渐开线直齿轮瞬态微观热弹流润滑分析

考虑了瞬态效应、轮齿表面油膜温度场和轮齿表面纵向粗糙度等因素,对渐开线直齿圆柱齿轮的弹流润滑问题进行研究。载荷由双齿或单齿承担,根据实际载荷谱简化的轮齿载荷曲线,利用压力求解的多重网格法和弹性变形求解的多重网格积分法以及温度求解的逐列扫描技术,得到渐开线直齿轮瞬态微观热弹流润滑问题的完全数值解,讨论了轮齿间油膜的厚度、压力、温度沿啮合线的变化规律。数值计算结果表明,齿轮表面纵向粗糙度对轮齿间油膜的压力、膜厚、温升都有较大影响。考虑轮齿表面粗糙度后,油膜压力和温升明显增大,并随压力的增加而影响越来越显著,粗糙峰使油膜压力分布和温度分布产生振荡,轮齿表面的粗糙峰对摩擦因数影响较小,摩擦因数和最高温升在节点两侧最大。     

考虑黏压效应的风电齿轮热弹流分析

在线接触热弹流润滑的基础上,考虑黏压效应,对风电行星轮系齿轮副进行热弹流润滑数值分析,并采用热弹流润滑数值方法和ISO/TS 6336-22计算了齿轮副的最小油膜厚度、安全系数和闪温温度,并比较各主要啮合点的压力和油膜厚度分布。结果表明：与使用ISO/TS 6336-22计算的结果对比,采用热弹流润滑理论计算的油膜更厚,但安全系数更小;在风电齿轮副热弹流润滑分析时应考虑压力对黏度的影响;风电主齿轮箱齿面因啮合产生油膜厚度随温度增加会迅速降低,最小油膜厚度会随载荷增加迅速减小,因此风电齿轮箱要保证足够的润滑,并尽量避免在高于额定载荷下长时间持续运行     

渐开线直齿圆柱齿轮非稳态热弹流润滑分析

应用多重网格技术,不考虑轮齿表面粗糙度的影响,假设润滑剂为牛顿流体,考虑齿轮重合度对轮齿载荷的影响,根据实际轮齿载荷谱简化的轮齿载荷函数,求得了渐开线直齿圆柱齿轮非稳态热弹流润滑问题的完全数值解。结果表明,考虑油膜温升后,温度对轮齿啮入和啮出点的油膜厚度有显著影响。齿轮啮合过程中的最大油膜压力、最高油膜温升和轮齿间摩擦因数最大值都发生在啮合节点附近。在传动比大于1时,齿轮啮合过程中的最小油膜厚度通常在轮齿的初始啮入点。两轮齿间的油膜温升和摩擦因数受滑滚比、卷吸速度和载荷的影响。     

Analysis of wheel and rail adhesion under wet condition by using elastic–plastic microcontact model

This paper presents a numerical model to investigate the adhesion characteristics of the wheel/rail contact with consideration of surface roughness under wet conditions. The elastohydrodynamic lubrication theory is used to obtain the load carried by water, and the statistical elastic–plastic microcontact model presented by Zhao–Maietta–Chang is applied to calculate the load carried by asperities contact. Meanwhile, the thermal influencing reduction factor is used to consider the inlet heating effects on the film thickness, and the change of water viscosity is also taken into consideration due to the flash temperature generated by the moving rough surfaces. Furthermore, the present work investigates the dependence of the wheel/rail adhesion coefficient on train speed, surface roughness amplitude, the initial temperature, the plasticity index and the maximum contact pressure under wet condition. Copyright © 2014 John Wiley & Sons, Ltd.     

考虑表面粗糙度和热效应的线接触非牛顿混合润滑分析

为了研究表面粗糙度及热效应对非牛顿混合润滑的影响,基于平均流量模型,考虑表面粗糙度以及热效应,建立线接触非牛顿混合润滑模型。研究表面粗糙度对膜厚、膜厚比、平均摩擦因数、载荷比以及温度分布的影响,并与等温解进行比较。结果表明:随着表面粗糙度的增大,油膜温度逐渐升高,尤其是出口区与入口区的温升最为显著,且油膜温升越大,载荷比及平均摩擦因数越大,膜厚比越小;与等温解相比,热解的膜厚比及平均摩擦因数小,载荷比大;等温与热条件相比,中心膜厚与最小膜厚随表面粗糙度的变化趋势差异显著,说明热效应对混合润滑的影响不可忽略。     

Analysis of rough line contacts operating under mixed elastohydrodynamic lubrication conditions

Heavily loaded machine elements, such as gears, usually operate in the mixed lubrication regime. Surface roughness has a significant effect on the pressure distribution, the subsurface stress field, and the friction coefficient. Based on the superposition of a dry rough and a fully flooded smooth contact, a mixed lubrication model has been developed. The roughness profile is assumed to be known. Surface deformation is calculated by taking into account the pressure distribution that is built up by asperity contacts, asperity interactions, and lubricant flow. Thermal and sliding effects are incorporated into the analysis. Non‐Newtonian lubricant behaviour is considered by using a power‐law rheological model. The pressure distribution, subsurface stress field, and friction coefficient were calculated from the model at several points along the contact path for an FZG type C gear pair. It was shown that a significant part of the load is carried by the contacting asperities. The position of the maximum shear stress is very close to the surface.     

冷轧铝工作区的混合润滑特性研究

为研究冷轧铝工作区的混合润滑特性,基于平均流量理论建立考虑表面粗糙度的冷轧铝工作区混合润滑模型,并通过相关文献的数据验证模型的正确性.在不同轧制速度、润滑油黏度以及前后张应力条件下对整个工作区内的润滑特性进行分析,研究轧制工艺参数对油膜厚度、接触面积比以及应力分布的影响.仿真结果表明:随着轧制速度的提高,轧制压力有一定...     

Combined effects of surface roughness and viscosity variation due to additives on long journal bearing

Abstract

The combined effects of surface roughness and viscosity variation due to additives on long journal bearing are analytically studied. The variation in viscosity along the film thickness is considered. The presence of solid particles in the lubricant is an increased effective viscosity, which increases the load carrying capacity and decreases the frictional coefficient, whereas the viscosity variation tends to decrease both the load carrying capacity and coefficient of friction for non-micropolar fluid case. The modified Reynolds type equation for surface roughness has been derived on the basis of Eringen’s micropolar fluid theory. The generalised stochastic random variable with non-zero mean, variance and skewness is assumed to mathematically model the surface roughness on the bearing surface. Numerical results were obtained for the fluid film pressure, load carrying capacity and the coefficient of friction. It is observed that the combined effect is to increase the load carrying capacity and to decrease the coefficient of friction, which improves the performance of the bearing.     

Numerical evaluation of pressure from experimentally measured film thickness in EHL point contact

This paper is concerned with elastohydrodynamic lubrication, especially the determination of lubricant film thickness and contact pressure within a point contact of friction surfaces of machine parts. A new solution technique for numerical determination of contact pressure is introduced. The direct measurement of contact pressure is very difficult. Hence, input data of lubricant film thickness obtained from the experiment based on colorimetric interferometry are used for the calculation of pressure using the inverse elasticity theory. The algorithm is enhanced by convolution in order to increase calculation speed. The approach described in this contribution gives reliable results on smooth contact and in the future, it will be extended to enable the study of contact of friction surfaces with asperities. Copyright © 2007 John Wiley & Sons, Ltd.     

粗糙度各向异性对润滑接触面摩擦的影响

齿轮、轴承、凸轮等重载接触副的性能受表面粗糙度的显著影响。高负载情况下的摩擦因数与润滑接触面粗糙度的各向异性相关。测量的表面粗糙度可以分解为一系列具有不同波长、幅值的正弦表面粗糙度,因此,考虑各向异性正弦表面粗糙度,构建粗糙表面点接触瞬态弹性流体动力润滑(TEHL)模型,提出基于多重网格算法的粗网格构造新方法,提高粗糙表面润滑问题求解的稳健性。研究表面粗糙度各向异性对高负载情况下摩擦因数的影响规律。结果表明,粗糙度的各向异性影响接触面压力、油膜厚度分布、粗糙度形变量,从而影响摩擦因数。提出一个组合函数来量化粗糙度各向异性对摩擦因数的影响,表明全膜润滑到混合润滑的过渡不仅与载荷、速度等工况参数相关,还与粗糙度各向异性相关。     

A study on the effect of starvation in mixed elastohydrodynamic lubrication

The effect of starvation in mixed elastohydrodynamic lubrication (EHL) regime is studied. Numerical simulations are conducted for both line and point (elliptical) contacts with the consideration of the surface roughness. The degree of starvation is linked directly to the reduction in the lubricant mass flow rate. Results are presented to gain insight on the influence of starvation on the film thickness as well as the interaction between the surface asperities. Extensive sets of simulation results are used to quantify the effect of starvation in the EHL of rough surfaces. Expressions are developed to predict the percentage of the load carried by the surface asperities (asperity load ratio) as well as the reduction of the central and minimum film thickness in the starved mixed EHL.     

A partial elastohydrodynamic theory for the running-in process of hobbed gears

The running-in process of hobbed gears has been studied experimentally. The initial wear was found to be small although it increased with running speed and load. To explain the results, a simulation procedure was developed that was based on a random surface model and a proposed relation between film thickness, surface roughness and running conditions. A new oil model was used for the analysis of conditions between meshing rough flanks. The wear and deformation of asperities during the running-in period is due to direct contact between the asperities. The parameters determining wear and deformation are the adhesion and temperature between the asperities in contact.     

齿轮传动的瞬态弹性流体动力润滑

本文考虑了流体可压缩性，衙合度对轮齿荷的影响以及变曲率，变速度的瞬态效应，给出了齿轮传动瞬态弹流润滑方程及其求解方法，在引入齿轮传动的实际工况参数后进行完全数值解，得到了两齿轮在啮合线任意上的油膜压力分布和油膜形状以及最小油膜厚度沿啮合线的变化曲线。     

Effect of viscosity variation due to lubricant additives in journal bearings

Micropolar fluid theory, which is a possible non-newtonian model of a suspension of rigid particle additives, is applied to the study of the lubrication of an infinitely long and an infinitesimally short journal bearing. The variation in viscosity along the film thickness is taken into consideration. The prominent feature of the presence of solid particles in the lubricant is an increased effective viscosity which increases the load capacity and decreases the coefficient of friction. Whereas viscosity variation tends to decrease both the load and the coefficient of friction for the non-micropolar case, the combined effect is to increase the load and to decrease the coefficient of friction.     

Influence of Oil Viscosity,Chemical Oil Structure,and Chemical Additives on Friction Loss of Spur Gears (Concerning the Influence of Synthetic Oil and Mineral Oil)

The friction loss of gears and its quantitative estimation are important problems because of their relevance to energy conservation and load-carrying capacity. Recent research results do not provide satisfactory estimates of friction loss of spur gears. Therefore, the authors carried out experiments to study the influences of lubricating oil viscosity and additives, as well as base oil type and load and rotational speed on friction loss of spur gears. Base oil types used were paraffin mineral, poly-α-olefin, and polyglycol with several oil viscosities. An EP and a mild EP additive were studied in these oils. Finally, the temperature rise of teeth of gears as a function of friction power loss was investigated, and an empirical formula for calculating the temperature rise of the spur gear teeth was derived.     

The Effectiveness of Boundary and Hydrodynamic Lubrication when Cold Rolling Aluminum Metal

How hydrodynamic and boundary lubrication affect a lubricant's film strength when cold rolling aluminum was studied using a laboratory mill. The film strength of the lubricant was determined by increasing the amount of reduction until a rapid rise in load and temperature produced a herringbone pattern on the surface of the metal. The hydrodynamic lubrication was changed by increasing the viscosity of the base oil or by increasing the rolling speed. The boundary lubrication was changed by increasing the concentration of the additives or by changing the type of additives. The results of the test showed that either increasing the amount of the hydrodynamic lubrication or increasing the amount of the boundary lubrication were effective ways to increase the film strength of the lubricant; however, the effectiveness of each decreased as the calculated film thickness of the lubricant increased. It is proposed that this can be explained by the decrease in contact area between the work roll asperities and the surface of the sheet as the thickness of the lubricant film increases.     

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.     

Effect of Lubricant Contamination on Gear Wear

In this work the degradation of spur gears lubricated in a severe dusty environment studied. An experiment was carried out, which simulates the operation of gears in contaminated media such as the Sahara desert, quarries, or mines. The present study gives the effect of the presence of solid bodies in lubricants during surface contact. This paper shows that the use of a lubricant contaminated by very fine sand particles, leads to significant wear in the first few operating cycles, in zones with a high rate of sliding. This wear is more significant at the gear tooth root than at the tip. In order to understand the wear phenomenon, Scanning Electronic Microscopy (SEM) images were taken. The presence of contaminants, leads to an increase in friction, and therefore raises the temperature; consequently the roughness increases. The roughness values become more significant with the presence of particles smaller than 40 μm in the lubricant.     

Temperature—The Key to Lubricant Capacity

Failure of a nonreactive mineral oil can be predicted by Blok's formula for determining the maximum temperature between two bodies in rolling and sliding contact. Evaluation of many lubricants on a geared roller lest machine revealed that the lubricant failure for any particular lubricant-material combination occurs at a constant, critical contact temperature over wide ranges of load, sliding velocity, surface velocity, specimen temperature, film thickness, and viscosity grade. Coefficient of friction can be predicted by a parameter involving the unit load, inlet viscosity, sum velocity, and sliding velocity. The load capacity of a lubricant varies inversely with specimen temperature for a constant set of lest conditions. Electrical resistance measurements across the contact zone aided in identifying the lubricant failure point and in revealing the action of two deposit-forming additives.