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.

Flood Risk Mapping of the Benin Municipalities at the Intersection of the Coastal Sedimentary Zone and the Crystalline Surface

Climate change and population growth have led to the increase and/or intensification of flooding becoming a major issue. The objective of this study is to visualize flooding risk of municipalities at the intersection of the coastal sedimentary zone and the crystalline surface. The methodology adopted is based on geomatic approach, which involves documentary research, processing and assisted classification using remote sensing images and multi-criteria analysis of the Geographic Information System (GIS). Flooding risk is very high at 8.85% in Djidja, Toffo, Zè and Bonou municipalities. In other municipalities such as Agbangnizoun, Abomey, Bohicon, Za-Kpota and Cove, it is high of 46.85%. To the Southeast of the study area, it is located on the eastern and western banks of Oueme Valley. The medium risk represents 26.35% and is located in the municipalities of Ouinhi and Adjohoun. The other municipalities have a low rate of 17.95%. Risk modeling has made it possible to access the various levels of rising water that can cause flooding. Land-use planning decisions can be influenced by the results of this study.

An elastic-plastic contact model for line contact structures

Although numerical simulation tools are now very powerful,the development of analytical models is very important for the prediction of the mechanical behaviour of line contact structures for deeply understanding contact problems and engineering applications.For the line contact structures widely used in the engineering field,few analytical models are available for predicting the mechanical behaviour when the structures deform plastically,as the classic Hertz’s theory would be invalid.Thus,the present study proposed an elastic-plastic model for line contact structures based on the understanding of the yield mechanism.A mathematical expression describing the global relationship between load history and contact width evolution of line contact structures was obtained.The proposed model was verified through an actual line contact test and a corresponding numerical simulation.The results confirmed that this model can be used to accurately predict the elastic-plastic mechanical behaviour of a line contact structure.

A fast compound direct iterative algorithm for solving transient line contact elastohydrodynamic lubrication problems

A fast compound direct iterative algorithm for solving transient line contact elastohydrodynamic lubrication （EHL） problems is presented. First, by introducing a special matrix splitting iteration method into the traditional compound direct iterative method, the full matrices for the linear systems of equations are transformed into sparse banded ones with any half-bandwidth; then, an extended Thomas method which can solve banded linear systems with any half-bandwidth is derived to accelerate the computing speed. Through the above two steps, the computational complexity of each iteration is reduced approximately from O（N^3/3） to O（β^2N）, where N is the total number of nodes, and β is the half-bandwidth. Two kinds of numerical results of transient EHL line contact problems under sinusoidal excitation or pure normal approach process are obtained. The results demonstrate that the new algorithm increases computing speed several times more than the traditional compound direct iterative method with the same numerical precision. Also the results show that the new algorithm can get the best computing speed and robustness when the ratio, half-bandwidth to total number of nodes, is about 7.5% 10.0% in moderate load cases.

Moving contact line problem: Advances and perspectives

The solid-liquid interface, which is ubiquitous in nature and our daily life, plays fundamental roles in a variety of physical-chemical-biological- mechanical phenomena, for example in lubrication, crystal growth, and many biological reactions that govern the building of human body and the functioning of brain. A surge of interests in the moving contact line （MCL） problem, which is still going on today, can be traced back to 1970s primarily because of the exis- tence of the ＂Huh-Scriven paradox＂. This paper, mainly from a solid mechanics perspective, describes very briefly the multidisciplinary nature of the MCL problem, then summarizes some major advances in this exciting research area, and some future directions are presented.

Experimental investigation of EHD grease lubrication in finite line contacts

The objective of this study was to investigate the grease-lubricated film-forming mechanisms in the finite line contact and to improve the grease-lubricated finite line contact’s film-forming capacity.An elastohydrodynamic lubrication(EHL) test rig with two interferometry microscopes,which could simultaneously monitor two different contact locations in the finite line contact,was constructed in order to study the influences of the grease thickener formulation on the film thickness and lubrication condition.By using the relative light intensity method,the thickness maps of the grease-lubricated film were calculated from the interferometer images captured by the two microscopes.The test results revealed that the grease thickener’s formulation had remarkable effects on film formation and the perturbation of film thickness.For the lithium-based grease,the film’s thickness near the two ends of the roller was prone to severe perturbation caused by the conglomeration of clumps that were hard to shear.For the aluminum-complex-based grease,the fibers tended to accumulate in the middle of the roller rather than at the two ends.The urea-based grease could be easily sheared into smaller particles.In addition to the straight-line profile rollers,the logarithmic profile rollers were tested and found to effectively enhance the axial grease flow,increase the axial shear stress,and thus shear more fibers into particles within the contact area.

New Monitoring Technologies for Overhead Contact Line at 400 km.h-1

Various technologies have recently been developed for high-speed railways, in order to boost commercial speeds from 300 km.h： to 400 km.h-1. Among these technologies, this paper introduces the 400 km-h-1 class current collection performance evaluation methods that have been developed and demonstrated by Korea. Specifically, this paper reports details of the video-based monitoring techniques that have been adopted to inspect the stability of overhead contact line （OCL） components at 400 km.h-1 without direct contact with any components of the power supply system. Unlike conventional OCL monitoring systems, which detect contact wire positions using either laser sensors or line cameras, the developed system measures parameters in the active state by video data. According to experimental results that were obtained at a field-test site established at a commercial line, it is claimed that the proposed mea- surement system is capable of effectively measuring OCL parameters.

NUMERICAL SIMULATION OF THE FLOW WITH CONTACT LINES

The paper proposes a physical model for the motion of the contact line and the gas-liquid interface. The local motion of the contact line at the solid wall is assumed and the interface between gas and liquid is traced by a level function. The finite volume method and staggered grids are used to solve the governing equation numerically. The motion of the water column in a vertical pipe is computed and the results are in good agreement with experimental data.

Measurement of the friction coefficient of a fluctuating contact line using an AFM-based dual-mode mechanical resonator

A dual-mode mechanical resonator using an atomic force microscope （AFM） as a force sensor is developed. The resonator consists of a long vertical glass fiber with one end glued onto a rectangular cantilever beam and the other end immersed through a liquid-air interface. By measuring the resonant spectrum of the modified AFM cantilever, one is able to accurately determine the longitudinal friction coefficient ξv along the fiber axis associated with the vertical oscillation of the hanging fiber and the traversal friction coefficient ξh perpendicular to the fiber axis associated with the horizontal swing of the fiber around its joint with the cantilever. The technique is tested by measurement of the friction coefficient of a fluctuating （and slipping） contact line between the glass fiber and the liquid interface. The experiment verifies the theory and demonstrates its applications. The dual-mode mechanical resonator provides a powerful tool for the study of the contact line dynamics and the rheological property of anisotropic fluids.

Load distribution of involute gears along time-varying contact line

Base on the theory of energy minimization, a numerical algorithm is established to calculate load distribution, and the relationship curve of spur gear load distribution is obtained, and the load distribution ratio changes from 033 to 067 in double contact zone. This theory is adopted to compute the load distribution of helical gear along time-varying contact line, and the load distribution varies with the instantaneous position of the meshing point and the length of contact line, and the maximum value of load appears at the pitch point. Compared with the load distribution results, the helical gear changes more smoothly than spur gear. The load distribution provides a basis for calculate tooth bending deformation and critical stress.

ESTIMATION OF RESIDUAL CONTACT PRESSURE IN HYDRAULICALLY EXPANDED CRA-LINED PIPE

The mechanically bonded CRA-lined pipe is developed to meet the need forcorrosion-resistant alloy steel pipe. Residual contact pressure at the interface of lined pipe isimportant factor that governs the quality of lined pipe. A simplified theoretical method ispresented to predict the residual contact pressure created by hydraulic pressure. The calculatingequation related hydro-forming pressure to the residual contact pressure between two metal faces isderived. And the validation of the proposed equation is accomplished by comparing its result tothose obtained by experimental investigation.

ANALYSIS OF THE SINGULARITY FOR THE VERTICAL CONTACT PROBLEM OF LINE CRACK-INCLUSION

Taking the short-fiber composite materials as engineering back-ground, utilizing the existing basic solutions of single inclusion and single crack, the plane problem of vertical contact interactions between line crack and rigid line inclusion in infinite plane (matrix) from the viewpoint of crack fracture mechanics is studied. According to boundary conditions, a set of standard Cauchy-type singular integral equations of the problem is obtainable. Besides, singular indexes, stresses and stress intensity factors around the contact point are expressed. Numerical examples are given to provide references to engineering.

隧道围岩-衬砌接触面剪切特性模拟研究

探究隧道围岩-衬砌接触面在不同法向应力及不同粗糙度条件下的剪切特性规律,对进一步研究隧道围岩与衬砌间的相互作用及岩体稳定性具有重要的理论和工程意义。为考虑粗糙度条件,利用分形理论,通过改变分形公式中的分形维数D及分形粗糙度G生成5种不同接触面,基于二维颗粒流程序(PFC^(2D)),建立接触面数值剪切模型,尺寸为150 mm×150 mm。开展同一接触面在不同法向应力下,数值模拟剪切试验及不同接触面在同一法向应力下的数值模拟试验;将数值剪切试验与室内剪切试验获得的剪切应力-剪切位移曲线进行对比,验证数值剪切模拟的可靠性。研究结果表明:(1)数值模型剪切破坏产生的裂隙主要集中于中间接触面处,破坏后的应力主要集中于接触面粗糙度最大处,破坏裂纹可分为剪切裂纹和张拉裂纹,其中张拉裂纹占主要优势;(2)剪切应力-剪切位移过程曲线存在爬坡、啃断、滑移三大阶段,具有明显的峰值强度和残余强度,法向位移随着剪切位移的增加而增大,产生剪胀效应;(3)随着法向应力增加,剪切和张拉裂纹数量增加,破坏现象越明显,峰值强度和残余强度增大,剪胀效应减小;(4)随着粗糙起伏度增大,即分形维数D的增大或者分形粗糙度G的减小,破坏裂纹数量增加,其中张拉裂纹增加较明显,峰值强度和残余强度增大,剪胀效应增大。

线接触弹流润滑摩擦副刚度阻尼拟合公式

弹流润滑油膜具有显著的弹簧阻尼作用,对齿轮、滚动轴承、凸轮等高副接触零件的动力学性能具有重要影响,然而目前关于弹流摩擦副刚度阻尼的认识还不统一。运用数值方法求解线接触弹流润滑摩擦副的摩擦学-动力学耦合模型,获得线接触弹流润滑摩擦副在简谐激励下的阻尼环,通过阻尼环识别出线接触弹流润滑摩擦副的刚度和阻尼;用变量控制的方法研究载荷、卷吸速度、材料参数等对线接触弹流润滑摩擦副刚度和阻尼的影响,并分析载荷、卷吸速度影响线接触弹流润滑摩擦副刚度阻尼的机制。结果表明,线接触弹流润滑摩擦副刚度阻尼随载荷增加而变大,随速度增加而减小。在数值解的基础上,拟合出线接触弹流润滑摩擦副刚度和阻尼公式,结果显示,载荷对弹流润滑摩擦副的刚度和阻尼影响最显著,而且弹流润滑摩擦副的刚度随载荷、速度和材料参数的变化幅度比阻尼的大。对拟合公式精度的检验表明,在很宽的参数范围内,拟合公式计算结果与数值解的相对误差小于10%,所提出的刚度和阻尼拟合公式具有很高的精确性。

基于角度传感器的弓网相对坐标检测技术研究

在电气化公路弓网相对坐标的检测中,基于机器视觉的非接触式检测技术的检测精度受图像采集环境的影响较大,基于光电传感器的接触式检测技术的检测精度受传感器安装密度限制。提出了一种基于角度传感器的接触式相对坐标检测技术,用于电气化公路的弓网相对坐标检测。首先,基于双接触线的电气化公路接触网,搭建弓网相对坐标检测实验台,建立弓网相对坐标与角度信息关联函数;然后,研究系统刚度、角度传感器线性度对实验台检测误差的影响规律,建立多项式修正函数对关联函数进行修正;最后,基于修正的弓网相对坐标关联函数,进行弓网相对坐标检测实验,得到实验台检测的绝对误差为±1 mm,相对误差为±0.5%,具备较高的检测精度。

浮选颗粒条栅结构表面润湿行为特性研究

矿物颗粒间表面润湿性差异是浮选成功的关键,受表面化学性质与物理形貌结构的双重影响。为进一步明确表面物理形貌结构对液滴在矿物颗粒表面上润湿行为的影响,采用光刻显影技术制备了5种具有不同粗糙度系数和表面面积分数的条栅结构聚二甲基硅氧烷(PDMS)表面,并利用自制的动/静态接触角测量系统及润湿三相接触线行为测试系统对液滴在PDMS表面上的润湿行为进行了测试。动/静态接触角测试结果表明:当表面粗糙度系数相同时,固体表面面积分数增加,条栅结构表面不同润湿方向上的接触角均呈减小趋势,而当表面面积分数相同时,条栅结构表面不同润湿方向上的接触角则与固体表面粗糙度系数呈正相关;此外,各样品表面垂直于条栅结构方向的动/静态接触角均大于平行方向(即θ_(⊥)>θ_(∥)),且不同润湿方向上接触角的差异随样品表面润湿性的增强而减小。动态接触角测试结果还表明:表面接触角滞后(Δθ=θ_(a)-θ_(r))与表面面积分数呈正相关,而与表面粗糙度系数呈负相关,且前进与后退接触角的预测值与试验值基本吻合,说明动态接触角能够真实地反映固体表面润湿性;此外,在液滴滚动时,其运动行为总是周期性地发生后端接触线先从固体表面分离,而后液滴重新与固体表面发生黏附形成新的前端接触线的过程,这种运动特性在不同条栅结构表面上完全相同。润湿三相接触线行为测试结果表明:液滴在条栅结构表面优先沿着条栅结构方向润湿或去润湿,而跨越条栅结构润湿时,受表面微结构的“钉扎”作用,润湿半径远小于平行润湿方向,且三相接触线在不同条栅结构表面的移动均呈现“解钉—钉扎—再解钉—再钉扎”的一种断续周期性过程。研究结果深化了矿物颗粒表面物理形貌结构对其润湿行为特性的影响,可为后续通过表面形貌调控颗粒表面润湿性起到一定的理论支撑作用。

基于线激光的压缩机曲轴圆度和平面度测量

目前人工使用千分表测量空调压缩机曲轴圆度和平面度时存在易伤工件表面、效率低和不能精确评定等问题。针对上述问题,设计了一套基于线激光位移传感器的空调压缩机曲轴圆度和平面度非接触式测量系统。首先,通过测量标准量棒,提出一种系统误差的标定方法;其次,基于线激光采样数据,开发了一种曲轴横截面圆度测点的提取算法,并将系统误差用于测点补偿,实现曲轴圆度测量;接着根据曲轴平面测点间的斜率分离出轮廓线,通过均匀下采样方法获取精简点云数据并采用最小二乘法实现曲轴平面度测量;最后,基于上述方法开展了曲轴圆度和平面度的测量实验。实验结果表明:该测量系统的圆度测量精度<4μm,平面度测量精度<2μm,圆度重复度测量误差<0.8μm,平面度重复度测量误差<0.3μm,满足曲轴圆度和平面度快速准确的测量需求。

微量供油下的线接触副润滑增效分析

实验发现亲/疏油交替供油的功能润湿表面能提高微量供油下有效润滑的成膜性能。基于此,建立了有限长滚子副润滑模型,分析了交替供油的亲/疏油带宽及工作参数对润滑性能的增强规律。研究发现,微量供油条件下可利用交替供油方式达到线接触副润滑增效的目的,但供油交替变换使接触区润滑性能不稳定,且润滑增效作用会受功能表面亲/疏油带宽和卷吸速度的影响。

黄药体系中气泡与不同粗糙度黄铜矿表面碰撞黏附机理研究

在黄铜矿浮选过程中,矿物表面的粗糙度及黄药浓度的变化会直接影响气泡与矿物表面的黏附和铺展,从而影响浮选效果。为了探究黄铜矿表面的粗糙度和黄药浓度对气泡与黄铜矿碰撞黏附行为的影响,使用砂纸对黄铜矿进行打磨,得到不同粗糙度的样品,然后进行气泡在矿物表面的碰撞黏附试验,并对气泡局部速度、气泡碰撞黏附时间、三相接触线长度随时间的变化、气泡接触角进行了测试分析。结果表明:粗糙度较大的黄铜矿表面有尺寸较大、数量较多的粗糙结构,会促进气泡与矿物表面之间水化膜的薄化和破裂,有利于黏附的形成,但黏附产生后黄铜矿表面的粗糙结构阻碍了气泡在矿物表面的进一步铺展;黄药浓度的增加使得黄铜矿表面生成的疏水性薄膜厚度增加,增强了对样品表面粗糙结构的覆盖作用和黄铜矿表面的负电性,提高了黄铜矿的疏水性,不利于气泡与黄铜矿形成黏附,但有利于气泡在黄铜矿表面形成黏附后的进一步铺展。该成果可用于黄铜矿的高效浮选回收利用研究。

圆锥滚子球基面的立式无磁磨削

圆锥滚子立式球基面无磁磨削具有效率高、导盘不偏载且方便多工位布局的优点,在滚子制造领域日益受到重视。针对该磨削方式,分析了球基面的磨削成形原理、砂轮轴线与滚子公转轴线错位的必要性、隔离盘转速波动及其影响等,结果表明:该磨削方式不存在原理性加工误差,其砂轮轴线与滚子公转轴线有必要错位,从而使砂轮工作面由球面变为圆环面,实现了滚子球基面的线接触磨削;隔离盘转速存在波动,将进料管设置在距离磨削区尽量远的位置并对隔离盘设置转动阻尼,有利于避免隔离盘转速波动产生的负面影响。