Thermal characteristics analysis and error prediction for lubricated multi-link high-speed precision presses

Thermal models are important in the process of predicting the thermal characteristics and corresponding thermal error of multi-link high-speed precision presses (MLHSPPs) with an oil-lubrication system. Previous models only involved the effects of bearing stiffness, temperature change of bearings, flexibility of crank shaft on the heat generation power, while the influences of revolute clearance joint and flexibility of linkage are seldom considered, which inevitably reduces the accuracy of thermal analysis. To overcome this problem, dynamic models of flexible multi-link mechanisms (MLM) with clearance, lubrication, crankshaft-bearing system are constructed, the interaction forces between pin and bushing are obtained to calculate its heat generation power. Then, an improved model of MLHSPP with lubrication is proposed to analyze the temperature evolution and the thermal error between slider and work table at the position of LDP, by considering bearing stiffness, temperature change of bearings, flexibility of crank shaft, linkage, clearance, lubrication and thermal contact resistance all together. Compared with results from traditional models, the simulation data from this improved thermal model agree well with experiment, which proves the validity of the proposed model. Furthermore, the temperature rise and the thermal error of MLHSPP between slider and work table at the position of LDP under different input speeds, lubricating oil flux and contact angles of ball bearing were also studied.

     

Effect of the lubricating layer on rotor stability in sliding bearings

The structure of the forces acting from the lubricating layer on the rotor during nonstationary lubricant flow in sliding bearings is discussed. A closed system of differential nonlinear equations of rotor motion in the sliding bearing is obtained. Based on the closed system of equations, the problem of stabilization of the rotor motion in the bearing is solved.     

大型活塞压缩机异常振动的原因及对策

对一台六列M型活塞压缩机组的振动和噪声异常、一级和二级连杆大头瓦快速失效的原因进行了分析,并研究实施了在轴系上加装配重体,以适度增大轴系的转动惯量,调整轴系扭转振动固有频率的改造措施,有效消减了轴系的扭转振动,大幅度减小了机组的振动和噪声,提高了连杆大头瓦的使用寿命。     

固体润滑剂在轴承上的应用研究

以水轮发电机轴承为应用研究实例，介绍了轴承镶嵌固体润滑剂的摩擦磨损机理，镶嵌轴承套的结构，固体润滑剂材料；并用摩擦学性能试验及台架模拟试验验证；在水轮发电机轴承上使用固体润滑剂可以提高润滑性能、降低摩擦系数，使摩擦副间能不断形成自补偿固体润滑转移膜，说明在重载，低速，摆动，间歇运动和泥水环境苛刻条件下工作的水轮发电机轴承使用固体润滑剂，比液体润滑具有更优越的性能。     

Application of Ultrasonic Sensing to Monitoring Lubrication Conditions in a Refrigeration Compressor

Understanding lubrication conditions in a refrigeration compressor is valuable for machine design and ensures the reliability of air conditioners. In this work, the lubrication conditions of a journal bearing in a scroll compressor were evaluated by applying ultrasonic sensing. An ultrasonic probe was attached to a journal bearing supporting a crank shaft in the compressor. The probe transmitted ultrasonic pulses toward the lubricant film between the shaft and the bearing and then received reflections. The lubricant film can be monitored by measuring the reflection amplitude of the ultrasound, which increases with the thickness of the thin lubricant film. With the whirling shaft in the bearing, the minimum reflection amplitude was measured as an index of the minimum lubricant film thickness in the bearing during stable and transient operations of the compressor. Then the measured reflection amplitude was compared with the Sommerfeld number, which is also known to increase with lubricant film thickness. The measured minimum reflection amplitude mostly changed in trend similar to that of the Sommerfeld number. However, the measured minimum reflection amplitude behaved differently during the first 400 s in the startup process. An observation of the lubricant reservoir showed generation of small bubbles in the lubricant in the period. Overall, test results support the usability of the ultrasonic measurement to trend monitoring of the lubricant film thickness in the journal bearing in the compressor. The existence of bubbles in the journal bearing was indicated by the results of the ultrasonic measurement and observation.     

The solution of Reynolds equation under natural boundary conditions for hydrodynamic journal bearings

The solution of Reynolds equation for hydrodynamic pressures of the load-carrying lubricating layer in journal bearings is discussed.The accepted boundary conditions are shown to be helpful in explaining more accurately the physical meaning of the lubricant flow process and in assuming the boundary curvature for the load-carrying lubricant film in the convergent-divergent zone of the bearing clearance.New algorithms for determining the above curve boundary in the process of the numerical solution of a basic differential equation are suggested. The technique used for the theoretical study of the bearings made it possible to provide results of greater accuracy for their principal operating characteristics such as load-carrying capacity, frictional losses and lubricant consumption.     

离子双电层动态输运特性及电场对液体油膜压力的影响

随着流体动压润滑向纳米尺度发展,离子双电层对润滑性能的影响不能忽视。考虑到润滑过程中摩擦副相对速度是可变的,提出一种考虑离子动态输运特性与流场及电场耦合的离子双电层润滑模型,分析摩擦副相对运动速度和Zeta电势差对润滑膜的影响。分析结果表明：摩擦副相对运动造成了电势不均衡分布,平衡电势偏向于运动壁面Zeta电势,且相对速度的增大加剧了不均衡性;Zeta电势差对润滑液体承载能力影响显著,当Zeta电势差从0开始增大时,双电层电黏度效应及润滑液体承载能力先增大后减小。提出的模型实现了速度可变的双电层润滑瞬态仿真,为变工况下的双电层润滑性能分析奠定理论基础。     

Vacuum tribological behaviour of self‐lubricating quasicrystalline composite coatings

High‐temperature‐resistant self‐lubricating coatings are needed in space vehicles for components that operate at high temperatures and/or under vacuum. Thick composite lubricant coatings containing quasicrystalline alloys as the hard phase for wear resistance can be deposited by a thermal spray technique. The coatings also contain lubricating materials (silver and BaF₂ CaF2 eutectic) and NiCr as the tough component. This paper describes the vacuum tribological properties of TH103, a coating of this type, with a very good microstructural quality. The coating was deposited by high‐velocity oxygen fuel spraying and tested under vacuum using a pin‐on‐disc tribometer. Different loads, linear speeds, and pin materials were studied. The pin scars and disc wear tracks were characterised using a combination of scanning electron microscopy and energy dispersive spectrometry. A minimum mean steady friction coefficient of 0.32 was obtained when employing an X750 Ni superalloy pin in vacuum conditions under 10 N load and 15 cm/s linear speed, showing moderate wear of the disc and low wear of the pin.     

Periodic variational Rayleigh problem of the gas-film lubrication theory

A solution to the variational problem for a plain bearing (slider) on gas-film lubricant with periodicity conditions is considered. Using the calculus of variations, the shape of the lubricating layer providing maximum levitation force is determined. Along with the compressibility number, the parameters in the problem are the ceiling value of the profile function, and its limiting value corresponds to the results obtained by Rayleigh. Characteristics are presented for the optimum bearing in the case of different compressibility numbers.     

Molecular Behavior of Room-temperature Ionic Liquids under Lubricating Condition

The molecular behavior of room-temperature ionic liquids (RTILs) under lubricating condition was analyzed using fourier transform infrared spectroscopy equipped with a pin-on-disk tribometer to simultaneously measure the friction force, normal load, and IR spectrum. When 1-metyl-3-butylimidazolium trifluoromethanesulfonate ([BMIM]OTf), which is miscible with water, was used as a lubricant, the water content increased with time, and the ratio of water to cation remained constant even though the film thickness reduced under the lubricating condition at a load of ~25 N. When 1-metyl-3-butylimidazolium tetrafluorophosphate ([BMIM]PF₆), which is water-insoluble, was used as a lubricant, the water content was quite small and increased slightly with time, and the ratio of water to cation also remained constant even when a normal load of ~25 N was applied. The SUJ2 pin surface showed oxidative discoloration after the friction test using [BMIM]OTf, but there was little change in color when[BMIM]PF₆ was used. XPS results indicated that iron oxide, chromium oxide and sulfate were observed on the worn pin surface using [BMIM]OTf and the CaF₂ disk. However, iron oxide and iron phosphate were observed for the worn pin surface using [BMIM]PF₆ and the CaF₂ disk. These results suggest that the amount of water contained in the RTILs as well as window materials have a significant effect on the tribo-chemical reaction of RTILs.     

The effect solid particle lubricant contamination on the dynamic behavior of compliant journal bearings

The proposed work concerns a theoretical and numerical investigation of the effect of solid particle contamination of lubricant oils on the static and dynamic characteristics of a finite length compliant journal bearing operating under isothermal conditions with laminar flow. In the present investigation, we use simple models based on the Einstein's mixture theory, which is characterized by the presence of suspended rigid particles in a fluid. Using the classical assumptions of lubrication, a Reynolds equation is derived and solved numerically by the finite difference method. The displacement field at the fluid film bearing liner interface due to pressure forces is determined using the elastic thin layer model. The results obtained show that the presence of suspended rigid particles in the lubricating oil (solid contamination) has significant effects on the hydrodynamic performance characteristics such as the pressure field, friction force, flow rate, elastic surface deformation as well as stability maps of the rotor‐bearing system (critical mass and whirl frequency) especially at high volumetric concentration.     

往复压缩机轴系扭振有限元分析

某6列往复压缩机因曲轴扭振,出现烧连杆瓦和断轴现象,调整压缩机曲轴转速及行程后,问题得到解决。利用Ansys有限元软件,建立调整前、后轴系有限元模型,分别对各轴系进行模态和瞬态动力分析。结果发现,轴系第1列曲柄销上节点振幅共振时远大于第6列,在压缩机第1、2列连杆瓦处产生冲击载荷的可能性很大,从理论上揭示曲轴多次在第2列曲柄根部断裂的原因;在同等共振状态下,压缩机行程的减小与曲柄振幅的降低成非线性关系得到确认。     

Bio-Fuel-Contaminated Lubricant and Hardening Effects on the Friction and Wear of AISI 1045 Steel

A study has been made on the wear and friction of hardened AISI 1045 steel using a tri-pin-on-disc type of friction and wear apparatus. During the investigation the linear pin wear, coefficient of friction and rise in pin specimen temperature were monitored and wear and friction curves plotted. Wear surfaces and mechanisms were investigated by means of optical microscopy. Analysis of used lubricating oil was performed using FTIR spectroscopy.

It was shown that the wear rate, type of wear and friction coefficient were influenced by contaminating the lubricant with bio-fuel as well as the surface hardening treatment. Corrosive wear and pits on the specimen surface were found when plain bio-fuel was used as lubricating oil. The results also confirmed that better wear resistance was obtained from the surface-hardened steel specimen with 4 % bio-fuel-contaminated lubricant.

Results from this study will be useful in material selection for tribological components in diesel engines running on vegetable fuel.     

Formation and frictional properties of boundary lubricating and surface‐modified layers at elevated temperatures

The influence of heating on the properties of lubricating layers formed on steel by inactive and chemically active lubricant components has been studied by electrical probe methods. Model experiments combining X‐ray photoelectron spectroscopy analysis and measurements of friction and electrical characteristics in static and dynamic point contact have shown the approach to be promising in separate studies of the properties of the physically adsorbed layer (A‐layer) and chemisorbed layer (D‐layer) of deposits. It has been confirmed that D‐layers can be formed on metal surfaces at moderate temperatures (T ∼ 200°C) by both active additives and inactive components of mineral oil. Zinc dialkyldithiophosphate additives provide higher load‐bearing capacity of the A‐layer compared to pure mineral oil and can form D‐layers on steel at relatively low temperatures (of about 100°C). Lubricating layers with different physicomechanical and frictional properties can be formed depending on the chemical origin of the lubricating medium and the temperature regime.     

柴油机滑动轴承热流体动力润滑仿真研究

根据径向滑动轴承热流体动力润滑理论,基于JFO理论提出的质量守恒边界条件,建立同时包含油膜完整区和空 穴压力变化的单缸柴油机滑动轴承热流体动力润滑模型,采用有限差分法求解模型方程,仿真分析滑动轴承的油膜厚度、油膜压力、润滑油流量和温度等参数对润滑性能的影响,分析内燃机滑动轴承润滑特性,为轴承润滑可靠性设计提供一定的理论依据.     

变黏度静压滑动轴承高速时油膜动态润滑特性

静压滑动轴承转台直径大（D=4.5 m）,高转速运行时产生线速度值很大,其内部润滑油膜受压及剪切发热导致油膜变薄进而影响到机床加工精度和运行可靠性。针对新型Q1-205双矩形腔静压推力轴承,采用动网格技术探索变黏度条件静压轴承高速时的油膜动态润滑特性。建立该静压轴承的流量、承载力、油膜温升等理论模型,自定义用于控制边界层网格运动及变黏度的UDF程序,选取外载荷12 t,转速为80~200 r/min（线速度18~48 m/s）高速下的工况条件参数进行动态润滑特性数值模拟,并进行相同工况参数下的试验验证,揭示出高速时油膜厚度变化对油膜温度、油腔压力、封油边处流量的影响规律。研究发现,该型号轴承在承载12 t时,随着膜厚的减小,油膜剪切发热严重,温升加剧,且高速下受润滑油黏度变化影响造成压力损失严重,研究数据为工程上静压轴承可靠运行提供理论依据。     

The effect of inlet film boundary conditions on the steady state characteristics of hydrodynamic journal bearings

The well-known solutions for the pressure distribution in the lubricating film of a hydrodynamic journal bearing, satisfying the Reynolds boundary conditions, show a sudden change in the pressure gradient at the position of maximum film thickness, which is possible only if the lubricant is added precisely at this position. Since the pressure develops smoothly because of hydrodynamic action, a correction in the Reynolds boundary conditions is proposed and a new solution for the pressure distribution is obtained. The steady state characteristics of a hydrodynamic journal bearing using the new boundary conditions are compared with the well-known characteristics using the Reynolds boundary conditions.     

大型往复压缩机曲轴开裂的原因及改造

对一台六列M型往复压缩机曲轴多次在一级曲柄销上发生开裂的原因进行了分析，并研究实施了简便可行的调整轴系扭转振动固有频率的改造措施，有效消减了轴系的扭转振动，消除了曲轴在一级曲柄销上开裂的事故隐患。     

Analysis of Journal Bearing with Double-Layer Porous Lubricant Film: Influence of Surface Porous Layer Configuration

This article presents an analysis of a long journal bearing with a double-layer porous lubricant film using couple stress and Newtonian fluids. The porous layer with infinite permeability analyzed in this study simulates the surface layer. The Brinkman model was utilized to model the flow in the porous region. The effects of couple stresses were analyzed based on Stokes microcontinuum theory. A double-layer porous lubricant film configuration, with a low-permeability porous layer on top of a high-permeability bearing adherent porous layer, improved the journal bearing performance characteristics. A surface porous layered lubricant film configuration increased the load-carrying capacity and reduced the coefficient of friction in a journal bearing.