摩擦副表面微凹槽织构相关摩擦学理论及试验研究
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摘要
表面织构是指通过一定的加工技术在摩擦副表面加工制备出具有一定尺寸、形状和排列的图案。已有的研究表明,合适参数的表面织构可以显著改善机械零件表面的摩擦学性能。目前,对于微凹坑型表面织构的研究比较充分,而针对微凹槽型表面织构的摩擦学性能研究,尤其是在润滑理论的研究方面还比较少见。为此,论文首先通过多重网格法求解无量纲雷诺方程,较为系统地开展了具有规则直线形凹槽的全部织构化表面、局部织构化表面和V形凹槽的全部织构化表面流体动压润滑性能的研究。
对于具有规则直线形凹槽的全部织构化表面的研究中发现：直线形凹槽的宽度、深度、间距和倾斜角对润滑油膜承载力有重要的影响；存在使润滑油膜承载力达到最大的最优凹槽深度、间距和倾斜角,润滑油膜承载力随着凹槽宽度的增加而增大。通过合理优化直线形凹槽的几何参数能够显著提高表面的动压承载力。
对于具有规则直线形凹槽的局部织构化表面的研究中发现：直线形凹槽的深度、面积密度、倾斜角和织构化比值对润滑油膜承载力具有重要的影响,而凹槽的宽度对润滑油膜承载力几乎没有影响；存在使润滑油膜承载力达到最大的最优凹槽深度、倾斜角和织构化比值；润滑油膜承载力随着面积密度的增大而增大；通过优化直线形凹槽的几何参数,局部织构化表面所产生的润滑油膜承载力可以近似等价于Rayleigh阶梯形滑块。
对于具有规则V形凹槽的全部织构化表面的研究中发现：V形凹槽的角度对润滑油膜承载力具有重要的影响；存在着使得润滑油膜承载力达到最大的最优V形凹槽深度和横向槽间距；润滑油膜承载力随着V形凹槽的宽度和边长的增大呈线性递增的趋势,随着纵向槽间距的减小而减小。
在润滑理论研究的基础上,论文随后对微凹槽型表面织构的激光加工工艺试验和V形凹槽的摩擦学性能试验进行了初步的研究：
通过采用声光调Q二极管泵浦Nd:YAG激光器在45#钢冈试样表面进行微凹槽表面织构激光加工工艺试验,研究了工艺参数对微凹槽加工质量的影响。结果发现：泵浦电流、扫描速度和重复频率都是影响微凹槽几何形貌参数与加工质量的重要因素。
在UMT-2摩擦磨损试验机上,通过采用销-盘式摩擦副考察了V形凹槽表面织构对减摩性能的影响,研究发现：在45#钢表面制备V形凹槽表面织构能够有效减小表面的摩擦系数,尤其是在载荷较低、速度较大的工况条件下,V形凹槽的润滑减摩效果比较显著；通过试验结果与理论仿真结果的对比发现,两者具有一定的一致性,指出了两者产生差别的原因。
论文的研究结果丰富了表面织构的摩擦学理论,可为微凹槽表面织构的设计及在工程中的应用提供理论参考。
Surface texturing is a new technology for improving the contact and lubrication state of friction pairs by processing certain patterns with defined sizes, shapes and arrays on frictional surfaces. It's been shown that the tribological performance of mechanical components can be significantly improved by choosing suitable geometrical parameters of surface texture. At present, most researches focus on the textures of micro-dimples, however, there are only few studies paying attention to the textures of micro-grooves, especially in lubrication theoretical research. For this reason, by solving the dimensionless Reynolds equation with the multi-grid method, investigations on the hydrodynamic pressure of fully or partially textured surfaces with regular linear grooves, fully textured surfaces with regular micro V-grooves were systematically studied.
For fully textured surfaces with regular linear grooves, groove width, depth, spacing and orientation angle have significant effect on the load carrying capacity of the lubricating oil film. Optimum values of geometrical parameters such as groove depth, spacing and orientation angle can be found which correspond to maximum load carrying capacity. It is also noted that the load carrying capacity increases monotonically with increasing groove width. The results show that the hydrodynamic effect can be improved by employing optimized surface texturing design.
For partially textured surfaces with regular linear grooves, groove depth, spacing and orientation angle have significant effect on the load carrying capacity of the lubricating oil film. However, groove width has little or no effect on the load carrying capacity. Optimum values of geometrical parameters such as groove depth, orientation angle and textured fraction can be found which correspond to maximum load carrying capacity. It is also noted that the load carrying capacity increases monotonically with increasing area density. The results of the study show that the hydrodynamic lubrication performance can be equivalent to a Rayleigh step slider by optimizing the partial surface texturing according to the operating parameters of the mechanical components.
For fully textured surfaces with regular V-grooves, V-groove angle has significant effect on the load carrying capacity. Optimum values of geometrical parameters such as groove depth and transverse spacing can be found which correspond to maximum load carrying capacity. It is also noted that the load carrying capacity increases monotonically with increasing groove width and length, decreases with increasing longitudinal spacing.
Based on the investigation of lubrication theories, experimental investigations of laser processing of micro-groove surface texture and tribological performance of V-grooves has been performed.
Processing of the surface texture of micro grooves on 45* steel has been performed with a Q switched diode-pumped Nd:YAG laser. Effects of process parameters on the quality of micro-grooves have also been analyzed. It has shown that pumping current, repetition rate and scanning speed have significant effect on the geometrical parameters and quality of micro grooves.
UMT-2 tribometer with a pin-on-disk friction pairs has been used to test the tribological performance of V-grooves. The result shows that the laser textured specimens with regular V-grooves exhibited lower friction coefficient than untextured specimens. Especially under the conditions of low loads and high speeds, the tribological performance can be improved greatly by V-grooves. It is basic anastomotic between the theoretical simulation and the experiment results. The causes of these differences have also been analyzed.
The results obtained in the research diversify surface texture tribological theory, and provide a reference for the micro-groove design and its application.
对于具有规则直线形凹槽的全部织构化表面的研究中发现：直线形凹槽的宽度、深度、间距和倾斜角对润滑油膜承载力有重要的影响；存在使润滑油膜承载力达到最大的最优凹槽深度、间距和倾斜角,润滑油膜承载力随着凹槽宽度的增加而增大。通过合理优化直线形凹槽的几何参数能够显著提高表面的动压承载力。
对于具有规则直线形凹槽的局部织构化表面的研究中发现：直线形凹槽的深度、面积密度、倾斜角和织构化比值对润滑油膜承载力具有重要的影响,而凹槽的宽度对润滑油膜承载力几乎没有影响；存在使润滑油膜承载力达到最大的最优凹槽深度、倾斜角和织构化比值；润滑油膜承载力随着面积密度的增大而增大；通过优化直线形凹槽的几何参数,局部织构化表面所产生的润滑油膜承载力可以近似等价于Rayleigh阶梯形滑块。
对于具有规则V形凹槽的全部织构化表面的研究中发现：V形凹槽的角度对润滑油膜承载力具有重要的影响；存在着使得润滑油膜承载力达到最大的最优V形凹槽深度和横向槽间距；润滑油膜承载力随着V形凹槽的宽度和边长的增大呈线性递增的趋势,随着纵向槽间距的减小而减小。
在润滑理论研究的基础上,论文随后对微凹槽型表面织构的激光加工工艺试验和V形凹槽的摩擦学性能试验进行了初步的研究：
通过采用声光调Q二极管泵浦Nd:YAG激光器在45#钢冈试样表面进行微凹槽表面织构激光加工工艺试验,研究了工艺参数对微凹槽加工质量的影响。结果发现：泵浦电流、扫描速度和重复频率都是影响微凹槽几何形貌参数与加工质量的重要因素。
在UMT-2摩擦磨损试验机上,通过采用销-盘式摩擦副考察了V形凹槽表面织构对减摩性能的影响,研究发现：在45#钢表面制备V形凹槽表面织构能够有效减小表面的摩擦系数,尤其是在载荷较低、速度较大的工况条件下,V形凹槽的润滑减摩效果比较显著；通过试验结果与理论仿真结果的对比发现,两者具有一定的一致性,指出了两者产生差别的原因。
论文的研究结果丰富了表面织构的摩擦学理论,可为微凹槽表面织构的设计及在工程中的应用提供理论参考。
Surface texturing is a new technology for improving the contact and lubrication state of friction pairs by processing certain patterns with defined sizes, shapes and arrays on frictional surfaces. It's been shown that the tribological performance of mechanical components can be significantly improved by choosing suitable geometrical parameters of surface texture. At present, most researches focus on the textures of micro-dimples, however, there are only few studies paying attention to the textures of micro-grooves, especially in lubrication theoretical research. For this reason, by solving the dimensionless Reynolds equation with the multi-grid method, investigations on the hydrodynamic pressure of fully or partially textured surfaces with regular linear grooves, fully textured surfaces with regular micro V-grooves were systematically studied.
For fully textured surfaces with regular linear grooves, groove width, depth, spacing and orientation angle have significant effect on the load carrying capacity of the lubricating oil film. Optimum values of geometrical parameters such as groove depth, spacing and orientation angle can be found which correspond to maximum load carrying capacity. It is also noted that the load carrying capacity increases monotonically with increasing groove width. The results show that the hydrodynamic effect can be improved by employing optimized surface texturing design.
For partially textured surfaces with regular linear grooves, groove depth, spacing and orientation angle have significant effect on the load carrying capacity of the lubricating oil film. However, groove width has little or no effect on the load carrying capacity. Optimum values of geometrical parameters such as groove depth, orientation angle and textured fraction can be found which correspond to maximum load carrying capacity. It is also noted that the load carrying capacity increases monotonically with increasing area density. The results of the study show that the hydrodynamic lubrication performance can be equivalent to a Rayleigh step slider by optimizing the partial surface texturing according to the operating parameters of the mechanical components.
For fully textured surfaces with regular V-grooves, V-groove angle has significant effect on the load carrying capacity. Optimum values of geometrical parameters such as groove depth and transverse spacing can be found which correspond to maximum load carrying capacity. It is also noted that the load carrying capacity increases monotonically with increasing groove width and length, decreases with increasing longitudinal spacing.
Based on the investigation of lubrication theories, experimental investigations of laser processing of micro-groove surface texture and tribological performance of V-grooves has been performed.
Processing of the surface texture of micro grooves on 45* steel has been performed with a Q switched diode-pumped Nd:YAG laser. Effects of process parameters on the quality of micro-grooves have also been analyzed. It has shown that pumping current, repetition rate and scanning speed have significant effect on the geometrical parameters and quality of micro grooves.
UMT-2 tribometer with a pin-on-disk friction pairs has been used to test the tribological performance of V-grooves. The result shows that the laser textured specimens with regular V-grooves exhibited lower friction coefficient than untextured specimens. Especially under the conditions of low loads and high speeds, the tribological performance can be improved greatly by V-grooves. It is basic anastomotic between the theoretical simulation and the experiment results. The causes of these differences have also been analyzed.
The results obtained in the research diversify surface texture tribological theory, and provide a reference for the micro-groove design and its application.
引文
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