摩擦过程表面形貌动态变化模拟研究
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摘要
表面形貌是指零件在加工过程中因诸多因素综合作用而残留于零件表面的粗糙度、波度、形状误差及纹理等各种不同形状和尺寸的微观几何形态。摩擦过程中表面形貌动态变化过程的描述,是进一步深入研究表面形貌摩擦学效应的基础。本文根据脆性材料和塑性材料的特点,针对摩擦过程中的表面形貌相互作用问题,基于离散元原理,并利用该原理的一种应用程序——PFC程序,直观地对表面形貌相互作用过程进行了模拟。模拟结果表明在刚性光滑平面与理想粗糙表面相互作用之后,粗糙度变小,表面结构也发生较大变化。并且随着两个接触表面法向接近量的增大,粗糙表面的脱落颗粒数增加,磨损程度加剧。
Surface topography is the micro-geometry morphology remained at the surface of machine elements, which consists of roughness, waveness and form errors and caused by various random factors during machining. Description of the dynamic variations of surface topography in the friction progress is the basis for the research of tribological effects of surface topography. In this paper, according to the characteristics of brittle material and plastic material, the interaction mechanism of the surface topographys in the friction process is studied based on the principle of discrete element method. The Particle Flow Code program (or PFC program) is employed to simulate the interaction process of contacting surface topographys and digital descriptions of dynamic variations of the surface are given. Simulation results show that the roughness of surface become smaller after the interaction between rigid smooth surface and the ideal rough surface, and the surface structure changes. With the increase of normal approaching of the two contacting surfaces, the number of detached particles from the rough surface increases, indicating that the degree of wear between contacting surfaces increases.
Surface topography is the micro-geometry morphology remained at the surface of machine elements, which consists of roughness, waveness and form errors and caused by various random factors during machining. Description of the dynamic variations of surface topography in the friction progress is the basis for the research of tribological effects of surface topography. In this paper, according to the characteristics of brittle material and plastic material, the interaction mechanism of the surface topographys in the friction process is studied based on the principle of discrete element method. The Particle Flow Code program (or PFC program) is employed to simulate the interaction process of contacting surface topographys and digital descriptions of dynamic variations of the surface are given. Simulation results show that the roughness of surface become smaller after the interaction between rigid smooth surface and the ideal rough surface, and the surface structure changes. With the increase of normal approaching of the two contacting surfaces, the number of detached particles from the rough surface increases, indicating that the degree of wear between contacting surfaces increases.
引文
[1]刘小君,方新燕,刘焜,桂长林.产品性能与加工表面质量设计[J].合肥工业大学学报(自然科学版),2005,28(7):781~783.
[2]郑林庆.摩擦学原理[M].北京:高等教育出版社,1993.
[3]温诗铸.摩擦学原理[M].北京:清华大学出版社,1990.
[4]冯秀.表面形貌的研究现状及发展趋势[J].润滑与密封,2006,174(2):168~170.
[5] Thomas A P, Thomas T R. Engineering surface as fractals, fractal aspects of materials[J].Pittsburgh: Materials Research Society, 1986,75 ~ 77.
[6] Majumdar A, Bhushan B. Fractal model of elastic plastic contact between rough surfaces[J].Tram of ASME, 1991,113 (1):1 ~ 11.
[7]葛世荣, K Tonder.粗糙表面的分形特征与分形表达研究[J].摩擦学学报, 1997, 17(1):73 ~ 80.
[8]葛世荣,索双富.表面轮廓分形维数计算方法的研究[J].摩擦学学报, 1997, 17(4): 354 ~ 362.
[9]费斌,蒋庄德.工程粗糙表面粘着磨损的分形学研究[J].摩擦学学报, 1999, 19 (1):78 ~ 82.
[10]陈庆虎,李柱.表面粗糙度评定的小波基准线[J].计量学报,1998,10:254~257.
[11]陈庆虎,李柱.表面粗糙度提取的小波频谱法[J].机械工程学报, 1999,3:41~43.
[12]陈庆虎,周轶尘.表面奇异特征的小波提取[J].武汉交通科技大学学报,1999, 23(4):343~346.
[13]陈庆虎,谢峰,谢铁邦等.小波滤波的频率结构分析及其在表面形貌分析中的应用[J].武汉交通科技大学学报, 1998,122:231~234.
[14]郭百巍,陈大融.结合小波分析和分水岭分割法的微观表面形貌分析方法[J].中国机械工程,2007,18(17):2043~2047.
[15]杨练根,谢铁邦,蒋向前等.表面形貌的Motif评定方法及其发展[J].中国机械工程, 2002, 21(3):1862~1865.
[16]黄平,孟永刚,徐华.摩擦学教程[M].北京:高等教育出版社,2008.
[17] Dundurs J, Tsai K C, Keer L M. Contact Between Elastic Bodies With Wavy Surfaces [J]. Journal of Elasticity,1973,3:109~115.
[18] Berthe D, Vergne Ph. An Elastic Approach to Rough Contact with Asperity Interactions [J]. Wear,1987,1l7:211~222.
[19] Seabra J, Berthe D. In fluence of Surface Waviness and Roughness on the Normal Pressure Distribution in the Hertzian Contact [J]. ASME Journal of Tribology,1987, 109: 462~470.
[20] Ioannides E, Kuijpers J C. Elastic Stresses below Asperities in Lubricated Contacts [J].ASME Journal of Tribology,1986,108:394~402.
[21] Komvopoulos K, Choi D H. Elastic Finite Element Analysis of Multi-Asperity Contacts [J]. ASME Journal of Tribology,1992,114:823~831.
[22]杨楠,陈大融,孔宪梅.多粗糙峰弹塑性接触的有限元分析[J].摩擦学学报,2000,20(3):202~206.
[23]郭百巍,孟秀云,陈大融.微粗糙表面接触的仿真研究[A].全国仿真技术学术会议论文集[C].2005.500~507.
[24] Dmitrieva A I, Popov V L, Psakhie S G.. Simulation of surface topography with the method of movable cellular automate [J]. Tribology International,2006,39:444~449.
[25]冯嫦杰.表面相互作用下表面形貌表征及微造型表面润滑分析[硕士学位论文].合肥工业大学摩擦所,2008.
[26] Sobis T, Engel U, Geiger M. A theoretical Study on Wear Simulation in Metal Forming Processes[J]. Mater. Process. Technol,1992,34(1—4):33~40.
[27] Weidel S, Engel U. Surface characterization in forming processes by functional 3D parameters[J].The International Journal of Advanced Manufacturing Technology, 2007,33:130~136.
[28]王泳嘉,邢纪波.离散单元法及其在岩土力学中的应用[M].沈阳:东北工学院出版社,1991.
[29] Cundall P.A. PFC2D user’s manual (version 3.1).Itasca Consulting Group,Inc,2004.
[30]张昭.筒仓压力及流态的颗粒流数值模拟[硕士学位论文].郑州工程学院,2004.
[31]曾远.土体破坏细观机理及颗粒流数值模拟[博士学位论文].同济大学,2006.
[32]杨洋,唐寿高,王居林.颗粒离散元法中阻尼系数、刚度系数和时步的选取方法[J].计算机辅助工程,2007,16(3):65~68.
[33] W. McGuire and R. H. Gallagher. Matrix Structural Analysis [M].1979.
[34] Mindlin R.D. and Deresiewicz H.D. Elastic Spheres in Contact under Varying Oblique Force[J]. Appl.Mech.Trans.A.S.M.E.1953,75:327~344.
[35] Cundall,P.A. Computer Simulations of Dense Sphere Assemblies[J]. Micromechanics of Granular Materials.1988:113~123.
[36]汤铭权,张传海,宜沈平.机械工程金属材料实用知识[M].北京:机械工业出版社,1981.
[2]郑林庆.摩擦学原理[M].北京:高等教育出版社,1993.
[3]温诗铸.摩擦学原理[M].北京:清华大学出版社,1990.
[4]冯秀.表面形貌的研究现状及发展趋势[J].润滑与密封,2006,174(2):168~170.
[5] Thomas A P, Thomas T R. Engineering surface as fractals, fractal aspects of materials[J].Pittsburgh: Materials Research Society, 1986,75 ~ 77.
[6] Majumdar A, Bhushan B. Fractal model of elastic plastic contact between rough surfaces[J].Tram of ASME, 1991,113 (1):1 ~ 11.
[7]葛世荣, K Tonder.粗糙表面的分形特征与分形表达研究[J].摩擦学学报, 1997, 17(1):73 ~ 80.
[8]葛世荣,索双富.表面轮廓分形维数计算方法的研究[J].摩擦学学报, 1997, 17(4): 354 ~ 362.
[9]费斌,蒋庄德.工程粗糙表面粘着磨损的分形学研究[J].摩擦学学报, 1999, 19 (1):78 ~ 82.
[10]陈庆虎,李柱.表面粗糙度评定的小波基准线[J].计量学报,1998,10:254~257.
[11]陈庆虎,李柱.表面粗糙度提取的小波频谱法[J].机械工程学报, 1999,3:41~43.
[12]陈庆虎,周轶尘.表面奇异特征的小波提取[J].武汉交通科技大学学报,1999, 23(4):343~346.
[13]陈庆虎,谢峰,谢铁邦等.小波滤波的频率结构分析及其在表面形貌分析中的应用[J].武汉交通科技大学学报, 1998,122:231~234.
[14]郭百巍,陈大融.结合小波分析和分水岭分割法的微观表面形貌分析方法[J].中国机械工程,2007,18(17):2043~2047.
[15]杨练根,谢铁邦,蒋向前等.表面形貌的Motif评定方法及其发展[J].中国机械工程, 2002, 21(3):1862~1865.
[16]黄平,孟永刚,徐华.摩擦学教程[M].北京:高等教育出版社,2008.
[17] Dundurs J, Tsai K C, Keer L M. Contact Between Elastic Bodies With Wavy Surfaces [J]. Journal of Elasticity,1973,3:109~115.
[18] Berthe D, Vergne Ph. An Elastic Approach to Rough Contact with Asperity Interactions [J]. Wear,1987,1l7:211~222.
[19] Seabra J, Berthe D. In fluence of Surface Waviness and Roughness on the Normal Pressure Distribution in the Hertzian Contact [J]. ASME Journal of Tribology,1987, 109: 462~470.
[20] Ioannides E, Kuijpers J C. Elastic Stresses below Asperities in Lubricated Contacts [J].ASME Journal of Tribology,1986,108:394~402.
[21] Komvopoulos K, Choi D H. Elastic Finite Element Analysis of Multi-Asperity Contacts [J]. ASME Journal of Tribology,1992,114:823~831.
[22]杨楠,陈大融,孔宪梅.多粗糙峰弹塑性接触的有限元分析[J].摩擦学学报,2000,20(3):202~206.
[23]郭百巍,孟秀云,陈大融.微粗糙表面接触的仿真研究[A].全国仿真技术学术会议论文集[C].2005.500~507.
[24] Dmitrieva A I, Popov V L, Psakhie S G.. Simulation of surface topography with the method of movable cellular automate [J]. Tribology International,2006,39:444~449.
[25]冯嫦杰.表面相互作用下表面形貌表征及微造型表面润滑分析[硕士学位论文].合肥工业大学摩擦所,2008.
[26] Sobis T, Engel U, Geiger M. A theoretical Study on Wear Simulation in Metal Forming Processes[J]. Mater. Process. Technol,1992,34(1—4):33~40.
[27] Weidel S, Engel U. Surface characterization in forming processes by functional 3D parameters[J].The International Journal of Advanced Manufacturing Technology, 2007,33:130~136.
[28]王泳嘉,邢纪波.离散单元法及其在岩土力学中的应用[M].沈阳:东北工学院出版社,1991.
[29] Cundall P.A. PFC2D user’s manual (version 3.1).Itasca Consulting Group,Inc,2004.
[30]张昭.筒仓压力及流态的颗粒流数值模拟[硕士学位论文].郑州工程学院,2004.
[31]曾远.土体破坏细观机理及颗粒流数值模拟[博士学位论文].同济大学,2006.
[32]杨洋,唐寿高,王居林.颗粒离散元法中阻尼系数、刚度系数和时步的选取方法[J].计算机辅助工程,2007,16(3):65~68.
[33] W. McGuire and R. H. Gallagher. Matrix Structural Analysis [M].1979.
[34] Mindlin R.D. and Deresiewicz H.D. Elastic Spheres in Contact under Varying Oblique Force[J]. Appl.Mech.Trans.A.S.M.E.1953,75:327~344.
[35] Cundall,P.A. Computer Simulations of Dense Sphere Assemblies[J]. Micromechanics of Granular Materials.1988:113~123.
[36]汤铭权,张传海,宜沈平.机械工程金属材料实用知识[M].北京:机械工业出版社,1981.
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