非牛顿流体弹流润滑膜失效的理论与实验研究
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摘要
经典弹流润滑理论虽然能够精确预测一般工况下矿物油的弹流润滑膜厚度,却不能精确预测工作在苛刻工况下的含有各种聚合物添加剂的矿物油以及合成润滑油的弹流润滑膜厚度,表现为实测弹流润滑膜厚度比经典弹流理论预测值低或者弹流润滑油膜失效,润滑油的非牛顿流变特性是主要原因。现有的非牛顿流体弹流润滑膜失效的理论研究主要着眼于工况参数对润滑膜润滑特性的影响,其结果与实验结果并不吻合,因而,现在的非牛顿流体弹流润滑理论不能用于指导润滑设计
本文针对非牛顿流体弹流润滑,研究润滑膜的剪切稀化和粘塑性非牛顿流变特性对弹流润滑膜特性影响,从理论和实验两个方而探讨非牛顿流体弹流润滑膜失效的机理以及弹流润滑膜承载能力与润滑油非牛顿流变特性的关系。
本文在理论上将完善非牛顿流体弹流润滑分析方法,建立新的非牛顿流体等温线接触弹流润滑理论。基于理论分析结果,研究润滑油的非牛顿流变效应对弹流润滑膜失效的影响。本文还将提出非牛顿流体弹流润滑的实验方法,通过实验验证本文建立的非牛顿流体弹流润滑理论的准确性,表明润滑油非牛顿流变特性与弹流润滑膜失效有直接关系。
本文主要研究内容如下：
(1)提出一个能包含润滑油粘弹性、剪切稀化特性和粘塑性的非牛顿流变模型,并对该流变模型能否反映弹流润滑工况下润滑油的非牛顿流变特性进行验证。
(2)基于改进型非牛顿流变模型推导出弹流润滑的雷诺方程,联立粘压方程、密压方程和载荷方程等对等温弹流润滑问题进行完全数值分析。
(3)理论分析润滑油的非牛顿流变特性对弹流润滑膜压力分布和油膜形状分布等润滑膜特性的影响,并与经典弹流润滑相关理论进行比较。
(4)理论研究弹流润滑膜厚对滚动速度的依赖偏离经典弹流润滑理论与润滑油非牛顿流变特性的关系。
(5)理论研究弹流润滑膜厚对载荷的依赖偏离经典弹流润滑理论与润滑油非牛顿流变特性的关系。
(6)回归出非牛顿流体弹流润滑膜厚度修正系数公式,在工程应用中,用改修正系数乘以牛顿流体弹流润滑膜厚度,可以非常方便地得到非牛顿流体弹流润滑膜厚度值。
(7)设计专门的实验对本文的相关理论研究结果进行验证。
An early validation of the classical Newtonian elastohydrodynamic lubrication (EHL) film thickness formula found it to be accurate for mineral oils in normal operating conditions but not to be accurate for mineral oils in harsh operating conditions or mineral oil/polymer blends and some synthetic oils. In such condition, the real EHL oil film is much thinner than classical Newtonian EHL theory predicts or even disappears. It was assumed that non-Newtonian rheological properties of lubricants were responsible for films being thinner than predicted by Newtonian theory. Currently theoretical studies on non-Newtonian EHL film failure mainly focus on the effects of operating parameters on EHL characteristics, but results still can not coincide with experimental results. Therefore, the current non-Newtonian EHL theories are still not applicable to lubrication design.
The current paper focuses on the study of non-Newtonian EHL. The influence of shear-thinning and viscoplastic non-Newtonian properties of lubricants on EHL characteristics was mainly studied. The film failure mechanisms of non-Newtonian EHL were studied through theory and experiment, and the relationship of EHL film load-carrying capacity with the lubricant non-Newtonian properties was also studied.
The current paper improves the non-Newtonian fluid EHL analytical approach, and establishes a new kind of theory of isothermal line contact non-Newtonian EHL. The non-Newtonian EHL theory shows that lubricant non-Newtonian rheological properties can directly cause EHL film instability and failure. On the other hand, this paper also put forward new kinds of non-Newtonian EHL experimental approaches. Non-Newtonian EHL theory established in this paper was verified by experiments. It shows that EHL film failure has the relationship with the lubricant non-Newtonian rheological properties. The main research contents are as following:
(1) The current paper put forwards a new non-Newtonian rheological model. The new model includes the following lubricant properties: viscoelastic property, shear-thinning property and plastic property. Whether the new rheological model can reflect lubricant flow properties under EHL operating condition will be verified.
(2) A full numerical analysis for the isothermal line contact EHL is studied based on the new non-Newtonian rheological model.
(3) Influence of non-Newtonian properties on pressure distribution and film shape distribution of EHL is analysized theoretically and compared with classical Newtonian EHL theory.
(4) Influence of non-Newtonian properties on relationship between EHL film thickness and rolling speed is analysized theoretically.
(5) Influence of non-Newtonian properties on relationship between EHL film thickness and load is analysized theoretically.
(6) Correction factor formula to predict EHL film thickness for non-Newtonian lubricants is developed. In practical engineering applications, the film thickness can be easily obtained through the corresponding Newtonian film thickness multiplied by the correction factor.
(7) Special experiments are designed to verify the theoretical results.
本文针对非牛顿流体弹流润滑,研究润滑膜的剪切稀化和粘塑性非牛顿流变特性对弹流润滑膜特性影响,从理论和实验两个方而探讨非牛顿流体弹流润滑膜失效的机理以及弹流润滑膜承载能力与润滑油非牛顿流变特性的关系。
本文在理论上将完善非牛顿流体弹流润滑分析方法,建立新的非牛顿流体等温线接触弹流润滑理论。基于理论分析结果,研究润滑油的非牛顿流变效应对弹流润滑膜失效的影响。本文还将提出非牛顿流体弹流润滑的实验方法,通过实验验证本文建立的非牛顿流体弹流润滑理论的准确性,表明润滑油非牛顿流变特性与弹流润滑膜失效有直接关系。
本文主要研究内容如下：
(1)提出一个能包含润滑油粘弹性、剪切稀化特性和粘塑性的非牛顿流变模型,并对该流变模型能否反映弹流润滑工况下润滑油的非牛顿流变特性进行验证。
(2)基于改进型非牛顿流变模型推导出弹流润滑的雷诺方程,联立粘压方程、密压方程和载荷方程等对等温弹流润滑问题进行完全数值分析。
(3)理论分析润滑油的非牛顿流变特性对弹流润滑膜压力分布和油膜形状分布等润滑膜特性的影响,并与经典弹流润滑相关理论进行比较。
(4)理论研究弹流润滑膜厚对滚动速度的依赖偏离经典弹流润滑理论与润滑油非牛顿流变特性的关系。
(5)理论研究弹流润滑膜厚对载荷的依赖偏离经典弹流润滑理论与润滑油非牛顿流变特性的关系。
(6)回归出非牛顿流体弹流润滑膜厚度修正系数公式,在工程应用中,用改修正系数乘以牛顿流体弹流润滑膜厚度,可以非常方便地得到非牛顿流体弹流润滑膜厚度值。
(7)设计专门的实验对本文的相关理论研究结果进行验证。
An early validation of the classical Newtonian elastohydrodynamic lubrication (EHL) film thickness formula found it to be accurate for mineral oils in normal operating conditions but not to be accurate for mineral oils in harsh operating conditions or mineral oil/polymer blends and some synthetic oils. In such condition, the real EHL oil film is much thinner than classical Newtonian EHL theory predicts or even disappears. It was assumed that non-Newtonian rheological properties of lubricants were responsible for films being thinner than predicted by Newtonian theory. Currently theoretical studies on non-Newtonian EHL film failure mainly focus on the effects of operating parameters on EHL characteristics, but results still can not coincide with experimental results. Therefore, the current non-Newtonian EHL theories are still not applicable to lubrication design.
The current paper focuses on the study of non-Newtonian EHL. The influence of shear-thinning and viscoplastic non-Newtonian properties of lubricants on EHL characteristics was mainly studied. The film failure mechanisms of non-Newtonian EHL were studied through theory and experiment, and the relationship of EHL film load-carrying capacity with the lubricant non-Newtonian properties was also studied.
The current paper improves the non-Newtonian fluid EHL analytical approach, and establishes a new kind of theory of isothermal line contact non-Newtonian EHL. The non-Newtonian EHL theory shows that lubricant non-Newtonian rheological properties can directly cause EHL film instability and failure. On the other hand, this paper also put forward new kinds of non-Newtonian EHL experimental approaches. Non-Newtonian EHL theory established in this paper was verified by experiments. It shows that EHL film failure has the relationship with the lubricant non-Newtonian rheological properties. The main research contents are as following:
(1) The current paper put forwards a new non-Newtonian rheological model. The new model includes the following lubricant properties: viscoelastic property, shear-thinning property and plastic property. Whether the new rheological model can reflect lubricant flow properties under EHL operating condition will be verified.
(2) A full numerical analysis for the isothermal line contact EHL is studied based on the new non-Newtonian rheological model.
(3) Influence of non-Newtonian properties on pressure distribution and film shape distribution of EHL is analysized theoretically and compared with classical Newtonian EHL theory.
(4) Influence of non-Newtonian properties on relationship between EHL film thickness and rolling speed is analysized theoretically.
(5) Influence of non-Newtonian properties on relationship between EHL film thickness and load is analysized theoretically.
(6) Correction factor formula to predict EHL film thickness for non-Newtonian lubricants is developed. In practical engineering applications, the film thickness can be easily obtained through the corresponding Newtonian film thickness multiplied by the correction factor.
(7) Special experiments are designed to verify the theoretical results.
引文
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