基于小波的零件表面微观形貌多尺度重构

采用激光测量仪对车削机加工零件表面进行测量,获得零件亚纳米级的微观形貌数据,利用小波分析分时分频精细表达以及多分辨率分析的特点,建立粗糙表面多尺度重构模型,对基于真实测量数据的微观表面进行宏微观重构,并提出在不同尺度上提取粗糙表面的微凸体以精简数据的方法,从而实现在MATLAB和Pro/E中的微观表面建模仿真。提取的低频成分为零件表面二维和三维评定提供了基准,不同尺度上微观粗糙表面的重构为在不同精密等级上分析机加工工艺对零件表面粗糙度的影响提供了方法,Pro/E中重构的表面为有限元分析零件宏微观几何形貌与摩擦、润滑和密封的关联机制提供了几何模型。     

微观随机粗糙表面接触有限元模型的构建与接触分析

基于相关文献提出粗糙表面模拟方法,通过软件工具在ANSYS中建立微观粗糙表面接触有限元模型,利用该模型分析载荷对弹塑性变形和接触面积的影响。结果表明:随着正压力的增大,粗糙表面上不断地有微凸峰与平面发生弹性接触变形,接触斑点(或接触斑点群)的数目逐渐增加,斑点中心区域的弹性变形很快达到最大,微凸峰负荷变形的同时也使斑点四周区域受到挤压;初始接触时,轮廓高度较大的微凸峰率先发生弹性变形,随着压力的增大,金属材料所受应力达到屈服极限同时粗糙表面的弹性变形和塑性变形的集中区域不断增加,真实接触面积不断增大;接触区数目的增多和接触区面积的增加都可以导致接触面上真实接触面积增加;随着压力的增大,真实接触面积的增大并不是由于接触区数目的增多,而是微观接触区面积的增大。     

零件真实粗糙表面构建及微观接触性能分析

目前对于微观粗糙表面模型的构建主要采用统计数学方法和分形方法,建模的前提基于大量假设和简化,不能真实反映表面形貌特征。因此提出了采用三维数字化测量与逆向工程相结合建立零件真实粗糙表面的方法,并分析微观接触性能。利用三维形貌测量仪测量得到真实粗糙表面形貌数据,并经过数据精简、去噪处理,采用逆向建模方法得到真实粗糙表面的三维实体模型;应用有限元分析技术,分析粗糙表面接触性能,包括结合面接触应力随载荷变化规律、不同加工方式零件界面真实接触面积变化规律,以及结合面受力-变形关系等。该方法有利于揭示零件微观界面接触机理,为进一步研究宏微观接触性能提供了方法参考。     

机械结合面接触模型有限元分析

借助LI-3型表面形貌测量仪对磨削加工的铸铁试件进行了三维形貌测量,基于实测表面数据逆向建模得到三维有限元模型,并导入ANSYS软件中建立该粗糙表面的接触模型。通过对不同采样长度下的机械结合面接触模型进行有限元仿真分析,研究了其接触面积、最大变形量和接触压力随载荷的变化关系。结果表明,采样长度越小,越能体现表面形貌精细结构,微凸体分布更加均匀。相同粗糙度、不同采样长度下表面接触特性的探索对于从微观方向解释宏观现象,揭示结合面作用机理的本质,具有良好的参考价值。     

螺栓联接界面表面分形及接触研究

针对由螺栓联接的两个粗糙表面微观特征和实际接触情况进行了研究。采用分形函数模拟生成了粗糙面轮廓曲线,发现分形参数对传统粗糙度参数有影响;探讨了分形维数D与机械加工面传统粗糙度参数Ra的关系;利用表面分形模拟数据和实验测量数据建立了有限元接触模型。运用Abaqus软件对模型计算表明:随着接触载荷(螺栓预紧力)的增加,接触面积也相应增加;在相同接触载荷(螺栓预紧力)下,表面越光滑,接触面积越大;当接触面积增加到某一值后,改变不明显,且接触面积小于名义接触面积。这一结论可以很好的解释超声波能量在螺栓联接界面的传递机理,即预紧力-真实接触面积-能量三者的关系,为超声波能量法在螺栓松动监测中的应用提供理论基础。     

新的粗糙表面弹塑性接触模型

提出一种新型的粗糙表面弹塑性微观接触模型.该模型的建立基于接触力学理论和接触微凸体由弹性变形向弹塑性变形及最终向完全塑性变形的转化皆是连续和光滑的假设.研究单个微凸体在载荷逐渐增加时的变形规律,并重点推出弹塑性变形区间的接触方程.在此基础上应用概率统计理论导出了粗糙表面的接触载荷、平均分离和实际接触面积之间的数学关系式.在不同的塑性指数和载荷条件下,该模型与GW弹性模型和CEB弹塑性模型就实际接触面积和法向距离的预测结果进行了对比.结果表明,在同样塑性指数和载荷条件下比GW模型预测的实际接触面积大但法向距离小,且两者的差距随塑性指数和载荷的增加而增大.因此该模型的预测结果更加符合人们的试验观察和直觉,能够更加科学和合理地描述两个粗糙表面的微观和宏观接触状态.     

过盈配合单向分形界面微观接触面积研究

通过对模拟压缩机叶轮和轴过盈配合的试件表面轮廓进行分析,发现切削加工的粗糙配合表面具有单向粗糙度特征,同时垂直加工纹理方向的表面轮廓具有明显分形特性。基于M-B分形接触的修正模型,建立了具有单向粗糙度分形特征表面的理论接触模型,推导出接触面积与法向载荷的函数关系式。结合真实粗糙表面,建立了具有分形特性的单向粗糙度实体模型,利用有限元分析软件对实体模型进行了仿真分析,验证了接触面积与法向载荷函数关系的正确性。     

基于分形理论的结合面微观接触特性分析

为了研究结合面微观接触特性,基于分形理论,建立粗糙表面轮廓模型,进行结合面接触趋近耦合研究。通过二维粗糙表面与光滑表面微观接触趋近过程的仿真分析,研究分形维数、表面粗糙度、位移载荷对结合面接触状态的影响机理。提出利用激光声表面波检测粗糙结合面接触的方法,并进行了实验验证。研究结果表明,粗糙表面微凸体形貌是决定材料接触性能的关键因素;微凸体接触形成的真实接触面积远小于名义接触面积。工程问题中,通过名义接触面积计算出的载荷与材料表面实际承受的载荷存在较大差异。     

机械密封环端面各向异性分形接触分析

在 M-B 分形接触模型的基础上,建立机械密封环端面各向异性的数学模型。在考虑表面各向异性的情况下,分别利用弹性力学和分形接触模型相关原理求出端面接触载荷和弹塑性接触面积,分析表面纹理参数、端面接触载荷和接触面积三者之间的关系。结果表明：当施加一定的接触载荷时,随着表面纹理参数增大,真实接触面积增大,但增速逐渐变缓,弹塑性接触面积的比值在增大;在表面纹理参数不变时,随着真实接触面积的增加所需的接触载荷增大,但增加速逐渐变缓,弹塑性接触面积的比值随着接触载荷的增大而增大。在粗糙表面各向同性和各向异性两种情况下,接触载荷与接触面积的变化趋势是一致的,但考虑表面各向异性时,能更好地反映出真实粗糙表面各个参数之间的关系。     

机床导轨表面接触模型的有限元分析

为寻求机床导轨结合面不同粗糙信息下的动态特性,分形粗糙表面数值模型和实测粗糙表面二者的相关性,需对各种相关参数下的粗糙表面进行接触分析。运用有限元分析软件ANSYS,针对粗糙表面三维模型,分析不同参数表面的接触行为,以期寻找出不同粗糙信息接触形态特征参数之间的关系,并证明分形数值模拟能真实表征工程粗糙表面。     

粗糙表面间密封性能研究进展

在微观尺度下的静密封界面表面形貌是粗糙不平的，两粗糙表面上的微凸体在载荷作用下会接触形成孔隙；随着接触压力的减小或观察尺度的增加，当孔隙增加到一定数量时孔隙之间会相互连通形成泄漏通道，影响密封性能。现有的粗糙表面密封分析基于均化思想、逾渗理论和多孔介质思想等方法建立泄漏通道模型，考虑表面粗糙度、表面纹理以及表面载荷等对密封性能的影响。对现有的粗糙表面间密封性能的研究现状进行综述，分析现有的粗糙表面密封研究方法存在的不足之处，指出粗糙表面间密封研究可能的方向，为进一步研究粗糙表面密封机制提供了参考。     

粗糙表面弹性微动接触数值研究

由于实际工程表面多为粗糙表面,这里研究了粗糙表面对微动接触中压力和切向应力的影响。研究接触过程中法向载荷保持不变,切向载荷为周期性的交变载荷。首先,建立接触算法和模型,其算法核心是利用共轭梯度法(CGM)计算微动接触中的表面压力及切向应力并使用快速傅里叶变换(FFT)加快计算速度。然后,在验证算法正确的基础上,分析正弦和非高斯粗糙表面接触的压力和切向应力的分布,通过对光滑与粗糙表面的研究对比,表明:(1)在正弦表面接触切向应力分布呈现尺寸效应;(2)在非高斯表面接触中,切向应力分布跟光滑表面形状类似;同时由于粗糙峰存在,粗糙表面下的切向应力比光滑表面下的要大,研究粗糙表面微动接触对实际工程具有重要意义。     

双粗糙平面法向接触建模方法的有限元对比分析

基于统计学方法,Greenwood和Tripp(GT模型)提出双粗糙平面法向接触(双粗模型)可以等效为单粗糙平面与刚性平板之间的接触(单粗模型),但这种等效处理缺乏对接触应力场分析以及材料硬化的考虑。为进一步研究GT模型,基于高斯粗糙表面数字化表征,通过控制自相关长度和滤波方法,得到双粗糙平面及其等效单粗糙平面;借助有限元软件ABAQUS对2组模型法向接触进行建模及分析。结果表明:2组模型预测的接触刚度和接触面积符合较好,但接触压力与接触面积关系存在差异;2组模型预测的等效应力和接触压强的应力幅值以及云图的分布区域大致相近,但双粗模型由于存在大量微凸体侧接触,弱化接触状态以及材料硬化,因而应力幅值偏低。     

基于接触分形理论的机械结合面法向接触刚度模型

为能够从理论上建立起具有尺度独立性的机械结合面法向接触刚度的理论模型,从而解决以往研究 荼存在的缺陷与不足,在一定的假设下,基于球体与平面的赫兹接触理论和接触分形理论,首次从理论上给出了具有尺度独立性的机械结合面法向接触刚度分形模型,并取得了与实验一致的数字仿真研究结果。     

Fractal prediction model of thermal contact conductance of rough surfaces

The thermal contact conductance problem is an important issue in studying the heat transfer of engineering surfaces,which has been widely studied since last few decades,and for predicting which many theoretical models have been established.However,the models which have been existed are lack of objectivity due to that they are mostly studied based on the statistical methodology characterization for rough surfaces and simple partition for the deformation formats of contact asperity.In this paper,a fractal prediction model is developed for the thermal contact conductance between two rough surfaces based on the rough surface being described by three-dimensional Weierstrass and Mandelbrot fractal function and assuming that there are three kinds of asperity deformation modes:elastic,elastoplastic and fully plastic.Influences of contact load and contact area as well as fractal parameters and material properties on the thermal contact conductance are investigated by using the presented model.The investigation results show that the thermal contact conductance increases with the increasing of the contact load and contact area.The larger the fractal dimension,or the smaller the fractal roughness,the larger the thermal contact conductance is.The thermal contact conductance increases with decreasing the ratio of Young’s elastic modulus to the microhardness.The results obtained indicate that the proposed model can effectively predict the thermal contact conductance at the interface,which provide certain reference to the further study on the issue of heat transfer between contact surfaces.     

基于多孔介质理论的双粗糙面金属静密封泄漏模型

粗糙面微观几何形貌是影响静密封泄漏特性的重要因素。应用粗糙面的三维点云数据,将粗糙面进行离散化处理,进而将由双粗糙面构成的密封界面等效为三维逾渗栅格模型,基于多孔介质理论计算得到密封界面的孔隙率和渗透率,从而建立了一种双粗糙密封界面的泄漏率模型。搭建金属静密封泄漏率测量试验台,通过对环面金属静密封泄漏特性的试验研究,验证了该泄漏模型的有效性。利用该模型分析了表面纹理方向、粗糙面波动频率与材料特性对金属静密封泄漏特性的影响。结果表明：各向异性粗糙面构成的密封界面具有较好的密封性能;粗糙面波动频率越大,密封性能越好;低硬度材料易于实现有效密封;在重载情况下,粗糙面微观几何形貌对孔隙率与泄漏率的影响不显著。     

A numerical model of friction between rough surfaces

This paper describes a computational method to calculate the friction force between two rough surfaces. In the model used, friction results from forces developed during elastic deformation and shear resistance of adhesive junctions at the contact areas. Contacts occur between asperities and have arbitrary orientations with respect to the surfaces. The size and slope of each contact area depend on external loads, mechanical properties and topographies of surfaces. Contact force distribution is computed by iterating the relationship between contact parameters, external loads, and surface topographies until the sum of normal components of contact forces equals the normal load. The corresponding sum of tangential components of contact forces constitutes the friction force. To calculate elastic deformation in three dimensions, we use the method of influence coefficients and its adaptation to shear forces to account for sliding friction. Analysis presented in Appendix A gives approximate limits within which influence coefficients developed for flat elastic half-space can apply to rough surfaces. Use of the method of residual correction and a successive grid refinement helped rectify the periodicity error introduced by the FFT technique that was used to solve for asperity pressures. The proposed method, when applied to the classical problem of a sphere on a half-space as a benchmark, showed good agreement with previous results. Calculations show how friction changes with surface roughness and also demonstrate the method's efficiency.     

Theoretical and Finite Element Analysis of Static Friction Between Multi-Scale Rough Surfaces

The current work considers the multi-scale nature of roughness in a new model that predicts the static friction coefficient. This work is based upon a previous rough surface contact model, which used stacked elastic–plastic 3-D sinusoids to model the asperities at multiple scales of roughness. A deterministic model of a three-dimensional deformable rough surface pressed against a rigid flat surface is also carried out using the finite element method (FEM). The accuracy of the deterministic FEM model is also considered. At the beginning of contact, which is surface-point contact, the asperities or peaks are isolated, sharp, and the contact areas consist of an inadequate number of elements and sources of error. In this range of contact, the results are not presented as real or accurate. As the normal load increases, the number of the contact elements become larger, and thus, the results become more accurate. That is, the deterministic FEM results are most accurate at high loads. Spectral interpolation is used to smooth the geometry in between the original measured nodes. The effects of normal load and plasticity index on static friction are then analyzed. The results predicted by the theoretical model are also compared to other existing rough surface friction contact models and the FEM results. They are in a good qualitative agreement, especially for higher loads and higher plasticity indices. The FEM model also has significant error, but it is more accurate at higher loads where the proposed multi-scale static friction model and FEM model are in better agreement.     

Surface separation and contact resistance considering sinusoidal elastic–plastic multi-scale rough surface contact

The current work considers the multi-scale nature of surface roughness in a new model that predicts the real area of contact and surface separation as functions of load. This work is based upon a previous rough surface multi-scale contact model which used stacked elastic–plastic spheres to model the multiple scales of roughness. Instead, this work uses stacked 3D sinusoids to represent the asperities in contact at each scale of the surface. By summing the distance between the two surfaces at all scales, a model of surface separation as a function of dimensionless load is obtained. Since the model makes predictions for the real area of contact, it is also able to make predictions for thermal and electrical contact resistance. In accordance with concerns in previous works that the iterative calculation of the real contact area in multi-scale methods does not converge, this work not only tests but also gives conditions required for convergence in these techniques. The results are also compared to other existing rough surface contact models.