐蚀样品蚀坑深度,并分析表面粗糙度对样品腐蚀损伤的影响。结果当腐蚀时间不超过6h时,2A12铝合金样品在EXCO溶液中的腐蚀类型主要为点蚀,随着时间的延长,将向全面腐蚀发展。粗糙度值高的试件表面有打磨时形成的较深表面纹理,这些纹理制约了点蚀坑的扩展,使蚀坑沿纹理的方向发展,有演化为微裂纹的可能性,蚀坑边界的不规则处也会萌生微裂纹。粗糙度值较小的样品,腐蚀损伤也较小,但粗糙度对腐蚀损伤的影响随时间的延长而减弱。结论常温下,2A12铝合金在EXCO溶液中首先发生点蚀,由于蚀坑向四周扩展的速度快于深度方向,使腐蚀类型从点蚀向全面腐蚀演变。表面粗糙度对2A12铝合金样品腐蚀损伤形貌的演化有重要影响,表面微观几何特征通过制约蚀坑扩展方向的方式来改变样品的腐蚀行为,并造成腐蚀损伤的明显差异。随着腐蚀时间的延长,材料逐渐失去其原有表面微观几何特征,表面粗糙度对腐蚀行为的影响下降。

齿轮粗糙界面时变啮合刚度算法与特性分析

基于粗糙界面的分形接触模型,引入曲面接触系数来表征齿轮在啮合过程中曲率和基体变形对啮合界面微凸体分布函数的影响,提出了一种考虑齿轮啮合界面粗糙形貌的齿轮时变啮合刚度修正算法,获得了表面形貌参数、材料特性参数和输入转矩对齿轮时变啮合刚度特性的影响规律。结果表明,齿轮时变啮合刚度随着表面粗糙度的增大而减小,随着材料强度和输入转矩递增。

Influence of high-speed milling parameter on 3D surface topography and fatigue behavior of TB6 titanium alloy

High-speed milling of titanium alloys is widely used in aviation and aerospace industries for its high efficiency and good quality.In order to optimize the machining parameters in high-speed milling TB6 titanium alloy,experiments of high-speed milling and fatigue were conducted to investigate the effect of parameters on 3D surface topography and fatigue life.Based on the fatigue fracture,the effect mechanism of surface topography on the fatigue crack initiation was proposed.The experiment results show that when the milling speed ranged from 100 m/min to 140 m/min,and the feed per tooth ranged from 0.02 mm/z to 0.06 mm/z,the obtained surface roughness were within the limit（0.8 μm）.Fatigue life decreased sharply with the increase of surface equivalent stress concentration factor.The average error of fatigue life between the established model and the experimental results was 6.25%.The fatigue cracks nucleated at the intersection edge of machined surface.

汽车水泵轴承密封圈力学分析模型和寿命计算方法

汽车水泵轴承密封圈的密封性能与唇口过盈量密切相关。利用力学知识和Hertz接触理论推导了密封圈与轴表面的接触应力分布计算模型,分析了不同唇口过盈量下接触应力变化规律;采用自适应相关函数模拟轴的微观表面形貌,并计算了由于轴的表面微观不平度导致的轴转动一周时密封圈唇口接触应力的变化规律;根据疲劳理论和雨流法随机计数原理构建了密封圈疲劳寿命预测方法,并预测了密封圈的疲劳寿命随唇口过盈量变化的规律。本文的研究结果可为汽车水泵轴承密封圈技术的进一步研究和应用提供理论帮助。

岩石节理形貌粗糙度系数与分形维数及几个参数的关系分析

为了更加准确地描述岩石节理形貌粗糙度系数(JRC),利用26组花岗岩试样劈裂形成模拟天然节理和20组人工预制具有不同JRC系数值的试样来模拟节理表面形貌,研究了节理三维形貌各向异性分形特征、JRC以及剖面线平均分形维数和节理表面分形维数之间的关系。并且在前人研究的基础上,分析了其他学者较少研究的几个参数,即节理剖面系数R_p、粗度轮廓的最大波谷深度R_v、粗度轮廓的均方根(RMS)的偏差R_q及峰度系数Sku几个统计参数和JRC之间的相关关系。结果表明,尽管各方向的分形维数差异较小,但是仍然存在各向异性特征。JRC与分形维数之间存在较为明显的指数关系,而剖面线平均分形维数和节理表面分形维数之间存在很强的线性相关关系,JRC与R_p、R_v、Sku之间的相关关系为线性关系,且R_p、R_v与JRC的相关关系拟合结果很相似,均为线性相关。而JRC与R_q之间存在抛物线的关系,拟合结果 JRC=3.80013+4.3267e43.3276Rq。通过运用分形和统计参数联合描述JRC更加全面。

Effect of hydrogen peroxide concentration on surface properties of Ni-Cr alloys

The effect of concentration of hydrogen peroxide （H2O2） on the surface properties of Ni-Cr alloys was studied. Surface roughness and surface morphology of Ni-Cr alloys were evaluated by surface profiler and scanning electron microscopy after being immersed in different concentrations of H2O2 for 112 h. Surface corrosion products of Ni-Cr alloys were analyzed by photoelectron spectrograph after being immersed in 0% and 30% H2O2. The order of increasing surface roughness of Ni-Cr alloys after being immersed in different concentrations of H2O2 was 0〈3.6%〈10%〈30%. As the concentration of hydrogen peroxide increased, the surface roughness of Ni-Cr alloys increased and the surface morphology showed different degrees of corrosion. According to the XPS results, the corrosion products formed on the outmost surface layer of the studied samples are Ni（OH）2 and BeO.

考虑润滑粗糙界面的叶片辊轧机辊系非线性振动特性

针对粗糙形貌导致界面行为发生变化进而影响叶片辊轧机辊系动力学特性的问题,建立了综合考虑支撑轴承以及楔板的表面形貌影响的叶片辊轧机辊系的垂直振动模型,计算了不同粗糙形貌的楔板与轧辊的接触载荷以及支撑轴承的非线性接触刚度。采用数值积分法求解了叶片辊轧机辊系垂直振动的动力学方程,分析了界面粗糙形貌对轧机辊系动力学响应特性的影响。研究结果表明:叶片辊轧机辊系振动位移幅值随着分形维数的增大逐渐减小,振动频率幅值也随之减小,且系统出现次谐波振动,表现出多频率振动现象。研究结果为实现辊轧机系统垂直振动控制提供了理论依据。

Dynamic characteristics of gear system under different micro-topographies with the same roughness on tooth surface

The topography of gear meshing interfaces is one of the key factors affecting the dynamic characteristics of the gear transmission system.In order to obtain the contact characteristics of meshing gear pair with different surface micro-topographies,an interface feature model and a tribo-dynamics coupling model for the gear system are proposed in this paper.The effects of the gear tooth surface micro-topography on the oil film distribution,contact damping and friction are considered.The time-varying meshing stiffness and the static transmission error are included in the abovementioned models.An exemplary gear pair is analyzed using the proposed models to investigate the influence of the surface micro-topography on the dynamic characteristics of gear system under different micro-topographies and input torque conditions.Simulation results show that the effects of gear tooth micro-topography on the gear dynamic responses(including the friction and the vicious damping at the gear meshing interface and the vibration in the direction of offline of action)are highly dependent on the regularity of tooth surface.The vibration and noise can be significantly controlled by manufacturing a regular gear tooth profiles instead of random profiles.

考虑粗糙表面接触配合的航空发动机多级转子装配误差传递建模

传统的转子系统装配建模方法忽略了转子粗糙表面微观形貌的影响,可能导致装配误差传递建模和优化不精确等问题,在此背景下,提出了一种综合考虑定向误差、定位误差和表面粗糙形貌的航空发动机多级转子装配误差传递分析方法。首先,使用共轭梯度法模拟转子端面的粗糙表面微观形貌,在刚性接触假设下,提出了一种考虑平移、单点和轴线旋转,以及质心作用的接触求解算法,计算两个粗糙表面的装配倾斜角和配合面方程。然后,改进传统基于齐次变换矩阵的装配误差传递模型,建立了考虑粗糙表面接触配合的多级转子装配同轴度误差传递模型。最后,以航空发动机转子模拟件为对象,选取前轴和第一级盘进行实例分析,新模型的同轴度预测精度与传统模型相比提高了11.55%。研究结果表明,所提方法可以提高航空发动机多级转子装配精度预测的准确性,为航空发动机转子系统的精密装配提供了理论依据。

Examination and Research of the Surface Topography of Ultrasonic Vibration Honing Nd-Fe-B

The mechanism of ultrasonic vibration honing Nd-Fe-B has been briefly elaborated after the introduction of the strategic significance of processing Nd-Fe-B. Based on the formation principle of Scanning Electrtmic Microscope （SEM）, and at the examination with the aid of SEM to the ultrasonic vibration honing Nd-Fe-B material＇s superficial microscopic topography, the paper discusses the new processing nechanism according to the SEM examination picture. The research indicates that as a result of supersonic high frequency vibration, the path of the abrasion extends at the same time, and the supersonic cavitation effect forms the intense shock-wave, knpacting Nd-Fe-B material＇s intemal surface, providing the supersonic energy for the superticial abrasive dust＇s dimination, which directly explain that the honing processing efficiency is enhanced, and the processing surface roughness is high.

岩体粗糙单裂隙流体渗流机制的实验研究

岩体的天然裂隙结构与渗流行为异常复杂,岩体裂隙渗流机制与定量描述一直是岩土、矿业、地质、石油及天然气工程高度关注的难点问题.为了探究岩体粗糙裂隙的渗流机制和粗糙结构的影响,本文通过岩体单裂隙物理模型的水渗流实验,利用Weierstrass-Mandelbrot分形函数和PMMA材料制作了不同分形维数粗糙单裂隙的物理模型,利用高速摄相机记录了粗糙裂隙水渗流的全过程,分析了水渗流性质随裂隙粗糙性的变化规律及粗糙结构对渗流机制的影响,阐述了粗糙结构中水渗流的流动阻力构成,建立了水流阻力与裂隙粗糙性关系的分形模型,提出了粗糙单裂隙分形等效渗透系数和计算公式,为理解和定量描述岩体粗糙单裂隙渗流性质及其与裂隙结构之间的关系提供了实验依据和参考.

Wire electric discharge machining characteristics of titanium nickel shape memory alloy

Ti Ni shape memory alloys（SMAs） have been normally used as the competent elements in large part of the industries due to outstanding properties, such as super elasticity and shape memory effects. However, traditional machining of SMAs is quite complex due to these properties. Hence, the wire electric discharge machining（WEDM） characteristics of Ti Ni SMA was studied. The experiments were planned as per L27 orthogonal array to minimize the experiments, each experiment was performed under different conditions of pulse duration, pulse off time, servo voltage, flushing pressure and wire speed. A multi-response optimization method using Taguchi design with utility concept has been proposed for simultaneous optimization. The analysis of means（ANOM） and analysis of variance（ANOVA） on signal to noise（S/N） ratio were performed for determining the optimal parameter levels. Taguchi analysis reveals that a combination of 1 μs pulse duration, 3.8 μs pulse off time, 40 V servo voltage, 1.8×105 Pa flushing pressure and 8 m/min wire speed is beneficial for simultaneously maximizing the material removal rate（MRR） and minimizing the surface roughness. The optimization results of WEDM of Ti Ni SMA also indicate that pulse duration significantly affects the material removal rate and surface roughness. The discharged craters, micro cracks and recast layer were observed on the machined surface at large pulse duration.

Morphology characteristics of joint surface in rock mass

In order to quantify the characteristics of the surface of jointed rock mass,new equipment,the three-dimensional laser surface topography instrument,was used to accurately measure surface morphology of joints.Scan pictures and parameters were obtained to describe the rock joint surface characteristics,for example,the height frequency of surface,and mean square roughness.Using the method of fractal dimension,the values of joint roughness coefficient(JRC) were calculated based on the above parameters.It could access to the joint surface rock sample morphology of the main parameters of characteristic.The maximum peak height is 2.692 mm in the test joint plane.The maximum profile height is 4.408 mm.JRC value is 6.38 by fractal dimension computing.It belongs to the smooth joint surface.The results show that it is a kind of the effective method to quantitatively evaluate the surface topography by the three-dimensional laser surface topography instrument and the fractal dimension method.According to the results,during the process of underground large-scale mining,safe measures to prevent slip failure of the joint plane by controlling surface tension and shear mechanical response were proposed.

纳米接触过程中黏着规律的变化

本文应用大规模分子动力学方法,模拟了两种具有不同粗糙形貌的、刚性球形探头与弹性平面基体之间的纳米尺度接触,计算了探头与基体之间的拉离力和黏着功,研究了接触过程中界面黏着力随载荷的变化规律,分析了接触界面原子的法向应力分布.研究发现,原子级光滑接触的黏着力随着载荷的增大而线性增大,而原子级粗糙接触的黏着力-载荷曲线分为以不同斜率增长的两个阶段.相比于原子级光滑探头,原子级粗糙探头与基体之间具有较小的拉离力和黏着功,却在接触过程中形成了较大的黏着力.因此,拉离力和黏着功不能表征出纳米接触过程中原子吸引作用对界面法向力的贡献大小.

金属封严环泄漏率预测方法

针对金属封严环设计中泄漏率估算问题,综合对密封系统宏观结构和微观表面接触变形的考量,提出一种基于数值计算的泄漏率预测方法。对密封整体结构进行计算,以计算值(接触应力、接触面积)为输入参数,以表面粗糙度为评价指标建立微观粗糙表面,使用有限元法(FEM)进行接触计算后建立泄漏通道模型,在对泄漏缝隙内流体流动特性确定后通过计算流体力学(CFD)方法计算得到泄漏率。使用密封试验台进行泄漏率试验,将计算值与试验结果相比较。研究表明:随着接触应力增加、表面粗糙度值降低以及内外腔压差增长,密封系统泄漏率逐渐减小;所提出的方法极大地摆脱了泄漏率获取对于试验仪器的依赖性,并能够较为有效地预测金属密封结构的泄漏率,对先进的金属封严环的设计和评估具有重要意义。