大型水轮机组推力轴承油膜厚度在线监测研究

油膜厚度是反映推力轴承运行状态的重要参数,对油膜厚度进行实时在线监测有助于实现推力轴承的稳定运行。以某大型水轮机组推力轴承为例,结合其润滑流体的雷诺方程和油膜厚度方程,利用有限差分法分析了不同载荷和不同转速下推力轴承油膜厚度和压力分布的变化规律,并设计了一种油膜厚度实时在线监测方法。理论分析结果表明,当转速一定时,推力轴承油膜厚度先随着载荷的增大而增大,达到峰值后,随着载荷的增大而减小;当载荷一定时,油膜厚度随着转速的增大而增大。理论分析结果与该水轮机组推力轴承油膜厚度的在线监测数据完全吻合,验证了提出的油膜厚度在线监测方法的可靠性,为推力轴承运行状态的诊断提供了科学依据。     

齿轮箱传动轴扭矩与转速测试

设计一种应变式无线扭矩传感器,同时集成了转速测量功能,在测量传动轴扭矩时,同时能准确地测量出转速。该传感器节点内置独立的高精度桥路电阻和放大调理电路,可以通过上位机软件,实现1/4桥、1/2桥、全桥测量方式的自动切换,兼容了各种类型的桥路传感器。节点通过无线数字信号传输,将测得的应变及转速值无线发送到上位机数据测试系统,该传输方式消除了传统采用的长电缆传输带来的噪声干扰,使得整个测量系统具有很高的测量精度和很强的抗干扰能力。通过工程实际应用,测试结果显示,无线扭矩-转速传感器稳定可靠。     

椭圆轴承与圆轴承动力特性CFD数值分析

滑动轴承动力特性对旋转机械转子稳定性有着重要影响。将CFD动网格技术应用于椭圆轴承与圆轴承动力特性求解。在验证滑动轴承CFD动力特性求解模型准确性的基础上,建立基于CFD动网格技术的椭圆轴承动力特性求解模型,分析椭圆度、偏心率以及转速等因素对滑动轴承动力特性影响,比较分析椭圆轴承与圆轴承动力特性之间的差异。研究表明,椭圆轴承与圆轴承的承载力与刚度阻尼系数随着偏心率、转速的增加而增大;与圆轴承相比,椭圆轴承两个油楔形成两个流体动压区有效的增大轴承的阻尼,滑动轴承增加椭圆度可提高转子稳定性。     

Effect of tool rotational speed and probe length on lap joint quality of a friction stir welded magnesium alloy

The effects of tool rotational speed and probe length on lap joint quality of friction stir welded 2-mm AZ31B-H24 magnesium alloy were investigated in terms of welding defects, microstructure and mechanical properties. Tensile shear load initially increases with increasing tool rotational speed but decreases with further increase. However, the tensile shear load always increases with increasing probe length. The highest shear strength is obtained using a set of welding parameters resulting in a downward hooking defect at the maximum stress location of the top sheet. Sound lap joints with low distortion, lack of cavity, minor kissing bond and preferable hooking defects, and high tensile shear strength were successfully obtained, indicating the great potential of friction stir welding technique for magnesium alloys.     

径向浮环动静压轴承稳定性研究

以径向浮环动静压轴承为研究对象,针对轴颈和浮环建立了统一的动力学方程,用Routh-Hurwitz准则推导了径向浮环轴承的稳定性判据。用有限元法计算了某结构高速径向浮环动静压轴承的刚度系数和阻尼系数,在此基础上得到了不同偏心率下的失稳转速。由计算结果可以看出,浮环轴承具有极佳的稳定性,且随着偏心率的增加,失稳转速迅速提高。文章在高速浮环轴承稳定性整体建模和分析方面有较大的参考意义。     

单排球式回转支承动态力学性能研究

应用ANSYS/LS-DYNA软件建立回转支承的多体动力接触有限元模型,采用显式动力学有限元算法,综合考虑载荷和转速对回转支承的影响,对回转支承的运转过程进行数值模拟,得出了单排球式回转支承在运转过程中滚动体的动态响应、应力分布及滚道的米塞斯应力分布。并将计算结果与赫兹理论计算结果进行比较,验证了动态仿真的合理性,为回转支承的设计提供可靠的理论依据。     

Characterization of Wire Rope Defects with Gray Level Co-occurrence Matrix of Magnetic Flux Leakage Images

Magnetic flux leakage (MFL) techniques are used extensively for non-intrusively detecting and characterizing wire rope defects. Traditionally, MFL signals are captured with induction coil sensors. However, the output of coil sensors is related to the wire rope speed, and they can only provide the axial distribution along the wire rope. Hall sensors array are designed due to the limitation of coil sensors. In this paper, a Hall sensors array was designed to capture the MFL signals both axially and circumferentially. 30-channel data from Hall sensors are processed to compose a MFL image. A digital image process technique is introduced to preprocess the MFL image, the MFL images from different types of defects show different texture characteristics. Gray level co-occurrence matrix is utilized for feature extraction of the texture in the MFL image. Five typical eigenvalues (contrast, correlation, energy, homogeneity and entropy) are used as the inputs of back propagation (BP) networks. After training with typical samples, the BP networks show good performance in the quantitative recognition of different defects. The result of this work shows that texture analysis method for MFL image is suitable for feature extraction and quantitative detection of wire rope defects.     

Challenges in dissimilar friction stir welding of aluminum 5052 and 304 stainless steel alloys

In this study, dissimilar friction stir welding of aluminum 5052 and stainless steel 304 has been carried out with different process parameters. This investigation provides a better insight regarding the defect formation of the weld joints with tilt angles ranging from 0 ° to 2.5 °. The experiments were conducted according to Taguchi L9 orthogonal array by changing the tool rotational speed, and welding speed. The tool pin was kept 70 % towards the aluminum with the tool rotational speed ranging from 800 min⁻¹ to 1200 min⁻¹ with a varying traverse speed of 5 mm/min to 15 mm/min. The bottom part of the stir zone was perfectly welded without any defects. Tunnel defect was detected just above the bottom welded surface. Microstructural analysis reveals that the weld between both materials is formed on the retreating side, whereas on the advancing side, the weld was formed with void defects. Mostly, the stir zone is filled with irregular shaped aluminum and steel parts which were detached from the base material. Several other defects such as voids, cracks, and fragmental defects were observed in the stir zone irrespective of the process parameters. It was observed from the experimental investigations that the tunnel defect can be reduced by increasing the tilt angle.     

数字彩色像纸的照片品质控制

进入21世纪以来，数字照像在我国迅速推广、普及，普遍采用的方法是用数码相机拍摄．然后由专门的照像加工点用数字彩色像纸印成彩色照片。有别于传统的照像方法。数码照相机是用CCD或CMOS传感器记录影像的，在用彩色像纸印制时，可以由数码相机传感器储存的信号转换成对数字彩色像纸曝光的调制光，简化了整个成像过程，而且可以直接采用光能极强的激光代替传统的三原色印片光，大大加快了印片过程。本文针对数码彩色照片印片、冲洗加工过程的品质管理作了一个理论结合实际、全面而详细的阐述。     

铝合金薄板搭接高速 FSW 缺陷及断裂行为

目的 为了拓展搅拌摩擦焊技术应用,对薄板搭接结构高速搅拌摩擦焊工艺优化与工程应用提供 借鉴与指导。方法 采用圆锥无螺纹搅拌针,进行了 6061 铝合金薄板搭接高速搅拌摩擦焊接,对接头界 面缺陷及其断裂模式进行分析,探讨了转速对 6061 铝合金薄板搭接接头成形及性能的影响规律。结果 发现在无螺纹圆锥搅拌针、高转速（6000~9000 r/min）条件下,接头塑性金属在后退侧易形成飞边流出, 导致下板前进侧出现孔洞缺陷,且随转速增大,界面缺陷尺寸逐渐增大,当转速达到 10 000 r/min 时, 孔洞尺寸有所减小,此时接头拉剪强度最高,为 123 MPa。对试样拉剪断裂位置分析发现,高速搭接接 头断裂位置主要有两种,分别断裂在结合界面处或在前进侧下板,且转速在 9000 r/min 以上越趋向于在 结合界面断裂。结论 高转速搭接焊接必须协调轴肩相貌、焊接工装约束等条件,保证接头塑性金属充 分流动而不流失,才能获得成形良好无缺陷的接头。     

转速对6061铝合金搅拌摩擦搭接焊接头组织和力学性能的影响

目的 研究不同转速条件下6061铝合金搅拌摩擦搭接焊接头组织和力学性能的变化规律,为工程实践应用提供参考。方法 在不同旋转速度（800、1 200、1 500 r/min）下对4 mm厚的6061铝合金进行搅拌摩擦搭接焊实验,固定进给速度和轴肩下压量,研究搅拌头转速对接头宏观组织、微观组织和力学性能的影响。结果 所有接头均没有出现明显缺陷,当转速为1 500 r/min时,搅拌区晶粒尺寸细化明显,最大失效载荷达到母材的75%,上板和下板的硬度曲线都呈“W”形;当转速为800 r/min和1 200 r/min时,下板硬度曲线呈“V”形。随着转速的增大,有效搭接宽度逐渐增大,接头的平均拉剪强度也在增大,所有接头都在前进侧断裂,断裂形式均为拉伸断裂。结论 转速的提升增加了焊接热输入量和机械搅拌作用,促进了有效搭接宽度的增大和晶粒尺寸的细化,但未能改变钩状缺陷的形成及延伸方向。当转速为1500r/min时,热输入量较大,搅拌区范围相对较大,下板存在更大面积的搅拌区,其硬度规律与上板的相似。所有接头均为拉伸断裂,断裂位置在热影响区附近,说明搭接接头连接良好。     

轴箱轴承缺陷状态下的高速车辆振动特性分析

采用SIMPACK动力学软件,建立了一高速车辆出现轴箱轴承早期缺陷的动力学计算模型,将轴承假设为只有外圈和内圈两者之间的相互作用,轴承中的滚子直接等效成若干个力元,分别考虑了轴承的内、外圈以及滚子表面早期缺陷对车辆垂向振动特性的影响。仿真结果表明：当轴承表面出现早期缺陷时,轴箱振动加速度显著增大,而构架的加速度变化不大;当内外圈以及滚子缺陷尺寸（缺陷宽度和深度）相等时,轴承外圈缺陷对轴箱的加速度幅值影响最大,轴承滚子缺陷对轴箱加速度幅值影响最小;随着早期缺陷宽度的增加,3种轴承缺陷下的轴箱加速度幅值均逐渐变大;轴承早期缺陷能够引起轴箱的高频振动,但对车辆的平稳性影响甚微。     

Effect of friction stir processing conditions on fatigue behavior and texture development in A356-T6 cast aluminum alloy

Friction stir processing (FSP) was applied to A356-T6 cast aluminum alloy to modify the microstructure and to eliminate casting defects under two different tool rotational speeds. Plane bending fatigue tests had been conducted, revealing that FSP could enhance the fatigue strength where the lower rotational speed condition gave better results. The enhancement of fatigue strength was attributed to the elimination of casting defects. Crystallographic analysis by EBSD revealed that the texture induced by FSP had detrimental effect on growth resistance. The lower rotational speed condition resulted in the weaker texture, and consequently, further increase of fatigue strength was achieved compared with the higher rotational speed condition.     

基于长信号谱自相关的光纤光栅传感解调方法

针对光纤光栅传感领域波长高精度探测和传感复用光栅数量增多的需要,提出一种基于长信号相关谱的新型光纤光栅数字解调技术.该技术在可调谐滤波法的基础上,通过传感光栅与调制光栅反射谱卷积后的信号,即光电探测器的光强时间信号,进行自相关分析以实现对波长漂移的测量以及对传感光栅反射谱形状的识别,增强系统的复用能力,提高了性价比.模拟仿真表明,光纤光栅长信号相关数字解调方法可以准确测量光纤光栅波长的漂移,能更好实现传感复用.等强度悬臂梁实验验证该解调方法能实现光栅应变的高精度测量,优于传统的应变片测试.     

Microstructure and mechanical properties of dissimilar friction stir welding of 6061-to-7050 aluminum alloys

In this work, the microstructure and mechanical properties of friction stir welded dissimilar butt joints of 6061-to-7050 aluminum alloys were evaluated. Microstructure analysis of the cross-section of the joints revealed distinct lamellar bands and various degrees of intermixing that were correlated with tool rotational speed. Due to the distinct mechanical properties of the two alloys, microhardness measurements showed a consistent asymmetric hardness distribution profile across the weld nugget, regardless of tool rotational speed. Under monotonic tensile loading, an increase in the joint strength was observed with the increase in the tool rotational speed. Regarding fracture, the joints consistently failed on the 6061 aluminum alloy side. Furthermore, two modes of failure were observed, one through the stir zone and the other through the heat-affected zone. Inspection of the fracture surfaces suggested that inadequate material intermixing produced at low tool rotational speeds was the cause for the low mechanical strength and failure through the stir zone. On the other hand, the failure observed through the heat-affected zone at high rotational speeds was produced due to the material softening as confirmed by the microhardness measurements.     

深沟球轴承运转过程动态特性有限元分析

综合考虑轴承径向载荷及转速的影响,应用ANSYS/LS-DYNA软件建立了深沟球轴承多体动力接触有限元模型;以显式动力学有限元法为基础,采用全积分单元算法控制沙漏,设置质量缩放系数缩减计算时间,对内圈施加不同转速时的深沟球轴承进行动力接触分析,得出了深沟球轴承运转过程的动态响应及滚动体的应力分布。滚动体的最大和最小线速度分别出现在与内、外圈接触点上,各转速下滚动体与内圈接触的应力基本相同,滚动体与外圈接触的应力随转速增高而相应增大,滚动体与外圈间接触力的波动大于内圈,而滚动体与保持架间的作用力较小。研究表明,ANSYS/LS-DYNA是分析轴承运转过程动力接触问题十分有效的工具。     

基于天然纤维和热塑性树脂的包缠纺预型件:第2部分响应曲面方法模型的建立和过程优化

本文基于天然纤维和热塑性树脂,通过包缠纺纱工艺研究了包缠纱纺织预型件及其复合材料的加工性能.研究表明,中空锭捻度和中空锭转速是影响包缠纱预型件的纤维体积分数和性能的两个主要因素.并通过响应曲面方法建立了实验模型,来优化组合中空锭捻度和中空锭转速的参数以得到结构均匀的包缠纱线和预型件.结果表明该包缠纱适合于生产均一的预混料,可用于形成纺织结构预型件及复合材料.并且这些结果表明在许多不需要很高承载能力的应用中,用此方法加工的天然纤维复合材料有可能取代玻璃纤维复合材料.     

异种铝合金回填式搅拌摩擦点焊工艺的研究

目的 研究搅拌头转速和轴套下压量对异质铝合金回填式搅拌摩擦点焊接头的组织及力学性能的影响。方法 采用回填式搅拌摩擦点焊技术对7050铝合金和2524铝合金进行搭接焊试验,焊接完成后利用光镜、体式显微镜、扫描电镜对组织进行观察,另外,测试拉伸剪切载荷和显微硬度分布,最后对断裂行为进行了研究。结果 接头区域可以分为焊核区、热力影响区、热影响区、母材4个区域,焊核区晶粒呈细小等轴状,热力影响区晶粒呈粗大长条状。随搅拌头转速的增大,拉剪载荷降低,当转速为1500 r/min时拉剪载荷值最高,其值为7.499 44 kN。热影响区的显微硬度比母材低,最小值为HV106。接头的断裂方式可以分为剪切型断裂、塞型断裂、剪切-半环型断裂。结论 在一定工艺参数范围内,通过适当降低搅拌头转速能显著提高接头的拉剪载荷,轴套下压量对接头的断裂方式影响显著。     

Condition Monitoring of Slow‐Speed Shafts and Bearings with Acoustic Emission

Abstract: For various rotating machinery applications, condition monitoring using high‐frequency Acoustic emission (AE) technology has remained a subject of intense study since the late 1960s. This paper demonstrates the results of an investigation for detecting and monitoring natural crack initiation and propagation in slow‐speed rotating machinery with the AE technology. In addition to highlighting previous work published by the authors [ 1 - 3 ] on condition monitoring of slow‐speed rotating machinery, this paper presents experimental results on accelerated bearing fatigue under starved lubricating conditions. For these investigations, purpose‐built test rigs were employed for generating natural degradation on both a bearing and a shaft. It is concluded that crack initiation and propagation on slow‐speed bearings and shafts can be detected with the AE technology.     

低能载条件下C/C复合材料滑动摩擦磨损性能

采用MM-200型环-块摩擦磨损试验机测试了针刺碳毡增强C/C复合材料试样在不同载荷和转速条件下的摩擦磨损性能,借助数码显微镜和扫描电镜观察分析了摩擦表面形貌。结果表明:当转速较低时,摩擦系数比较稳定,磨损率随载荷提高而增大;当转速较高时,低载荷试样摩擦系数不大,磨损率有所增加,而高载荷试样的摩擦系数在5分钟左右时出现峰值然后回落并保持稳定,磨损率急剧增加,说明磨损机制发生变化;摩擦面平行于X-Y向的C/C复合材料磨损率较小,具有较好的摩擦磨损性能。