内外膜独立供油径推联合浮环轴承性能分析与实验研究
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摘要
动静压滑动轴承具有摩擦功耗低、精度高、寿命长、稳定性好等突出优点,在航空航天、发电设备及精密加工机床等高速、超高速旋转机械上具有良好的应用前景。汽车发动机、底盘以及零部件制造的高速、高精度机床主轴系统也广泛地采用各类滑动轴承。而动静压浮环轴承是提高轴承-转子系统转速的有效手段,受到国内外学术界和企业界的高度重视。目前的动静压浮环轴承大多采用内外膜统一供油方式和外部节流器,内外膜供油压力不能单独调节,难以充分发挥其优越性。如果采用内外膜独立供油,将有助于调节轴承-转子系统的特性,但内外膜独立供油动静压浮环轴承的性能和系统稳定性受到轴承结构、供油压力变化及深腔中气穴的影响。如何设计这种新型轴承结构,如何实现轴承系统的合理建模及分析各参数对轴承性能的影响规律是改善轴承性能的基础。
本文以径向-推力联合浮环动静压轴承为研究对象,采用圆台柱销内反馈节流方式,提出新型的内外膜独立供油径推浮环轴承结构形式;采用流体动力学和有限元方法,建立径推浮环轴承静动特性仿真模型;以此为基础,分析供油压力、气穴等参数对轴承性能的影响规律;为了验证新型结构和建模方法的合理性,开发了可实现内外膜独立供油的径推浮环轴承-转子实验台并进行了实验。研究工作主要包括以下三个方面:
(1)新型内外膜独立供油径向-推力联合浮环轴承结构设计
针对圆柱轴承不能承受轴向载荷而圆锥轴承受锥角限制轴向载荷不宜过大的问题,本文采用径推联合浮环轴承,提高了结构紧凑性,可同时承受径向和轴向载荷,避免了额外的轴向限位;针对统一供油浮环轴承内外膜相互制约的问题,提出了内外膜独立供油的新结构,为实现内外膜压力的单独调节进而提高油膜动态性能打下了基础;针对传统内部节流器节流腔面积大、功耗高的问题,提出了新型圆台柱销内部节流方式,有效地减少了节流腔的面积,在不增加轴承尺寸的情况下降低内部节流的功耗,且避免了小孔、毛细管等外部节流器易于引起的油路堵塞。
(2)内外膜独立供油径推浮环轴承静动态特性仿真建模及稳定性分析
本文从层流理论的Navier-Stokes方程出发,推导出独立供油时径推浮环轴承内外膜的控制方程,建立了基于有限元法的轴承静动态特性分析方法。在此基础上,分析了轴承静动特性随供油压力、偏心率、转速等设计参数的变化规律。结果表明:该轴承的摩擦功耗等静特性参数对供油压力的变化不敏感,但动特性参数对供油压力的变化敏感度较高。
针对高速运转时径推联合浮环轴承稳定性问题,建立了计入轴颈质量和浮环质量的内外膜动力学模型,采用Routh-Hurwitz稳定性判别准则,推导了计入浮环质量的径推联合浮环轴承三维稳定性判别准则,确定了浮环轴承的稳定工作区域,研究了内外膜供油压力对轴承稳定性的影响。在此基础上,设计了一种供油压力反馈控制装置,为通过调整内外膜供油压力来控制轴承-转子系统的稳定性提供了参考。
针对内外膜供油压力的改变导致浮环轴承油腔(尤其是深腔)出现气穴的问题,根据气液两相流理论,导出了考虑气穴的径推联合浮环轴承内外膜的变密度变粘度无量纲动态Reynolds方程和深腔流量平衡方程,分析了不同转速和不同偏心率下含气率分别为0和0.1时轴承的静动态性能。结果表明:小偏心率时深腔气穴对轴承性能影响较为明显,而随着偏心率的增大及转速的提高,气穴的影响程度降低。
(3)内外膜独立供油径推联合动静压浮环轴承-转子实验
在上述理论分析的基础上,确定了径推联合浮环实验轴承设计参数,建立了能实现内外膜独立供油的径推联合浮环轴承-转子系统的实验台,提出了独立供油工况下内外膜参数的测量方法,通过实验测试了该轴承的压力分布、承载力、摩擦力矩、流量、温升等静特性参数,采用三次激振法测定了实验轴承的刚度、阻尼等动特性参数,通过理论结果与实验结果的比较,验证了本文建模方法的有效性。所开发的径推浮环动静压轴承完成了38000 rpm的现场试车实验。
理论分析和实验结果表明,独立供油径推浮环动静压轴承具有结构紧凑、易于调整、启动停车方便、摩擦功耗低、稳定性好等优点,和圆锥轴承相比可承受更大的轴向力。独立供油的结构使得高速、超高速在线控制轴承的稳定性成为可能,对浮环动静压轴承的设计具有较好的指导作用。
Externally pressurized hydrostatic/hydrodynamic bearings have become increasingly popular in many super high speed machines such as astronavigation, generators and high speed processing machine tool due to their remarkable characteristics in respect of low friction, high accuracy, long life, smooth operation, high fluid film stiffness, damping capacity etc. Hybrid bearings are also widely used in many vehicle components such as engine crankshaft, drive system, steering system and chassis. Adopting floating ring hybrid bearing is the effective method to increase the rotational speed of rotor-bearing system. Among most hybrid bearings in common use, the external restrictors are used and the oil is supplied both to the inner fluid film and the outer fluid film. Therefore the external restrictors are easy to be plugged and the inner and outer oil supply pressure can not be adjusted independently. The performance of rotor-bearing system can be controlled if the oil is supplied respectively to the inner fluid film and the outer fluid film independently. How to design the new structure bearing and how to build the model and analyze the influence of parameters on bearing characteristics is the base to improve the bearing performance.
This paper presents a theoretical and experimental study concerning the static and dynamic performance of hybrid journal-thrust floating ring bearing with inner and outer fluid film independent oil supply. A new structure fluid lubricated floating ring hybrid bearing compensated by interior round pin restrictor is designed. The static and dynamic characteristics model of the journal-thrust floating ring hybrid bearing was established with finite element method (FEM) simulation. The influences of oil supply pressure, cavitations on bearing performance are analyzed. In order to verify the rationality of new structure and simulation model, the experimental rig with independently oil supply is established. This dissertation focuses on the following three aspects:
(1) The structure design of journal-thrust floating ring hybrid bearing with independent oil supply
The cylindrical hybrid bearings have no axial load carrying capacity and the conical bearing can support limited axial load due to conical angle. While the journal-thrust hybrid bearing combines the advantages of journal bearing and thrust bearing and can support great radial and axial loads at the same time. A new structure fluid lubricated hybrid bearing with independent oil supply is designed in order to adjust and improve the bearing dynamic performance. The new structure interior round pin restrictor which can reduce the restrictor pocket area and decrease friction power loss without increasing the bearing size and can avoid blockage effectively is studied in detail.
(2) The static and dynamic performance simulation model and stability analysis of journal-thrust floating ring bearing with independent oil supply
Bases on laminar current theory, the equations governing the flow of inner and outer fluid film in the journal-thrust floating ring bearing are established with FEM simulation. The variation regularity of static and dynamic performance with oil supply pressure, eccentricity and rotational speed are analyzed. It can be seen from the results that the static characteristics coefficients are not sensitive to oil supply pressure, but the dynamic characteristics parameters varies obviously with oil supply pressure.
The stability is very important for the high speed rotational system. The dynamic simulation model for inner and outer fluid film is established separately considering the shaft mass and floating ring mass. The three dimension stability criterion is deduced using Routh-Hurwitz stability criterion. On the base of theoretically analysis, a set of oil supply feedback device is designed in order to control the stability of rotor-bearing system on line.
The change of oil supply pressure will bring bubbles to the bearing pockets, especially in deep pockets. The dimensionless Reynolds equations of the variable density and viscosity with inertia term which govern the inner and outer film of this hybrid floating-ring bearing are developed. The static and dynamic characteristics coefficients with air rate 0 and 0.1 of this bearing are obtained under different eccentricity and rotational speed. It can be seen from the results that the performance varied obviously due to cavitations under small eccentricity. With the increase of eccentricity or rotational speed, the influences of cavitations weaken.
(3) Experiment study of journal-thrust floating ring hybrid bearing
Based on above theoretical analysis, the appropriate structure parameters of journal-thrust floating ring bearing are determined and a delicate test rig with independent oil supply is constructed. The pressure distribution, load carrying capability, friction moment, and volume flow rate are measured under different operating conditions. The stiffness and damping coefficients of the bearing are measured using impulse excitation method and compared with theoretical calculation results. So the validity of simulation model is verified. The journal-thrust floating ring hybrid bearing is applied to a certain turbine expansion unit and runs steadily over 38000 rpm.
Numerical results and experimental results show that the journal-thrust floating ring bearing with independent oil supply has the advantages of low friction, high stability and easy being controlled. It can bear great axial load compared with conical bearing. Also it is possible to control the stability of high speed bearing on line with independent oil supply structure. Above all, the research fruits in this dissertation have important value to guide the design of floating ring bearing.
本文以径向-推力联合浮环动静压轴承为研究对象,采用圆台柱销内反馈节流方式,提出新型的内外膜独立供油径推浮环轴承结构形式;采用流体动力学和有限元方法,建立径推浮环轴承静动特性仿真模型;以此为基础,分析供油压力、气穴等参数对轴承性能的影响规律;为了验证新型结构和建模方法的合理性,开发了可实现内外膜独立供油的径推浮环轴承-转子实验台并进行了实验。研究工作主要包括以下三个方面:
(1)新型内外膜独立供油径向-推力联合浮环轴承结构设计
针对圆柱轴承不能承受轴向载荷而圆锥轴承受锥角限制轴向载荷不宜过大的问题,本文采用径推联合浮环轴承,提高了结构紧凑性,可同时承受径向和轴向载荷,避免了额外的轴向限位;针对统一供油浮环轴承内外膜相互制约的问题,提出了内外膜独立供油的新结构,为实现内外膜压力的单独调节进而提高油膜动态性能打下了基础;针对传统内部节流器节流腔面积大、功耗高的问题,提出了新型圆台柱销内部节流方式,有效地减少了节流腔的面积,在不增加轴承尺寸的情况下降低内部节流的功耗,且避免了小孔、毛细管等外部节流器易于引起的油路堵塞。
(2)内外膜独立供油径推浮环轴承静动态特性仿真建模及稳定性分析
本文从层流理论的Navier-Stokes方程出发,推导出独立供油时径推浮环轴承内外膜的控制方程,建立了基于有限元法的轴承静动态特性分析方法。在此基础上,分析了轴承静动特性随供油压力、偏心率、转速等设计参数的变化规律。结果表明:该轴承的摩擦功耗等静特性参数对供油压力的变化不敏感,但动特性参数对供油压力的变化敏感度较高。
针对高速运转时径推联合浮环轴承稳定性问题,建立了计入轴颈质量和浮环质量的内外膜动力学模型,采用Routh-Hurwitz稳定性判别准则,推导了计入浮环质量的径推联合浮环轴承三维稳定性判别准则,确定了浮环轴承的稳定工作区域,研究了内外膜供油压力对轴承稳定性的影响。在此基础上,设计了一种供油压力反馈控制装置,为通过调整内外膜供油压力来控制轴承-转子系统的稳定性提供了参考。
针对内外膜供油压力的改变导致浮环轴承油腔(尤其是深腔)出现气穴的问题,根据气液两相流理论,导出了考虑气穴的径推联合浮环轴承内外膜的变密度变粘度无量纲动态Reynolds方程和深腔流量平衡方程,分析了不同转速和不同偏心率下含气率分别为0和0.1时轴承的静动态性能。结果表明:小偏心率时深腔气穴对轴承性能影响较为明显,而随着偏心率的增大及转速的提高,气穴的影响程度降低。
(3)内外膜独立供油径推联合动静压浮环轴承-转子实验
在上述理论分析的基础上,确定了径推联合浮环实验轴承设计参数,建立了能实现内外膜独立供油的径推联合浮环轴承-转子系统的实验台,提出了独立供油工况下内外膜参数的测量方法,通过实验测试了该轴承的压力分布、承载力、摩擦力矩、流量、温升等静特性参数,采用三次激振法测定了实验轴承的刚度、阻尼等动特性参数,通过理论结果与实验结果的比较,验证了本文建模方法的有效性。所开发的径推浮环动静压轴承完成了38000 rpm的现场试车实验。
理论分析和实验结果表明,独立供油径推浮环动静压轴承具有结构紧凑、易于调整、启动停车方便、摩擦功耗低、稳定性好等优点,和圆锥轴承相比可承受更大的轴向力。独立供油的结构使得高速、超高速在线控制轴承的稳定性成为可能,对浮环动静压轴承的设计具有较好的指导作用。
Externally pressurized hydrostatic/hydrodynamic bearings have become increasingly popular in many super high speed machines such as astronavigation, generators and high speed processing machine tool due to their remarkable characteristics in respect of low friction, high accuracy, long life, smooth operation, high fluid film stiffness, damping capacity etc. Hybrid bearings are also widely used in many vehicle components such as engine crankshaft, drive system, steering system and chassis. Adopting floating ring hybrid bearing is the effective method to increase the rotational speed of rotor-bearing system. Among most hybrid bearings in common use, the external restrictors are used and the oil is supplied both to the inner fluid film and the outer fluid film. Therefore the external restrictors are easy to be plugged and the inner and outer oil supply pressure can not be adjusted independently. The performance of rotor-bearing system can be controlled if the oil is supplied respectively to the inner fluid film and the outer fluid film independently. How to design the new structure bearing and how to build the model and analyze the influence of parameters on bearing characteristics is the base to improve the bearing performance.
This paper presents a theoretical and experimental study concerning the static and dynamic performance of hybrid journal-thrust floating ring bearing with inner and outer fluid film independent oil supply. A new structure fluid lubricated floating ring hybrid bearing compensated by interior round pin restrictor is designed. The static and dynamic characteristics model of the journal-thrust floating ring hybrid bearing was established with finite element method (FEM) simulation. The influences of oil supply pressure, cavitations on bearing performance are analyzed. In order to verify the rationality of new structure and simulation model, the experimental rig with independently oil supply is established. This dissertation focuses on the following three aspects:
(1) The structure design of journal-thrust floating ring hybrid bearing with independent oil supply
The cylindrical hybrid bearings have no axial load carrying capacity and the conical bearing can support limited axial load due to conical angle. While the journal-thrust hybrid bearing combines the advantages of journal bearing and thrust bearing and can support great radial and axial loads at the same time. A new structure fluid lubricated hybrid bearing with independent oil supply is designed in order to adjust and improve the bearing dynamic performance. The new structure interior round pin restrictor which can reduce the restrictor pocket area and decrease friction power loss without increasing the bearing size and can avoid blockage effectively is studied in detail.
(2) The static and dynamic performance simulation model and stability analysis of journal-thrust floating ring bearing with independent oil supply
Bases on laminar current theory, the equations governing the flow of inner and outer fluid film in the journal-thrust floating ring bearing are established with FEM simulation. The variation regularity of static and dynamic performance with oil supply pressure, eccentricity and rotational speed are analyzed. It can be seen from the results that the static characteristics coefficients are not sensitive to oil supply pressure, but the dynamic characteristics parameters varies obviously with oil supply pressure.
The stability is very important for the high speed rotational system. The dynamic simulation model for inner and outer fluid film is established separately considering the shaft mass and floating ring mass. The three dimension stability criterion is deduced using Routh-Hurwitz stability criterion. On the base of theoretically analysis, a set of oil supply feedback device is designed in order to control the stability of rotor-bearing system on line.
The change of oil supply pressure will bring bubbles to the bearing pockets, especially in deep pockets. The dimensionless Reynolds equations of the variable density and viscosity with inertia term which govern the inner and outer film of this hybrid floating-ring bearing are developed. The static and dynamic characteristics coefficients with air rate 0 and 0.1 of this bearing are obtained under different eccentricity and rotational speed. It can be seen from the results that the performance varied obviously due to cavitations under small eccentricity. With the increase of eccentricity or rotational speed, the influences of cavitations weaken.
(3) Experiment study of journal-thrust floating ring hybrid bearing
Based on above theoretical analysis, the appropriate structure parameters of journal-thrust floating ring bearing are determined and a delicate test rig with independent oil supply is constructed. The pressure distribution, load carrying capability, friction moment, and volume flow rate are measured under different operating conditions. The stiffness and damping coefficients of the bearing are measured using impulse excitation method and compared with theoretical calculation results. So the validity of simulation model is verified. The journal-thrust floating ring hybrid bearing is applied to a certain turbine expansion unit and runs steadily over 38000 rpm.
Numerical results and experimental results show that the journal-thrust floating ring bearing with independent oil supply has the advantages of low friction, high stability and easy being controlled. It can bear great axial load compared with conical bearing. Also it is possible to control the stability of high speed bearing on line with independent oil supply structure. Above all, the research fruits in this dissertation have important value to guide the design of floating ring bearing.
引文
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