螺旋槽机械密封瞬态启动过程润滑特性

建立了螺旋槽机械密封瞬态启动过程润滑特性的计算模型,耦合求解了含流量因子、接触因子及质量守恒空化边界的雷诺方程、弹塑性粗糙峰接触方程及动力学方程,比较了不同运行工况及结构参数的润滑状态转变过程。结果表明：增速阶段流体承载力与液膜厚度不断增大,粗糙峰承载力逐渐减小至消失;相比较于流体动压润滑状态,混合摩擦状态的液膜刚度较大且振荡幅值明显,在到达脱开转速时刻有较大的轴向速度突变。受挤压效应影响,较小的启动加速度可以在低转速下进入流体润滑状态,较高的外压和较低的内压均有利于润滑状态的转变。随槽数的增加,脱开转速呈先增大后减小趋势,螺旋角与槽深的减小或槽坝比的增大均对润滑状态转变能力起促进作用。     

A statistical model of elasto-plastic asperity contact between rough surfaces

This work models statistically elasto-plastic contact between two rough surfaces using the results of a previous finite element analysis of an elasto-plastic sphere in contact with a rigid flat. The individual asperity contact model used accounts for a varying geometrical hardness effect that has recently been documented in previous works (where geometrical hardness is defined as the uniform pressure found during fully plastic contact). The contact between real surfaces with known material and surface properties, such as the elastic modulus, yield strength, and roughness are modeled. The asperity is modeled as an elastic-perfectly plastic material. The model produces predictions for contact area, contact force, and surface separation. The results of this model are compared to other existing models of asperity contact. Agreement exists in some cases and in other cases it corrects flaws, especially at large deformations. The model developed by Chang, Etsion and Bogy is also shown to have serious flaws when compared to the others. This work also identifies significant limitations of the statistical models (including that of Greenwood and Williamson).     

Numerical analysis of a surface-textured mechanical seal operating in mixed lubrication regime

This paper presents a numerical study of the behavior of a mechanical seal with textured surfaces. It is used to analyze the mechanisms underlying the enhancement of the hydrodynamic lift associated with surface texture in mechanical seals. The model solves the Reynolds equation coupled with a mass-conservative cavitation algorithm and takes into account asperity contact. It is shown that, unlike rough-textured surfaces, smooth-textured surfaces are unable to generate a load. The performance of two rough surfaces are compared with those of the same surfaces equipped with dimples. The effect of texture density and aspect ratio are studied as well.     

A Concurrent Reynolds BC Algorithm for Piston Ring Cavitation Lubrication Problems with Surface Roughness

Piston ring dynamics play an important role in the lubricant characteristics of reciprocating engines that lead to engine wear and high consumption of lubricating oil. Due to the complexity of realistic test and working conditions, a study of cavitation with surface roughness and its effect on piston ring lubrication was conducted in a simulation program based on mass-conserving theory that is solved with the Newton-Raphson method. Lubrication models such as mixed lubrication, asperity contact, blow-by/blow-back flow, and cavitation were used in this study. The simulation algorithm consists of four processes: establishment of the three different lubrication models, dealing with the finite difference method, numerical stability treatment for the cavitation zone, and the addition of surface roughness and the shear factor to the model. Results calculated with this model were compared with two other models, and an analysis of the results indicates that the developed simulation program can illustrate problems of piston ring lubrication in accordance with the state of art of lubrication theory.     

An Advanced Rough Surface Continuum-Based Contact and Sliding Model in the Presence of Molecularly Thin Lubricant

A model of molecularly thin lubricant layer behavior for rough, sliding contact is presented in this work as a function of lubricant layer morphology. Building on previous work by the authors where the lubricant layer was assumed to be uniform in thickness and morphology, lubricant contributions to contact are presently treated at the asperity level and the effects of lubricant bonding ratio and coverage are accounted for. Effective stiffnesses for lubricated asperities are used to calculate the bearing and shear forces, while variable surface energy is modeled at the asperity level and used within an improved continuum adhesive formulation. Contributions from asperities in lubricant and solid contact for partial coverage are determined within the context of a statistical mechanics model. The proposed model can be used to study the mixed nanolubrication regime expected during light contact or “surfing” recording in magnetic storage, where sustained nanolubricant contact would partially deplete mobile molecules from the contact interface.     

混合润滑条件下的斯特封高速摩擦与密封特性

为准确研究斯特封高速摩擦与密封特性,基于混合润滑理论,综合流体空化效应、密封接触变形和微观粗糙峰接触等因素影响,建立了斯特封摩擦与密封的数值计算模型.研究了往复运动速度和密封压力对油膜厚度、摩擦力和泄漏量的影响,搭建了往复密封试验台来验证模型的准确性.结果表明:计算摩擦力与实验摩擦力相近.混合润滑模型能更好地模拟高速柱...     

A Mixed Thermoelastohydrodynamic Lubrication Analysis of Mechanical Face Seals by a Multiscale Approach

This article presents an improvement to a previous multiscale approach used to model the mixed lubrication regime in a mechanical face seal. The physical mechanisms considered by the improved model are the surface roughness effects on the fluid film lubrication, the thermal deformations, and the heat transfer in the seal rings due to viscous and dry friction. The developed numerical model determines the pressure distribution by taking into account the effect of cavitation and contact asperity between the surfaces. Heat dissipation, heat transfer, and deformations are computed from the heat dissipated at the seal interface by a finite element technique. The multiscale model significantly reduces computation time while maintaining the accuracy of the results. The results obtained through a parametric study show that there are different operating zones where the lubricating film thickness is controlled by the roughness height or by the thermal effect.     

Improved Elastic Contact Model Accounting for Asperity and Bulk Substrate Deformation

An improved elastic contact model for a single asperity system is proposed accounting for both the effects of bulk substrate and asperity deformations. The asperity contact stiffness is based on the Hertzian solution for spherical contact, and the bulk substrate stiffness on the solution of Hertzian pressure on a circular region of the elastic half-space. Depending on the magnitude of the applied load, as well as the geometrical and physical properties of the asperity and bulk materials, the bulk substrate could have considerable contribution to the overall contact stiffness. The proposed single asperity model is generalized using two parameters based on physical and geometrical properties, and is also verified using finite element analysis. A parametric study for a practical range of geometric and physical parameters is performed using finite element analysis to determine the range of validity of the proposed model and also to compare it with the Hertz contact model. The single asperity model is extended to rough surfaces in contact and the contact stiffness from the proposed model and the simpler Greenwood–Williamson asperity model are compared to experimental measurements.     

Effect of contact conditions during thermo-mechanical contact between a thermal flying height control slider and a disk asperity

A three-dimensional thermo-mechanical model is developed for the transient contact between a thermal flying height control (TFC) slider and a disk asperity. The effect of contact conditions is investigated, including the friction coefficient and the circumferential disk velocity. The damage of the read–write shields due to contacts with disk asperities is studied along with the maximum temperature at the location of the read element. The effect of diameter and material properties of the asperity is also investigated. Strong dependence of deformation and maximum temperature is observed as a function of the diameter and material properties of the asperity.     

活塞环-缸套二维润滑特性的研究

基于二维平均流量模型和微凸体接触模型，研究了活塞环的二维润滑特性，并考虑了活塞系统偏摆、润滑油粘度变化及表面粗糙度等因素的影响。通过计算获得了活塞环－缸套间油膜厚度的二维分布。结果表明，油膜厚度沿周向是不均匀的。本文还对活塞环开口位置及偏摆的影响做了定量的分析。     

ELASTIC-PLASTIC ADHESION MODEL FOR SINGLE ASPERICAL ASPERITY MICROCONTACT

The adhesion of single asperity contacting with a rigid flat is investigated. The microcontact model of the deformable asperity is established utilizing fractal geometry, which makes the resuRed adhesion model to relate with the surface characteristics that the asperity belongs to. The Dugdale approximation is utilized to consider the adhesive interaction within and outside the contact area. Then the model for solving the elastic-plastic adhesion of single asperity is presented by combing the Maugis-Dugdale（MD） model. To illustrate the necessity of considering the plastic deformation in microcontact, simulations of the relationship between the adhesive contact load and the interference of the asperity are performed. The result shows that the presented model is more suitable for the solution of the elastic-plastic microcontact of spherical asperity due to intermolecular adhesive interactions.     

A Study of Dynamically Loaded Finite Journal Bearings in Mixed Lubrication Using a Transient Thermohydrodynamic Analysis

A transient analysis of dynamically loaded finite journal bearings in mixed lubrication is made by solving the modified generalized Reynolds equation, 2-D energy equation in the oil, and heat conduction equation in the journal simultaneously including mass conserving cavitation. ISOADI (isothermal shaft and adiabatic bushing inner surface) thermal boundary condition is used. Journal temperature is treated as quasi-steady over one loading cycle. Two kinds of contact model are used. Numerical solutions using the finite difference method are presented. Results shows that the bearing behavior is closely tied to the roughness texture and topography, asperity contact load, bearing geometry, and operating conditions.     

Influence of Fluid Slip on Operation Characteristics for High-Speed Spiral Groove Seal Ring

The multi-phase method applied in cavitation region believes gas and oil phase separated and oil slips over gas layer, so slip plays a role for fluid flowing in cavitation region. Spiral groove is widely applied in seal ring for its perfect hydrodynamic effect, but the cavitation is easy to occur in divergence region of groove. Therefore, influences of both cavitation and slip on operation characteristics for spiral groove seal ring at high speed have been discussed in multi-phase method. In order to attain this goal, a new hydrodynamic model based on multi-phase method, apparent local slip theory and JFO cavitation theory is built up. An accurate prediction of lubrication characteristics is represented by comparing with published experimental data. Also, the slip region is observed by a designed test and the observed results are almost the same with simulation, which further confirms the rationality of the new hydrodynamic model based on multi-phase method. The results show the cavitation ratio and area of slip region increase with the rise of speed and spiral angle. However, as to slip level, it rises with speed but decreases with spiral angle. Then, the damping and stiffness obtained from new model are compared with conventional model. Stiffness coefficient in new model is smaller than conventional model, while the damping coefficient is larger.     

Some insights into asperity temperatures in mixed-film lubrication

This paper investigates some fundamental thermal behavior of asperity contacts in mixed-film lubrication. First, the thermal interaction between the contacting asperity and the lubricant is studied. The analysis is based on transient simulations of a mixed-film contact problem under various contact conditions. The results suggest that the solid/fluid thermal interaction can be strong. The lubricant is shown to play an important role in asperity temperature. It not only generates heat through viscous shearing but also plays a role of cooling by transporting heat out of the thermally intensive asperity contacts. The interaction can significantly reduce asperity temperatures especially under high-speed conditions. The interaction also increases the lubricant temperature away from the asperity contact, thus facilitating thermal coupling among contacting asperities. Another thermal behavior of mixed-film contact studied is the effect of heat flow in the asperity contact in the direction perpendicular to the lubricant entrainment. Results suggest that the effect of this thermal side-flow is significant in low-speed contacts and diminishes when the entraining velocity becomes high. Further, the side-flow effect is much weaker in the mixed-film contact than in the dry contact and may be neglected in the modeling of complex mixed lubrication problems.     

Enhanced friction model for high-speed right-angle gear dynamics

The modeling of elastohydrodynamic lubrication friction and the analysis of its dynamic effect on right-angle gears, such as hypoid and spiral bevel types are performed in the present study. Unlike the classically applied empirical constant coefficient of friction at the contacting tooth surfaces, the enhanced physics-based gear mesh friction model is both spatial and time-varying. The underlying formulation assumes mixed elastohydrodynamic lubrication (EHL) condition in which the division and load distribution between the full film and asperity contact zones are determined by the film thickness ratio and load sharing coefficient. In the proposed time-varying friction model, the calculation of friction coefficient is performed at each contact grid inside the instantaneous contact area that is being subjected to mineral oil lubrication. The effective friction coefficient and directional parameters synthesized from the net frictional and normal contact forces are then incorporated into a nonlinear time-varying right-angle gear dynamic model. Using this model, the effect of friction on the gear dynamic response due to the transmission error and mesh excitations is analyzed. Also, parametric studies are performed by varying torque, surface roughness and lubrication properties to understand the salient role of tooth sliding friction in gear dynamics. The simulation results are included. But experimental verification is needed.     

考虑基体变形的混合润滑结合面接触特性

为研究混合润滑状态下粗糙表面基体变形对结合面接触特性的影响,建立了考虑基体变形的结合面接触刚度模型。首先,通过单微凸体-基体系统模型分别求解微凸体和基体的接触刚度,利用不动点迭代法获得微凸体真实变形量;其次,基于分形理论建立结合面固体接触刚度模型,通过固体接触刚度获得液体介质的接触刚度。根据仿真结果分析了基体变形、粗糙表面形貌以及润滑介质对结合面接触特性的影响规律。结果表明:当真实接触面积一定时,通过新模型计算的法向载荷小于忽略基体变形的模型;在接触前期,结合面的接触刚度主要由液体介质接触刚度主导,随着真实接触面积的增加,液体接触刚度占总刚度的比率越来越小,最后转变为固体的接触刚度主导结合面的接触刚度。该模型为研究混合润滑状态下结合面的接触特性提供了理论基础。     

Effect of asperity interactions on rough surface elastic contact behavior: Hard film on soft substrate

An improved elastic micro-contact model of rough surfaces accounting for asperity interactions is proposed. The contact behavior of a single asperity system is composed of a stiffer hemi-spherical asperity deformation and bellowing softer substrate deformation, which is then extended to rough surface contact including asperity interactions. Using the solution of substrate deformation, normal positions of individual asperities are adjusted during quasi-static contact, from which surface interactive forces are obtained. Analytical simulations are performed using the proposed rough surface contact model, whose results are compared to Greenwood-Williamson-based models and with experimental measurements.     

基于真应力-应变关系的粗糙表面法向接触模型

提出一种粗糙表面的法向弹塑性接触分析的建模方法。基于微凸体的弹塑性有限元接触模型,分别研究了40Cr、45和Q235三种钢材料的微凸体与刚性平面的法向接触特性。有限元模型中采用三种材料的真应力-应变关系,考察了不同强化特性对微凸体接触性质的影响。建立了微凸体在弹性、弹塑性、塑性变形阶段统一的接触变量变化规律的表达式。在此基础上应用概率统计理论建立粗糙表面法向弹塑性接触模型。所建立的接触模型中微凸体接触变量的变化规律完全基于弹塑性有限元模型的计算结果,无需将微凸体的变形过程区分为不同的变形阶段,避免了接触变量在各阶段采用不同函数表达式带来的连续性和光滑性问题,以及在弹塑性阶段采用插值函数的随意性问题。通过与其他接触模型的计算结果相比较,证明了所提出接触模型的合理性。     

Investigation of the strain distribution with lubrication during the deep drawing process

A lubrication/friction model can be implemented in FEM codes to predict the contact area ratio, friction coefficient and strain distribution in lubricated deep drawing process. In the lubrication analysis, the surface roughness effect on lubrication flow is included by using Wilson and Marsault's average Reynolds equation that is appropriated for mixed lubrication with severe asperity contact. With regard to the asperity contact theory, the well-known flattening effect is considered. Friction is expressed in terms of variables such as lubricant film thickness, sheet roughness, lubricant viscosity, interface pressure, sliding speed, and strain rate. The proposed lubrication/friction model combined with a finite element code of deep drawing process to predict the contact area ratio, friction coefficient and strain distribution. Numerical results showed that the present analysis provides a good agreement with the measured strain distributions.