纵-扭复合超声对滚齿面强化机理及表面特性研究

为了强化齿面,提高齿轮表面的使役性能,使用一种新的纵-扭复合强化加工方法对齿轮进行强化。首先,基于赫兹接触理论和齿轮啮合理论,建立了纵-扭超声滚压齿面等效应力的理论模型;其次采用有限元仿真技术对该加工方式进行了模拟;最后利用已经搭建好的试验平台进行了一系列的纵-扭超声对滚齿面强化试验。通过对比仿真与理论结果对比,施加纵-扭超声后可以有效的提高接触应力,中有无超声振动接触应力提高约1.7倍～2倍,致使齿轮表面材料发生屈服进而完成。试验结果进一步表明纵-扭超声滚强化压改善了齿面的表面特性。当施加纵-扭复合超声振动时,齿面残余应力随阻尼力矩增大而增加,沿齿廓方向残余应力呈现先增大后减小趋势,在节圆处残余应力值最大。齿面的显微硬度HV_1.0数值沿齿廓呈现时变特性,超声滚压强化加工可以改善齿面表面形貌。与传统滚压相比,超声滚压强化后表面峰谷间距加宽,粗糙度降幅可达45%～55%。因此,纵-扭超声对滚强化加工可以实现齿面强化、改善齿面特性,提高残余压应力和显微硬度、降低表面粗糙度并提高齿面质量。     

基于多参数耦合的滚动轴承油膜刚度分析

针对传统经验公式难以准确反映滚动轴承正常工作时油膜刚度动态变化的问题,根据滚动轴承运行时油膜状态分布,基于非Newton流体弹流润滑理论,考虑表面粗糙形貌、热效应、时变效应等因素,建立滚动轴承油膜刚度计算模型。通过数值计算,得到一个完整工作周期内油膜压力、膜厚、温度和刚度变化规律。结果表明:油膜刚度在一个周期内呈非线性变化,并随载荷、黏度、表面粗糙度幅值的增大而增大,随卷吸速度的增大而有所减小;油膜刚度的振荡频率随表面粗糙度波长和粗糙表面纹理走向与轴承滚动方向夹角增大而增大;滚动轴承正常工作时,油膜的温升最大,内圈次之,滚动体最小且不可忽略。     

基于动力学分析的大重合度直齿圆柱齿轮强度计算

为了探索大重合度直齿圆柱齿轮的承载能力,以2排交错布置、具有纵向重合度的直齿圆柱齿轮为研究对象,基于由动力学分析得到的轮齿间动态法向力的变化规律和齿轮的啮合点位置,采用有限元分析法计算其齿根弯曲应力,利用Hertz公式计算其齿面接触应力。通过计算可知：与静态工况相比,考虑齿轮传动系统动力学效应时,大重合度直齿圆柱齿轮的最大齿根弯曲应力增大了22.49%,最大齿面接触应力增大了10.94%;与渐开线标准直齿圆柱齿轮相比,大重合度直齿圆柱齿轮的最大齿根弯曲应力减小了17.08%,最大齿面接触应力减小了43.79%。结果表明,大重合度直齿圆柱齿轮的强度大幅提升,应用潜力巨大。     

不同制动速度下C/C复合材料摩擦面研究

采用MM-1000型摩擦磨损试验机测试了粗糙层基体炭C/C复合材料试样在不同制动速度下的摩擦磨损性能, 借助微区拉曼光谱和扫描电镜研究了试样摩擦面的结构与形貌。结果表明粗糙层基体炭C/C复合材料具有优异的摩擦速度特性。试样的摩擦系数和试验后摩擦面上碳原子的有序度无直接对应关系, 制动速度对摩擦系数的影响应归因于制动速度对摩擦面温升和摩擦膜厚度及完整性的影响。5m/s的低制动速度下, 试样因吸附水气摩擦系数持续低值(0.15), 摩擦面上无连续摩擦膜产生; 10m/s的制动速度下水气被解吸附, 摩擦面出现多层厚膜, 摩擦系数达到峰值(0.5), 此后, 随制动速度增加, 摩擦膜减薄, 材料磨损量呈下降趋势; 当制动速度增加到25m/s及以上, 摩擦面的温升导致氧化质量损失和线磨损增加, 摩擦系数也稍有衰减(0.3)。      

计及齿面摩擦的直齿轮动力学分析

建立了考虑齿面摩擦影响的六自由度非线性直齿轮动力学模型,以FZG试验专用A型齿轮为研究对象,计算了实际时变啮合刚度,基于混合润滑模型分析了不同齿面粗糙度对应的时变摩擦系数,利用数值仿真方法研究了齿面粗糙度改变对齿轮啮合力、摩擦力、轴承力以及动传动误差等信号的时频特征的影响,并利用FZG试验台对A型齿轮具有完好齿面和损伤齿面两种状态下的多个振动加速度时频信号进行比较分析,验证了仿真结果。结果表明：齿面摩擦力会抑制啮合线方向的振动,齿面粗糙度增大会减小动传动误差,但加剧摩擦力方向振动,从而导致系统振动幅值增加,结论对齿面微损伤的故障诊断有实用参考意义.     

直线运动滚动导轨副混合润滑研究

综合考虑了直线运动导轨副接触几何、预紧力、真实表面粗糙度、曲率系数等因素,建立了直线运动导轨副混合润滑数值模型,研究了滑块移动速度、曲率半径系数、工作载荷、表面粗糙度对导轨接触副润滑特性的影响,得到结论:导轨副法向工作载荷、最大赫兹接触压力和赫兹接触半径随着外加总载荷的增大而增大,平均膜厚随着载荷的增大而减小;混合润滑模型可预测导轨副在大范围工况条件下完整的润滑状态;直线运动导轨大多工作在混合润滑状态下,随着滑块移动速度的增加,接触界面由边界润滑状态向混合润滑状态转变,润滑性能逐渐提高;适当增加曲率半径系数,有利于润滑油膜的形成与稳定。     

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。     

混合润滑结合面法向接触刚度模型研究EI北大核心CSCD

在实际工作中,机械结合面一般加入润滑介质来减少磨损,因此将结合面微凸体等效为圆锥微凸体,并基于分形理论和改进的W-M函数建立混合润滑状态下结合面法向接触刚度三维分形模型。对模型进行模拟仿真,仿真结果表明:结合面无量纲法向接触总刚度随着分形维数的增大呈现出先增大后减小的趋势,且在分形维数为2.6附近时取得最大值;随着分形粗糙度参数的增大而减小;随着润滑介质的声阻抗增大而增大;混合润滑状态下结合面无量纲法向接触总刚度大于无润滑介质结合面无量纲法向接触刚度;最后与其他模型和试验数据进行对比,模型与试验数据更契合,验证了模型的正确性。混合润滑粗糙表面法向接触刚度模型的提出,为结合面的刚度预测和机械设备的性能优化以及结构改进提供良好的依据。     

振动冲击对海水润滑塑料轴承时变热弹流润滑的影响

建立了冲击载荷作用下综合考虑热效应和时变效应的海水润滑塑料轴承弹流润滑数学模型;利用压力求解的多重网格法,弹性变形的多重网格积分法及温度求解的逐列扫描技术数值模拟了连续冲击载荷作用下海水润滑膜压力及膜厚的分布;对比分析了正弦周期脉冲及三角形周期脉冲作用下的润滑膜中心压力、中心膜厚及最小膜厚随时间变化的特性;讨论了载荷幅值及脉宽对润滑膜特性的影响。数值计算结果表明,压力的变化周期同载荷的一致,膜厚的变化滞后于冲击载荷及压力的变化;随载荷幅值的增大,压力和膜厚的振幅增大,中心压力的对称线下移,相应膜厚的对称线上移;随脉宽的增大,中心压力的最大值变大,最小膜厚的最小值变小。     

考虑动载荷和表面粗糙度的渐开线齿轮摩擦因数的研究

 进行齿面摩擦因数的研究,对于减少摩擦损失、改善系统传动性能等具有重要的意义．建立渐开线圆柱齿轮的非线性时变单自由度动力学模型,求解得到动态啮合力和单对轮齿的受力．结合载荷分担概念和弹流润滑理论,得到考虑表面粗糙度和动态载荷的不同啮合位置处的齿面摩擦因数,并与静态载荷条件的结果进行对比．同时分析转速、表面粗糙度和润滑剂黏度等工作条件对摩擦因数的影响．研究结果表明：动态载荷对油膜厚度、油膜承载比例和摩擦因数均有一定程度的影响．进入啮合段,油膜较薄,油膜承载比例较低.退出啮合段,油膜增厚,油膜承载比例增高.转速对摩擦因数的影响并非单调的,摩擦因数先是随着转速的增大显著减小,而后随着转速的增大而增大．随着表面粗糙度的增大,摩擦因数随之明显增大．在一定的黏度范围内,随着润滑剂黏度的增大,摩擦因数随之明显减小．     

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。     

混合润滑状态下结合面的法向接触刚度研究

针对润滑条件下机械结合面的接触特性受油膜影响的问题,基于结合面接触刚度由油膜接触刚度和固体表面接触刚度组成的思想,建立混合润滑状态下结合面的法向接触刚度模型。采用三维的Weierstrass-Mandelbrot函数获得具有分形特征的粗糙表面,并基于统计学方法建立干摩擦条件下结合面的法向接触刚度模型,考虑了微凸体的完全弹性变形、弹塑性变形以及完全塑性变形过程。在此基础上,求解了油膜的等效厚度并建立油膜的接触刚度模型。结果表明:结合面的法向接触刚度随法向载荷的增加而增加,且混合润滑状态下结合面的接触刚度大于干摩擦条件下结合面的接触刚度;该模型避免了油膜厚度测量难的问题,为机械结构的润滑状态预测提供了帮助。     

Generalized griffith problem of shear with regard for the roughness of the crack surfaces

We study the generalized Griffith problem of longitudinal and transverse shear with regard for the roughness of the crack surfaces. The crack lips are modeled in the form of teeth. We study the process of contact of the teeth and its influence on the stress-strain state at the crack tip. The prefracture zone is modeled by cuts whose lips are in the complex stressed state and, hence, suffer the action of average shear and tensile stresses satisfying the Huber-Mises relations. As a result, we obtain expressions for the length of the plastic zone and crack-tip displacements in the cases of both transverse and longitudinal shear. Translated from Fizyko-Khimichna Mekhanika Materialiv, Vol. 36, No. 2, pp. 49–54, March-April, 2000.     

Soft layer bearing joints for spine arthroplasty

This paper investigates the application of a soft layer in one of the bearing surfaces of cervical and lumbar total disc arthroplasty devices. The disc arthroplasty was analytically modelled as a ball and socket joint, with the ball made from a metal and the socket made from an elastomer. The peak contact pressure and the minimum film thickness between the bearing surfaces were calculated, as the parameters of ball radius, radial clearance, angular velocity, soft layer Young’s modulus and thickness were varied. For the cervical and lumbar models the peak contact pressures were in the range 0.6–3.7 and 2.2–13.3 MPa, respectively. Values of minimum film thickness in the ranges 0.21–0.57 and 0.11–0.31 μm were determined for the cervical and lumbar models, respectively. The results indicate that lower contact pressures may be achieved using a soft layer, compared to conventional disc arthroplasty devices that have hard against hard bearing surfaces. The cervical disc may be able to operate with fluid film lubrication under some conditions, while the lumbar disc will have a mixed lubrication regime. The results of this study will help with design parameters for the design of future disc arthroplasty devices.     

Improvement in adhesion of the brackets to the tooth by sandblasting treatment

In oral orthodontic treatments, achievement of a good adhesion between brackets and teeth surfaces is essential. One way to increase adhesion is to apply a surface treatment of teeth facing surfaces through the projection of abrasive particles to produce a surface roughness which improves adhesion of the bracket to the tooth, because of the significantly increased contact between the two surfaces. The effect on adhesion through the use of this technique in different types of brackets, as well as through the use of different blasting particles, however, is yet not well described. In this study we have included three types of brackets which are commonly used in orthodontic therapies (two of them a mesh-type and the third one a micro-milled type) with a contact surface area of 11.16, 8.85 and 6.89 mm² respectively. These brackets were used combined with a sandblasting treatment with two different types of abrasive particles, alumina (Al₂O₃) and silicon carbide (SiC) and applied to natural teeth in vitro. The abrasive particles used are bio-compatible and usually used in achieving increased roughness for improved adherence in biomedical materials. Sandblasting was performed at 2 bars for 2 s; three particle sizes were used: 80, 200 and 600 μm. Non-blasted samples were used as control. Each of the pieces were cemented to natural teeth with a self-curing composite. Samples were stored in physiologic serum at 5°C temperature. Tensile tests were performed with a universal testing machine. Brackets treated with sandblasted particles were measured to have an increased adhesion as compared to the control sample. The highest bond strength was measured for samples sandblasted with alumina particles of 80 and 200 μm combined with micro-milled brackets. The recorded stresses did not exceed the tensile strength of tooth enamel.     

Micro and macro contact mechanics for interacting asperities

Contact of rough surfaces at micro and macro scales is studied in this paper. The asperities at micro scale are characterised by small radius of curvature whereas the waviness is characterised by large radius of curvature. When two rough surfaces come in contact, on the micro scale, of asperities contacts in a very small area leave large gaps between the surfaces; whereas on the macro scale the surfaces conform to each other under the application of load without gaps. Contact at micro scale is modelled by superposition of Hertzian stress fields of individual asperity contacts and the waviness at macro scale is modelled as a mixed boundary problem of rough punch indentation where displacements of uneven profile are prescribed along the region of contact. In both the cases for simplification the roughness is assigned to one surface making the other surface perfectly flat an assumption often made in contact mechanics of rough bodies. The motivation for modelling the asperities at micro scales comes from the preliminary results obtained from photoelastic experiments. Numerical results are presented based on the analytical results available for Hertzian contacts. The motivation for modelling the asperities at macro scales comes from the results available in literature for flat contacts from solving mixed boundary elasticity problems. A condition of full stick is assumed along the contact which is a common assumption made for rough contacts. The numerical results are presented for both the cases of rough contact at micro and macro scales.     

Analysis of finite journal bearings with longitudinal and transversal rough surfaces

This paper represents a numerical iterative scheme for calculation of finite 360° journal bearings with longitudinal and transversal rough surfaces. A modified Christensen's Reynolds type equation is solved numerically under isothermal boundary condition. The Reynold's boundary condition assuming that the pressure and its derivative vanish near the point of location of the minimum film thickness is used in an iterative scheme to find out this location. Results of the analysis show the great influence of surface roughness on the bearing behaviour, especially when the bearing operates at its hydrodynamic limit.     

滤波减速器润滑特性研究

为了研究啮合位置、载荷、转速等因素对滤波减速器润滑特性的影响, 建立了滤波减速器的内啮合润滑模型,将牛顿(有限元)法应用到弹流润滑方程组的求解中,利用Matlab软件,采用数值计算方法,实现了弹流润滑方程组的完全数值解,得到了滤波减速器轮齿在不同啮合位置、不同载荷以及不同转速下啮合轮齿表面油膜压力和油膜厚度值,分析了不同啮合位置、不同载荷以及不同转速下轮齿所处的润滑状态,得到了啮合位置、载荷以及转速等因素对轮齿润滑特性的影响规律.结果表明：在轮齿的啮入、啮出及节点处,润滑薄膜厚度值不一样,节点处的润滑膜厚值最小;载荷增大时,轮齿表面油膜压力会变大,而油膜厚度会变小;转速增高时,油膜厚度会变大,而油膜压力变化不大.     

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。