车辆传动系统密封环局部高温热点的热失稳建模研究

根据车辆传动系统密封环的服役特征,提出了一种密封环局部高温热点的热失稳有限元建模方法,可以用来计算密封环发生局部高温热点的临界速度。构建了密封温度存在扰动形式的表达式,基于伽辽金有限元算法,建立密封环局部高温热点的热失稳有限元模型,处理密封系统的热结构耦合关系,形成了密封环局部高温热点临界速度的计算方法。以铜基粉末冶金和灰铸铁密封环为例,计算了不同摩擦因数条件下发生高温热点的临界速度,并考察了临界速度与材料弹性模量、热导率、比热容、热膨胀系数的定量关系。利用自主开发设计的密封性能试验台进行密封热失稳试验研究,设计了密封环热失稳的试验方法,观测了两种密封材料温升及其扰动迁移情况,试验结果与模拟计算结果具有一致性,表明了密封环局部高温热点模拟方法的有效性。     

旋转密封两种热失稳现象的表征建模与特性研究

在车辆传动系统中的密封环,热失稳现象明显,为掌握热失稳的形成规律和影响机制,针对不同材料的密封环,进行热失稳建模计算与试验研究。根据密封环热失稳现象的特点,分别对局部高温热带和高温热点两种热失稳现象进行建模,基于伽辽金有限元方法,构建热-结构的耦合模型,把非均匀分布物理场及其扰动问题,转换为矩阵行列式进行求解,获得了不同密封材料发生热失稳的临界速度值。随着摩擦因数的增大,密封材料热失稳的临界速度值有下降的趋势。利用自主设计的密封环试验台进行试验分析和模型验证,设计了密封环局部高温热带和热点的试验验证方法,考察了聚酰亚胺和铜基粉末冶金材料密封环的热失稳试验过程,试验与计算结果具有一致性。对试验后的密封环,通过扫描电子显微镜观察密封表面形貌,符合局部高温热带和热点的特征,表明了密封环热失稳建模计算的有效性。     

等温密封环粗糙表面微观动态接触离散建模与状态分析

根据密封环的结构形式和服役特点,提出在微观尺度内密封环动态接触过程的离散建模方法。基于移动元胞自动机算法,结合复合材料密封环多种组成材料的特点,对密封摩擦副两粗糙表面局部接触区域进行离散建模。根据实际的工况条件加载相应载荷,通过可视化的模拟过程获得密封接触面微观动态响应,表达出磨损颗粒和润滑油组成的机械混合层的形成与演变过程,研究表明机械混合层对密封动态接触有显著影响,在混合摩擦过程中起到流体润滑和固体润滑的双重效果;同时定量模拟密封接触表面颗粒的旋转角和速度场,分析微观磨损颗粒运动规律;模拟计算获得瞬态摩擦因数曲线及其拟合曲线,通过与实测数据对比发现具有较高吻合度。表明微观动态接触离散模型在密封接触研究方面的适用性,是密封及其相关摩擦副微观接触状态分析的有效方法。     

基于ANSYS的高压机械密封温度场理论研究

根据热平衡方程推导出高压机械密封中的温升计算公式,并建立了机械密封件温度场的有限元模型,利用ANSYS分析软件求解密封环内部各节点的温度。根据温度场分布图,对影响密封环热影响的主要因素进行了讨论。结果表明:密封端面温度最高且靠近内径方向,应通过改善散热和加强冷却防止因摩擦热使正常压力下的液膜流体达到沸点并汽化;密封介质压力、密封端面的平均直径和转速的增加都会使摩擦热增加,从而使密封端面温度升高;不同密封介质的摩擦因数和传热系数会造成不同的温升;导热率越高扩散热量也就越多,选择导热率高的密封材料能有效地降低密封环温度。     

船舶艉轴机械密封温度场与热变形分析

船舶艉轴机械密封在运转时,密封环端面温度的分布及热变形对密封的泄漏有重要的影响。为了提高机械密封的密封性,采用有限元分析方法,运用整体法和分离法对机械密封的动、静环的温度场、热变形进行分析,研究在不同主轴转速下端面温度的变化情况。分析表明:机械密封端面的最高温度出现在接触区域的中间,并向内、外两侧递减;端面摩擦热与主轴的转速有密切的关系,转速越大,产生热量越多,温度越高;密封环的导热系数也对端面温度也有影响,导热系数越高,端面最高温度会越低;端面热变形量内径处大于外径处。     

热力变形下渣浆泵机械密封干摩擦磨损分析

机械密封在起停阶段或操作失误时常处于干摩擦状态,由此导致的热损伤与磨损将影响其密封性能。以某YWN8合金接触式机械密封为研究对象,建立基于硬度及磨损系数的磨损数值模型,试验测定摩擦副密封环的硬度、磨损系数、干摩擦因数,验证磨损数值模型的准确性;对机械密封磨损进行仿真模拟,研究摩擦副密封环在干摩擦运转时单力场及热力变形下的磨损深度,并用磨损理论值进行验证。结果表明：干摩擦运转时密封环端面温升较低,温度不是其失效的主要原因;热力变形后密封环内外径间隙增大,造成端面粗糙峰接触面积减小,黏着磨损较变形前呈下降趋势,导致多物理场下的磨损深度与理论值不符。     

等温密封环摩擦状态演变预测与试验研究

结合浮动密封环的工作特点,提出一种基于载荷分配概念的密封摩擦状态演变预测模型。设定载荷分配系数,对粗糙表面微凸体接触和流体润滑接触两个部分摩擦力进行建模计算,根据微凸体承载力和总承载力等参数信息获得总摩擦因数值。模拟计算获得反映密封接触特性的摩擦因数与转速、压力以及表面粗糙度的关系曲线,仿真曲线历经完整的摩擦与润滑区,能够对不同摩擦状态下的接触特性进行预测。利用密封系统试验台对模型进行分析和验证,结果表明两者变化趋势保持一致,具有共同特征,说明密封摩擦预测模型能够真实反映密封摩擦副的接触规律及其变化情况,是预测密封摩擦状态的有效方法。     

高温蒸汽风机用机械密封的研制

风机输送介质为高温蒸汽,主机内高温通过热传导导入密封环的热量、密封运转过程中产生的摩擦热和搅拌热综合引起密封端面温度升高,避免密封端面出现闪蒸现象,采用水作为冲洗液进行冲洗以控制密封环温度分布。在力和热的作用下,密封环产生变形,对密封环端面受力和热引起的变形进行计算预估,减少密封泄漏量,延长密封使用寿命。通过理论分析与试验验证相结合的方法,设计出适用于该风机的集装式、双端面、平衡型结构机械密封,完全满足现场使用要求。     

油泵用机械密封摩擦副界面热-结构耦合分析

以热-结构耦合数值计算理论为基础,同时施加温度和力载荷边界条件,对处于高速、高压等高参数极端工况热油泵用波纹管机械密封装置摩擦副界面进行了热-结构耦合数值建模与计算分析。研究了密封环摩擦副界面的温度场特点及温度、热应力分布规律,分析了密封环在温度载荷和力载荷耦合作用下密封环的变形情况。结果表明:最高温度产生在摩擦副内径处,最大热变形在摩擦副外径处;动静环配对材料的导热系数越大,产生的最高温度就越小;在摩擦副的外径侧产生的变形有利于形成收敛型间隙。     

基于Pro/E平台下的机械密封热变形分析

利用Pro/E的热力学分析对机械密封的动环进行有限元分析,通过对密封环摩擦热、搅拌热等因素的分析计算,分析密封环端面温度对密封环结构变形的影响。结果表明:内流式机械密封端面温度径向呈近似抛物线分布;密封环内的温度梯度使密封环产生热变形,导致形成圆锥型的端面;热变形会使密封环产生内应力。     

二维轴对称摩擦制动器瞬态热弹性失稳的研究

提出考虑摩擦层闸片厚度的影响,建立二维轴对称摩擦制动器热弹性失稳的数学模型。基于扰动分析法,推导摩擦副的温度场扰动以及不同热点分布模式下的热特征平衡方程。研究临界速度和扰动增长系数的变化规律。计算摩擦面瞬态名义温度随制动时间的变化关系。分析和比较不同摩擦副厚度比、热导率、弹性模量、比热容以及热膨胀系数对系统稳定性的影响。结果表明,当热点呈反对称分布时,系统发生热弹性失稳时所需的最低临界速度远低于对称分布模式,临界速度随扰动频率的增加呈先减小后增加的变化趋势。不同扰动频率对应的扰动增长系数随滑动速度近似呈线性增加,最低临界扰动频率对应的扰动增长系数最大。当扰动频率低于临界扰动值时,温度随扰动频率的增加而增加,反之,则降低。增加摩擦副的厚度、摩擦层闸片的热导率和比热容以及减小滑动层制动盘的热导率和热膨胀系数和摩擦层闸片的弹性模量均可以提高滑动摩擦系统的稳定性。     

Effect of convective cooling on frictionally excited thermoelastic instability

The effect of convective cooling on thermoelastic instability is evaluated using a finite element analysis. This is achieved by inserting a thermal convection term to the frictional heat generation in the formulation. It has been found that the convection or radiation heat dissipation can stabilize the thermal–mechanical feedback process, leading to a raised critical sliding velocity. Two representative models for brake and clutch systems are studied. The computational results reveal that the effect of thermal convection on the critical sliding speed is significant for liquid cooling (e.g. water, lubricants), but negligible for air convection. With the practical range of the convection coefficient estimated from the fundamental heat transfer theories, the critical speed in the presence of convection can be raised by two to three times as much as the original value. However, the wave number for the lowest critical speed remains almost unchanged regardless of the convective dissipation. The comparisons between linear and quadratic finite element interpolations are also made via a set of convergence studies. The results show that implementing quadratic elements in the friction layer has an obvious advantage over linear elements due to the rapid oscillations of the temperature across the thermal skin layer. This is particularly important in future studies when the problems in higher dimensions are of interest.     

斯特林机活塞杆帽式组合密封动密封性能分析

为研究斯特林发动机活塞杆无油润滑帽式组合密封的动密封性能,利用有限元分析软件Abaqus建立帽式密封的二维轴对称有限元模型,基于系统实际工况,研究工质压力对帽式密封性能的影响,得到不同压力下的有效密封区域。静态密封性能分析结果表明,帽式密封环与活塞杆的接触应力是密封的关键,动态密封性能分析结果表明,两者接触应力和密封区域随压力增大而增大,且外行程接触应力略大于内行程。通过热力耦合动态仿真模拟,分析环境温度、摩擦因数、往复运动速度对动密封性能的影响。结果表明:环境温度对帽式密封温度场影响不大,热源主要来自摩擦热;往复运动速度对其密封性能影响也不大,而摩擦因数的影响较大,摩擦因数越小,帽式密封的密封效果越好,使用寿命越长。     

Effect of the volume of a functionally graded material layer on frictionally excited thermoelastic instability

A finite element model is used to identify the effect of the volume of a functionally graded material (FGM) on thermoelastic instability (TEI). An optimal FGM volume that exhibits the highest critical speed was found to exist. Beyond the optimal FGM volume, the critical speed is much lower than that of a homogeneous steel layer. For all FGM volumes, the performance against TEI is dominant for the same nonhomogeneous parameter, which determines the compositional shape of the material property grading in the FGM. In addition, the thermal conductivity of the frictional material and the modulus of elasticity of the FGM were found to have the most significant impact on an increase in the critical speed.     

机械密封环的传热特性分析

研究机械密封端面摩擦热在动环、静环、端面间液膜和密封介质组成的传热系统中的传递规律。按换热面积守恒的原则将密封环简化为当量圆筒,提出动环和静环获得的摩擦热的计算方法,推导密封环的温度分布方程。结果表明,液膜摩擦热量随角频率的增加和平均膜厚的减小而增加。绝大部分摩擦热通过动环传递到介质,静环端面的温升较小。动环靠近介质侧的温度低于空气侧的温度,端面上的温度较高,且端面径向存在温度梯度。增大动环与介质的接触面积或选用热导率大的材料可降低动环上的最高温度和端面上内外径处的温差,提高机械密封的性能。     

Observations of thermoelastic instability in mechanical face seals

Sliding contact between the primary and mating rings of a mechanical seal will result in the generation of frictional heat. In some cases this resulting frictional heat will lead to a condition of thermoelastic instability of the sealing planes. Various field and laboratory cases are reviewed with respect to the development of surface disturbances at the seal interface. The effect of interface cooling on the sealing planes is also shown.     

Stability analysis of a rotating multi-layer annular plate with a stationary frictional follower load

This paper is concerned with examining the critical rotational speeds of a annular laminated disk and instability due to the existence of a stationary frictional follower load. A refined higher order layerwise zigzag theory (RHOT) is used to derive the governing equations of motion of a laminated disk. A four-node sector finite element incorporating RHOT is developed and applied for the stability analysis of a rotating multi-layer disk. The critical rotational speeds of a laminated disk made of isotropic layers and a laminated disk made of polar—orthotropic layers are calculated using the state—space method with respect to a moving frame and an inertial frame. The effect of a frictional follower load on the system stability is investigated using the frequency—speed diagram and the state—space method. It is found that the frictional follower load makes all forward modes with nodal diameters unstable over the entire rotational speed range. Total Lagrangian kinematics with the modified Newton method is used in the solution finding procedure.     

Numerical modeling of the thermal contact in metal forming processes

Heat flow across the interface of solid bodies in contact is an important aspect in several engineering applications. This work presents a finite element model for the analysis of thermal contact, which takes into account the effect of contact pressure and gap dimension in the heat flow across the interface between two bodies. Additionally, the frictional heat generation is also addressed, which is dictated by the contact forces predicted by the mechanical problem. The frictional contact problem and thermal problem are formulated in the frame of the finite element method. A new law is proposed to define the interfacial heat transfer coefficient (IHTC) as a function of the contact pressure and gap distance, enabling a smooth transition between two contact status (gap and contact). The staggered scheme used as coupling strategy to solve the thermomechanical problem is briefly presented. Four numerical examples are presented to validate the finite element model and highlight the importance of the proposed law on the predicted temperature.     

Frictionally excited thermoelastic instability in a thin layer of functionally graded material sliding between two half-planes

Frictionally excited thermoelastic instability (TEI) is investigated in the system of a layer of finite thickness which is composed of functionally graded material (FGM), sliding against two homogeneous frictional materials of half-planes at speed V. Results show that ceramic-based FGM, which is composed of ceramic at the sliding interface and steel at the middle of the layer, reduces the susceptibility towards TEI. The effect of nonhomogeneous parameters of FGM on critical speed is investigated for the several combinations of FGM such as steel- or ceramic-based FGM with positive and negative nonhomogeneous parameters, respectively. The material sensitivity to the critical speed for the nonhomogeneous parameter of FGM shows that the nonhomogeneous parameters of the thermal expansion coefficient are strong influential factors in ceramic- or steel-based FGM. The transient evolution of temperature perturbation is also obtained to determine the susceptibility towards hot spotting, showing that the ceramic-based FGM with negative nonhomogeneous parameters has the lowest temperature perturbation amplitude during engagement.     

螺旋槽机械密封泄漏率的控制方法

流体润滑的螺旋槽机械密封环端面在液膜摩擦热的作用下发生变形并构成径向楔形间隙。考虑液膜粘度随温度的变化，建立了液膜流动、密封环传热和热变形的耦合分析方法，依据该方法确定了与给定闭合力对应的端面间隙形式及泄漏率。研究表明，可通过调节闭合力可实现对泄漏率的控制；闭合力越大，液膜厚度越小，摩擦扭矩越大，泄漏率越小。