圆柱滚子轴承混合润滑状态下的超声法膜厚测量

圆柱滚子轴承由于其线接触特点被广泛应用于各类低速重载工况下的大型设备中,其运行性能和稳定性与滚子和内外圈间的接触润滑状态密切相关;基于等效刚度的超声法可用于实际工况的滚子轴承弹流润滑油膜厚度测量,但无法直接适用于低速重载工况下流体润滑和粗糙峰接触共存的混合润滑状态膜厚测量。为此,提出了一种混合润滑状态下的超声测量方法,建立了界面油膜刚度和粗糙体接触刚度的并联模型,通过引入接触系数并结合经验公式对超声法所测界面总刚度进行分解,获取混合润滑状态下的油膜刚度,进而得到更加准确的油膜厚度。将实验结果和理论结果的对比分析,验证了该模型的可行性和有效性。     

乳化液点接触润滑性能研究

利用光弹流试验台,从摩擦磨损的角度研究了不同滑滚比工况下不同浓度乳化液弹流润滑性能.实验结果表明:含水浓度低的乳化液(<=10％)与基础油产生的摩擦力基本相同,而高浓度乳化液产生的摩擦力明显增加.同时采用乳化液做润滑剂时,滑滚比工况下钢球表面会发生磨损,且磨损程度随着滑滚比和水浓度的增加而增大.     

求解线接触热弹流润滑问题的多目标最优化方法

本文给出了求解线接触热弹流润滑问题中线非线性方程组的多目标最优化方法，该法把求解润滑油膜压力函数和油膜厚度函数的微分方程转化成为求解一个双目标优化问题，求得了压力和膜厚的解析解，所得结果符合热弹流润滑的经典理论。     

求解线接触弹流润滑完全数值解的多重网格复合直接迭代法

本文将近来发展起来的一种新型数值计算技术一多重网格法引入求解线接触弹流润滑问题，并将求解弹流润滑中的有效迭代模式一复合直接失代模式与多重网格法相结合，使求解过程既快又稳定，精度又高。该方法可推广到其它耦合场问题的数值求解。     

基于接触电阻法测量润滑油膜厚度的方法研究

提出了一种基于接触电阻法测量润滑油膜厚度的方法，研制了一台可实时测量接触电阻以评价润滑膜厚的旋转摩擦试验机，分析了边界润滑与混合润滑区域中油膜厚度与接触电阻的相关性。该装置实现了在高精度加载与速度控制下，获得确定工况下的润滑状态，通过精密电路设计实时测量接触区内部接触电阻，并与相同工况下光干涉法测得的润滑膜厚进行对应，获得了接触电阻-润滑膜厚对应关系，拟合曲线相关系数为0.98,剩余标准差为4.56 nm。为在实际工况中表征润滑状态提供了技术支撑和数据支持。     

求解线接触弹流润滑完全数值解的多重网格重复合直接迭代法

本文将近来发展起来的一种新型数值计算技术一多重网格法引入求解线接触弹流润滑问题，并将求解弹流润滑中的的迭代模式－复合直接迭代模式与多重网格法相结合，使求解过程既快又稳定，精度又高，该方法可推广到其它耦合场问题的数值求解。     

混合弹流润滑下内啮合直齿轮动态特性磨损退化研究

针对现有磨损计算方法难以求解混合弹流润滑下内啮合齿轮磨损的问题,提出了黏着磨损与弹流润滑耦合的计算模型。根据弹流润滑理论计算油膜刚度,并将油膜刚度、齿面接触刚度以及承载系数结合构建了混合弹流润滑条件下的综合刚度模型以完善动力学模型。为深入分析混合弹流润滑下动态啮合力与磨损量之间的关系,将累加的磨损量作为齿侧间隙代入到动力学模型中,最终得到不同啮合次数下的动态啮合力和磨损量。考虑动态啮合力与润滑的影响能够呈现静态干摩擦中所没有的啮合动态冲击特性。计算结果表明:进入段的磨损量大于退出段的磨损量;动态啮合力会随着磨损量的增加,在进入段增大,在退出段减小;在磨损初期动态啮合力会随着磨损量增加迅速收敛;油膜刚度对动态啮合力较为敏感,而不会受初期磨损的影响;综合刚度与承载系数在初期磨损时不会变化。     

弹流油膜光学测试系统的特性分析

光干涉法是弹流润滑膜厚度测量的最有效的方法之一。传统的理论认为光弹流干涉主要是双光束干涉，即光干涉强度是油膜厚度的余弦函数，通常应用该余弦关系分析弹流干涉图象。然而，几个光弹流实验均表明干涉强度随油膜厚度的变化同科弦规律有明显的偏离。应用薄膜光学理论对光弹流测试系统进行了分析，干涉强度的计算结果和实验数据吻合一致，弹流光学系统的多光束干涉本质和金属膜的光吸收特性是干涉强度偏离余弦分布的原因。     

印刷机偏心滚子轴承接触应力与变形仿真分析

目的对偏心轴承接触应力与滚子静、动态变形进行研究,得到接触应力与变形和结构与工况因素的关系。方法在Hertz线接触与弹流润滑理论下,建立滚子接触应力模型及静、动态滚子间接触变形的关系模型,利用有限元软件Ansys仿真计算。建立静、动(润滑与转速)态下滚子变形之间的关系公式,分析印刷机偏心双列圆柱滚子轴承的接触应力与变形及相互关系。结果滚子与内外套圈的接触应力均随径向载荷的增大而增大,滚子与内套圈的接触应力大于滚子与外套圈的接触应力;滚子的总接触变形量与径向载荷呈正比关系,滚子的内外接触应力与滚子的总接触变形量也呈正比关系;滚子的边缘出现应力集中,须用设计凸度的方法降低,从而更好地提高偏心轴承的整体性能。结论根据接触应力与变形的关系,可为偏心轴承的设计与优化提供理论依据。     

考虑粗糙度的倾斜式双滚柱包络环面蜗杆传动弹流润滑分析

为了研究倾斜式双滚柱包络环面蜗杆传动共轭齿对在啮合传动过程中考虑粗糙度的润滑特性。根据该传动副的啮合理论,在弹性流体动力润滑理论基础上,基于牛顿流体弹流润滑模型建立了传动副的线接触简化模型和数学模型,考虑共轭齿面粗糙度对弹流润滑的影响,利用多重网格技术进行数值求解,得出一个共轭齿对从啮入到啮出不同啮合时刻的油膜厚度和油膜压力,并据此分析了滚柱半径、喉径系数、滚柱偏距、倾斜角对弹流润滑特性的影响。结果表明粗糙度的存在会造成传动副的油膜压力和油膜厚度产生波动,使最大油膜压力峰值增大,最小油膜厚度减小,因此粗糙度对该传动副的润滑是不利的;滚柱半径、滚柱偏距和倾斜角过大,喉径系数过小时,越不利于动压油膜的形成,对传动副的润滑越不利,要保持该传动副具有良好的润滑性能,滚柱半径、滚柱偏距和倾斜角不要过大,喉径系数不要过小。     

Performance of truncated surface asperities in elastohydrodynamic lubrication

The elastohydrodynamic lubrication in a sliding line contact between a flattened rough plane surface and a smooth plane surface is analytically studied. Both surfaces are assumed as elastic and parallel to one another. The flattened rough surface is treated as equivalent to a rough plane surface with uniformly distributed cylindrical asperities evenly truncated on the top. For understanding the elastohydrodynamic lubrication performance between these two plane surfaces, an inlet zone analysis is taken for the elastohydrodynamic lubrication formed between a truncated cylindrical asperity and the smooth plane surface. It is found from the obtained results that the asperity truncation reduces the elastohydrodynamic load-carrying capacity, and this effect is significant for low sliding speeds or/and heavy loads, while it is negligible for high sliding speeds and moderate loads. The asperity truncation increases the friction coefficient of the asperity contact especially at relatively light loads, while it only slightly increases the friction coefficient of the asperity contact at heavy loads. For heavy loads, the asperity truncation can have a significant effect on the reduction in the maximum surface temperature rise. It is recommended by the present study that the surface asperity be truncated in a certain degree in an elastohydrodynamic contact with high sliding speeds and relatively heavy loads because of giving the benefits of considerably reducing the maximum surface temperature rise while maintaining the elastohydrodynamic load-carrying capacity.     

Numerical solution of the point contact problem using the finite element method

The elastohydrodynamic lubrication problem, in which the lubricant pressure and film thickness are sensitive to surface deformation, is solved by using a finite element procedure and the Newton method. The numerical procedure is applied to the point contact problem, in which a thin lubricant film is maintained between two balls loaded together by a high load under conditions of pure rolling. The present analysis shows that pressure spikes are formed near the outlet region, a result which has been found in the line contact problem and which has been conjectured in the present problem.     

基于弹流润滑与动力学耦合的WN齿轮传动的强度设计

提出应用动力学与弹流润滑耦合原理进行WN (Wildhaber Novikov)齿轮强度分析的方法.依据振动学、油膜承载机理及其数值分析法,结合WN齿轮啮合原理,创建了该齿轮传动润滑与振动力学耦合分析模型.利用齿轮副的接触弹性和接触衰减描述轮齿弯曲载荷,考虑了啮合中同时啮合齿数变化对其刚度的影响,进行了啮合过程中多因素综合情况下的强度分析.计算分析与实验结果相符,为WN齿轮传动及其结构强度优化设计提供了参考.     

Numerical modeling of elastohydrodynamic lubrication in point or line contact for heterogeneous elasto-plastic materials

A semi-analytic solution is developed for heterogeneous elasto-plastic materials with inhomogeneous inclusions under elastohydrodynamic lubrication in point contact or line contact. The inhomogeneous inclusions within a material are homogenized as homogeneous inclusions with properly determined eigenstrains based on the equivalent inclusion method, and the surface displacements induced by these eigenstrains are then introduced into the gap between the contact bodies to update surface geometry. The accumulative plastic deformation is iteratively obtained by a procedure involving a plasticity loop and an incremental loading process. The model takes into account the interactions among the contact bodies, the embedded inclusions, and the plastic zones, thus leading to a solution of the surface pressure distributions, film thickness profiles, plastic zones, and subsurface stress fields. This solution is of great importance for the analysis of elasto-plasto damage of heterogeneous materials subject to lubricated contact.     

润滑状态下线接触滑动粗糙界面的动摩擦特性研究

滑动粗糙界面的摩擦润滑特性对界面的润滑设计和润滑状态预测具有重要的理论和实际意义。本文通过建立不同润滑状态下的滑动粗糙界面模型,基于界面的法向载荷由润滑油膜和粗糙体共同承担的载荷分配思想,采用Greenwood-Williamson统计模型描述粗糙表面形貌,考虑界面润滑的时变效应和润滑油的粘-压特性,建立了线接触滑动粗糙界面的油膜厚度方程和粗糙体接触压力方程,获得了整个润滑区的润滑油膜载荷比例因子、油膜厚度和摩擦系数随滑动速度的变化关系,推导了界面由混合润滑过渡为液压润滑的临界速度关系表达式,分析了滑动粗糙界面的润滑承载机理,获得了界面油膜厚度、摩擦系数和临界速度随界面形貌参数、法向载荷、润滑油属性参数的变化规律,为机械结构的界面润滑设计、润滑状态预测和润滑优化提供理论和实验参考。     

轮轨油污染黏着特性的研究

运用数值算法研究了轮轨在油污染时的黏着特性。以部分弹流理论为基础借助于多重网格作为数值计算工具建立了二维轮轨在油污染状态下考虑表面粗糙度的轮轨黏着计算模型。研究了在有油污染情况下轮轨间接触压力分布以及列车运行速度和接触压力对轮轨黏着系数的影响。给出了轮轨介质接触时的固体承载及液体动压分布。计算结果表明:随着速度的提高,黏着系数逐渐降低,最后基本上趋于稳定;随着接触压力的增大,黏着系数逐渐增大。     

A finite element-boundary element treatment for the analysis of elastohydrodynamic lubrication problems

A combined finite element evaluation of hydrodynamic pressure and boundary element calculation of film thickness is presented. The viscosity and the density of the oil are assumed to vary with pressure, however the isothermal condition is assumed to prevail. The technique is based on an iterative procedure by assuming an initial hydrodynamic pressure. The iteration cycle will then be followed by the calculation of the film thickness and hydrodynamic pressure to arrive at a converged solution. The bearings have been treated realistically as finite domain bodies and their deformations are evaluated by boundary element method. The accuracy of the technique is illustrated in elastohydrodynamic lubrication (EHL) of inclined slider and line contact problems.     

A rolling contact fatigue crack driven by squeeze fluid film

ABSTRACT A new model of surface breaking rolling contact fatigue (RCF) crack driven by a coupled action of a squeeze oil film built up in the crack interior and a pressure exerted at the external contact interface was developed. The model can be applied to the ‘nominally dry’ contact couples with an occasional presence of liquid in the crack interior (wheel/rail contact) as well as to the elastohydrodynamic lubrication (EHL) conditions. In the first case, the contact load is a result of solid/solid interaction and can be determined by solving the FE contact problem, but the liquid contained in the crack interior forms a thin film between the crack faces changing their interaction into the type of liquid/solid. This liquid is being periodically squeezed under contact load and acts as a ‘squeeze film’ known from the lubrication theory. In the second case, the liquid (lubricating oil) is permanently present in the contact area and consequently in the vicinity of the crack mouth. This creates conditions for filling the crack with oil. Similarly as in the first case, the ‘squeeze oil film’ is built between the crack faces. The contact load in this case results from a liquid/solid interaction and can be approximated by the pressure and traction distributions obtained from the numerical solution of the elastohydrodynamic contact problem. In both cases the model can be used to determine the Linear Elastic Fracture Mechanics (LEFM) crack tip stress intensity histories during cyclic loading and consequently to predict the crack growth rate and direction. An example of applying the model to the EHL case is given to explain the mechanisms and phenomena leading to the crack front loading. The cycle of rolling a roller over the crack was numerically simulated to obtain the mixed mode (I and II) SIF histories. In the analysis, the EHD pressure and traction were determined through the full solution of the EHD line contact problem accounting for the presence of a crack, whilst the pressure in the crack was found with the use of the wedge shaped squeeze oil film (SOF) model. Possible effects of the mode I and mode II stress intensity cycles on crack growth rate and direction are discussed. The solution indicates high pressure in the neighbourhood of the crack tip, exerted on the crack faces by the squeeze oil film. This leads to the ranges of the mode I and mode II SIF variations, which are larger than for the ‘dry’ and ‘fluid entrapment’ models, and can be an explanation for the crack growth rate observed in practice     

Rolling–sliding contact fatigue of surfaces with sinusoidal roughness

Surfaces of mechanical components under combined rolling and sliding motions may be subjected to accelerated contact fatigue failure due to increased number of microscopic stress cycles and pressure peak heights caused by rough-surface asperity contacts. Available rolling contact fatigue (RCF) theories were developed mainly for rolling element bearings, for which the effect of sliding is usually insignificant. In various types of gears, however, considerable sliding exist in the critical tooth contact area below the pitch line, where excessive wear and severe pitting failures originate. Ignorance of sliding is most likely the reason why the conventional RCF models often overestimate gear fatigue life. This paper studies the effect of sliding motion on the contact fatigue life of surfaces with sinusoidal roughness that mimicks the topography from certain manufacturing processes. A set of simple equations for stress cycle counting is derived. Mixed elastohydrodynamic lubrication simulations are executed with the considerations of normal loading and frictional shear. Relative fatigue life evaluations based on a subsurface stress analysis is conducted, taking into account the two sliding-induced mechanisms, which are the greatly increased number of stress cycles and the pressure peak heights due to surface interactions. Obtained results indicate that sliding leads to a significant reduction of contact fatigue life, and rough surface asperity contacts result in accelerated pitting failure that needs to be considered in life predictions for various mechanical components.