沟槽形表面织构对摩擦噪声的影响

用电加工方法在制动盘蠕墨铸铁材料表面加工出沟槽形表面织构(沟槽深度为30μm、宽度为150μm、间距为500μm),采用球—平面接触方式,选取直径为10mm的Si3N4球为对磨副,对沟槽形织构表面和光滑表面进行了摩擦噪声对比试验,研究了沟槽形表面织构对界面摩擦振动噪声的影响。试验结果表明(以下结论只针对本试验选定尺寸规格的沟槽形表面织构):法向载荷对织构表面产生摩擦噪声强度的影响较小,而对光滑表面产生摩擦噪声的水平具有重要影响;沟槽形织构表面在低法向载荷下较光滑表面更易产生摩擦噪声,但随着法向载荷从5N增大到10N,光滑表面产生的摩擦噪声强度迅速增大并与织构表面的接近;沟槽形表面织构使摩擦系统更易产生多频率的摩擦振动,较早地产生摩擦噪声且其主频率成分较复杂;沟槽形织构表面比光滑表面具有较高的摩擦因数和耐磨性,沟槽形织构的存在明显地改变了接触界面摩擦磨损行为和摩擦噪声特性,但其对应关系需要进一步深入研究。     

沟槽和圆坑织构抑制摩擦尖叫噪声研究

在列车制动盘试样表面加工出不同宽度的发散型沟槽织构和不同直径与间距的发散型圆坑织构后,将其与光滑表面进行摩擦噪声对比试验,并利用数值分析方法进行模拟分析,研究织构表面对摩擦尖叫噪声特性的影响及作用机理。结果表明,两种织构表面均能降低摩擦系统高频尖叫噪声,且尺寸分布合理的沟槽织构能明显地抑制噪声的产生。利用数值分析方法能较好地揭示织构影响界面摩擦噪声的机理,即对摩材料滑过织构表面并碰击其棱边时,所产生的作用力能起到主动控制界面摩擦噪声的作用,且能抑制某些特定频率的尖叫噪声的产生。     

滑动摩擦振动噪声的非线性显式动力学分析

利用有限元软件ABAQUS/Explicit(显式动态求解器)对球-平面接触条件下的滑动摩擦振动噪声进行了数值模拟分析。对比试验结果,探讨了摩擦噪声的发生机制,并分析了摩擦噪声发生时接触界面的运动特性。结果表明,摩擦噪声主要是由摩擦系统的自激振动引起的,法向振动与切向振动的耦合是系统产生自激振动和摩擦噪声的一个重要因素。当摩擦系统发生自激振动时,从面节点与主面的接触并不是连续不变的,两者在相对运动的过程中具有黏着-滑动-分离-黏着的特性。     

基于销/盘试验机的摩擦噪声试验与仿真研究

为了研究摩擦噪声的产生机制和影响因素,利用销/盘试验机对以转子式压缩机曲轴-法兰材料制成的销/盘试样进行摩擦噪声试验研究;应用ABAQUS有限元软件,建立销/盘试验机有限元模型,利用复特征值分析方法预测该系统摩擦噪声的主频,并与试验结果进行对比;讨论相关参数对系统的稳定性和摩擦噪声的影响。结果表明：销与盘法向和横向振动的耦合是引起系统自激振动和摩擦噪声的重要因素;当系统摩擦界面处的摩擦因数大于系统临界摩擦因数时,系统开始出现不稳定振动,且摩擦因数越大,系统越不稳定,越易出现摩擦噪声;法向载荷对系统稳定性的影响不大;选择具有合适弹性模量的摩擦副材料可以抑制摩擦噪声的产生。     

制动盘非光滑仿生表面对制动摩擦尖叫行为影响的研究

加工出3种非光滑仿生表面制动盘,即表面沟槽盘、表面圆坑盘和表面沟槽圆坑盘,利用有限元软件ABAQUS对3种非光滑仿生表面制动盘进行制动摩擦尖叫行为有限元分析,并与光滑制动盘进行对比。结果表明,制动器的振动模态主要表现为制动盘的面内和面外振动,并伴随有制动夹钳以及摩擦片的弯曲扭转运动。利用复特征值法计算系统尖叫倾向性系数后发现,制动盘表面经过非光滑仿生处理后,制动器的摩擦尖叫倾向性发生了明显改变,表面沟槽圆坑盘抑制尖叫的效果最佳,而表面沟槽盘在三者之中抑制尖叫的效果最弱。进一步采用瞬时动态分析对结果进行验证,结果表明:制动盘表面经过非光滑仿生处理后,系统振动加速度信号、弹性位移信号以及界面力信号的强度均有所降低,且表面沟槽圆坑盘在降低系统振动强度方面效果最为显著,系统稳定性得到明显提高;但是,由于沟槽和圆坑的棱边可能会形成应力集中区,因此可以采用抛光、打磨等方式对棱边进行一定处理,以提高表面使用寿命。     

汽车离合器接合过程中的摩擦振动行为分析

建立了离合器摩擦系统全尺寸模型,基于有限元软件ABAQUS的复特征值分析法和瞬时动态分析法研究了离合器接合过程中的摩擦振动现象,探讨了界面参数对离合器稳定性的影响和作用机理。结果表明,离合器接合过程中的振动模态主要表现为摩擦片的面外振动,通过削弱界面黏滑运动、提高界面摩擦因数和在摩擦片表面加工沟槽等手段能有效地改善摩擦振动,增强离合器接合稳定性。     

沟槽微织构硬质合金刀具的摩擦仿真分析

在硬质合金刀具表面加工微织构已成为减摩抗磨最有效的技术之一.为了分析表面微织构的几何参数对硬质合金刀具表面的减摩机理,利用ABAQUS有限元软件对微织构刀具表面的摩擦磨损过程进行模拟仿真,研究不同宽度、深度和间距的微织构参数对刀具摩擦过程中应力分布的影响.仿真模拟表明,硬质合金刀具表面的微织构可通过改变应力分布来改善应...     

沟槽型织构表面对界面摩擦学行为的作用机制

在球-盘接触状态下,研究具有不同宽度的沟槽型织构表面对界面摩擦学特性的影响,并揭示沟槽型织构表面对界面摩擦学行为的作用机制。试验结果表明:沟槽型织构表面显著地改变界面的摩擦学行为,特定尺寸参数的沟槽型织构表面能有效改善界面的摩擦磨损特性;沟槽的存在改变摩擦界面的接触状态,从而引起界面的法向位移和法向力信号产生突变;具有合理尺寸参数的沟槽型织构表面,能充分捕获界面的磨屑,避免对摩试样之间产生强烈的撞击作用,从而有效地改善界面摩擦学行为。     

制动片表面沟槽结构对盘式制动器热机耦合特性的影响

基于热-位移瞬态分析法,利用ABAQUS有限元软件建立盘式制动有限元模型,研究车辆在制动过程中制动片和制动盘的温度分布特性和振动行为。同时,在制动片摩擦面设计出3种不同分布的沟槽结构,研究沟槽分布对制动器热机耦合特性的影响。结果表明,制动片上设计沟槽能够降低摩擦面的温度,其中三沟槽制动片降温效果最好,双沟槽和三沟槽制动片通过形成多个高温区,可改善摩擦面局部过热。此外,制动片表面沟槽结构也能抑制系统的摩擦自激振动,装配双沟槽和三沟槽制动片的制动器制动全程没有产生摩擦自激振动,单沟槽制动片表现为低频摩擦自激振动,而装配光滑制动片的制动器各零件的振动在高频处发生了耦合,整体发生了强烈的摩擦自激振动。     

金属滑动干摩擦条件下高频噪声的测试与分析

基于面-面接触旋转式滑动干摩擦系统,选用A3&45#钢为摩擦副材料,研究相对滑动速度,表面压力对高频摩擦噪声的影响和规律。运用ABAQUS有限元模态分析高频摩擦噪声产生的原因与机理。通过实验与模态分析发现,摩擦高频噪声易于发生在相对滑动速度较低处。A3&45#摩擦副,在面-面接触旋转式滑动干摩擦条件下,产生的高频摩擦噪声能量集中分布在7950 Hz,9200 Hz。验证了干摩擦条件下,摩擦高频噪声是由于摩擦界面形成类似"锤击效应"的微凸体之间的运动,使得摩擦力高频成分和系统固有频率耦合引起的系统不稳定现象。     

Prediction of Power Losses Due to Tooth Friction in Gears

Sliding friction between gear teeth is recognized as one of the main sources of power loss in geared transmissions as well as a potential source of vibration and noise. Its accurate modeling is therefore of primary importance in efficiency and vibration analyses of mechanical transmissions. For lubricated contacts, various empirical friction laws based on results from simulators can be found in the literature. One of their limitations comes from the specimen surface texture, which is often different to that of actual gears. Moreover, most of these models were established for high slide-to-roll ratios and cannot be used for low slide-to-roll ratios as encountered near the pitch point in gears. In this article, friction measurements were derived from an EHL simulator with contact conditions and surface finish close to those in gears and which covers a wide range of sliding/rolling conditions. A new traction law is proposed and integrated in a three-dimensional dynamic model of gears with consideration of tooth friction. The numerical results are then compared with the experimental evidence from a gear test rig. It is observed that tooth friction can strongly affect dynamic transmissibility through bearing mounts. Finally, the need of an accurate friction model for reliable power loss predictions is stressed.

     

Comparative Study on the Complex Eigenvalue Prediction of Brake Squeal by Two Infinite Element Modeling Approaches

The complex eigenvalue analysis is currently a common approach to predict squealing vibration and noise. There are two methods for modeling friction contact in the complex eigenvalue analysis of friction systems. In one method, contact springs are used to simulate friction contact. In another method, no contact spring is used. However, it has been uncertain whether these two modeling methods can predict approximately identical results. In order to clarify the uncertainty, two finite element models of the same brake system for the brake squeal prediction are established and simulated by using ABAQUS and NASTRAN software tools, respectively. In the ABAQUS model, friction coupling is applied to determine normal contact force and no contact spring is assumed. Whilst in the NASTRAN model, the contact spring is assumed by the penalty method to simulate contact connection. Through the numerical simulations, it is recognized that even if the same mesh geometry is applied, generally, these two finite element approaches are not capable of predicting approximately identical unstable frequencies. The ABAQUS approach can predict instabilities of high frequency up to 20 kHz or more, while the NASTRAN approach can only predict some instabilities of high frequency, not all. Moreover, the simulation results also show that both the contact spring stiffness and mesh size have influences to some extent on the prediction results of squeal. The present comparative work illuminates that the modeling method without contact springs is more suitable to predict squealing vibration and noise, comparing to the modeling method with contact springs. It is proposed that one should prefer using the modeling method without contact springs to predict squealing vibration and noise. The proposed study provides the reference for predicting squealing vibration and noise.     

Surface Texture Effect on Friction of a Microtextured Poly(dimethylsiloxane) (PDMS)

The effect of surface textures on the friction of a poly(dimethylsiloxane) (PDMS) elastomer has been investigated at both macro and microscales using a nanoindentation-scratching system. Friction tests were conducted by a stainless-steel bearing ball with a diameter of 1.6 mm (macroscale tests) and a Rockwell diamond tip with a radius of curvature of 25 μm (microscale tests) under normal loads of 5, 10, and 25 mN and with a sliding speed of 1 μm/s. Coefficient of friction (COF) on the pillar-textured surface was found to be much lower than that on the smooth surface of the same material, and it was reduced by about 59% at the macroscale tests and 38% at the microscale tests. The reduction of COF can be attributed to the reduced contact areas. The use of the JKR model revealed that the adhesion force has less effect on contacts under higher normal loads. COFs in different sliding directions on the groove-textured surfaces were compared, and a friction anisotropic behavior was identified and analyzed.     

A study on the effect of surface topography on rough friction in roller contact

The friction behaviour of gear teeth in the context of tribology can have a strong effect on housing vibration, noise and efficiency. One of the parameters that greatly influences the friction under certain running conditions is surface roughness. In this work, rough friction was studied in lubricated sliding of roller surfaces, which were manufactured to simulate the real gear surfaces. By examining 3D surface topography of two mating bodies, both surface roughness and its effect on friction behaviour can be studied. In a previous study, a rough-friction test rig has been designed, constructed and initially verified. The types of surfaces involved in this study are ground, shot-peened, phosphated and electrochemically deburred. These rollers were subjected to the same friction testing procedures. Roller surfaces were then examined, and correlation between the topography and the frictional behaviour was analysed. Friction behaviour was interpreted in terms of Stribeck curves (friction coefficient as the function of Hersey parameter (ην/p)). The results showed that electrochemically deburred and certain phosphated surfaces provide lower friction coefficient values which are competitive to fine-ground surfaces in lubricated rolling/sliding contact.     

Effects of friction conditions on the formation of dead metal zone in orthogonal cutting – a finite element study

Abstract

A numerical study of the effects of friction conditions on the formation of dead metal zone (DMZ) is presented. The friction conditions are classified as three different cases in the form of coefficient: (1) constant coefficient of friction, (2) “smooth” and “sharp” change of the friction coefficient and (3) time-dependent friction coefficient. These friction cases are numerically investigated using the finite element (FE) code ABAQUS/Explicit. A FE model based on the arbitrary-Lagrangian–Eulerian approach is developed to simulate the cutting process and investigate the influences of the friction conditions. The simulated results, for a wide range of friction conditions, are obtained, analyzed and compared with previously published experimental/numerical data. It has been found that the friction coefficient has a direct effect on the amount and shape of DMZ, the sharp change of coefficient has a larger effect on the DMZ formation than the smooth one and the formation of DMZ is more determined by the value of the friction coefficient than its duration.     

轴承套圈沟道强化研磨加工中碰撞数值模拟分析

针对球轴承套圈强化研磨加工过程中的钢球与沟道的碰撞,采用ABAQUS软件建立了三维有限元模型,利用ABAQUS/Explicit显式算法进行动态数值模拟,从系统能量转换、表面强化及表面残余应力3个方面进行了分析。结果表明:强化研磨加工能够改善轴承沟道表面性能,产生有利于延长轴承寿命的表面残余压应力。