油气润滑技术在高速电主轴轴承上的应用

随着润滑技术的发展,油气润滑技术正逐步应用于高速电主轴轴承的润滑.在分析油气润滑工作原理的基础上,讨论了油气润滑技术在高速电主轴轴承上的应用及其特点.实践表明,相对脂润滑、油雾润滑而言,油气润滑更适应于高速主轴轴承的润滑要求.     

高速轴承油气润滑系统的研究及应用现状

随着高速加工技术的快速发展,油气润滑技术应用于高速机床/磨床电主轴轴承已成为目前发展的普遍趋势。概述近年来油气润滑系统应用于高速轴承的研究现状及应用进展,总结油气润滑系统组成、主要影响因素、油气两相流形成机制、润滑状态、关键部件研制等油气润滑系统的研究成果和应用现状,阐述油气润滑系统的设计难点,并提出油气润滑系统研究的未来发展方向。     

单线多卫星式油气润滑系统的研究

介绍了油气润滑系统的原理,设计了一种新型的油气润滑系统--单线多卫星式油气润滑系统,采用了油气卫星站的形式,使系统具有良好的扩展性.并采用PLC控制系统实现对油气润滑主站及各卫星站的状态监控及故障声光报警和信息显示.这种单线多卫星式油气润滑系统的设计及在轴承润滑方面的应用对加速该技术的标准化及推动我国油气润滑技术的发展具有现实的理论意义和实际意义.     

高速电主轴油气润滑问题的分析研究

油气润滑系统对高速电主轴的使用精度及寿命至关重要。针对高速电主轴在龙门加工中心安装调试时出现的油气润滑问题进行分析,确认油气润滑系统的使用环境,如油气混合阀安装位置、处理单元减压阀压力及油气润滑管道长度等会影响油膜形态和轴承运行情况。调整油气润滑系统使用环境后,油气润滑问题不再出现。     

油气润滑技术在轧机上的应用

首先介绍了钢铁冶金轧机润滑的现状和存在问题,提出了使用油气润滑技术的解决方案;然后阐述了油气润滑技术的原理、系统组成和主要技术参数,总结了油气润滑技术的优点;最后,指出了油气润滑技术发展的方向.     

滚动轴承油气润滑及喷油润滑温度场对比研究

分析滚动轴承内部生热机制,计算不同转速下油气润滑和喷油润滑的轴承滚道表面对流换热系数;应用Workbench流场分析模块,建立滚动轴承流体域几何模型,对不同转速下滚动轴承油气润滑和喷油润滑时轴承腔热流耦合温度场进行仿真分析。结果表明,当轴承转速较低时,油气润滑和喷油润滑时轴承腔最高温度基本相同,但油气润滑条件下轴承腔的整体温度远远低于喷油润滑方式;当轴承转速较高时,油气润滑条件下的轴承腔最高温度要远远低于喷油润滑条件下的轴承腔最高温度,从而验证了高速工况下油气润滑的优越性。     

TURBOLUB油气润滑技术(七)

5 油气润滑的典型应用 油气润滑的应用是从一些工况恶劣的部位尤其是冶金设备开始的,也就是说油气润滑从一开始应用就针对其它润滑方式很难解决的问题。比如高速线材轧机滚动导卫,由于转速极高(精轧区转速值可高达40000r/min),在采用油气润滑之前,每工作1～2班就得更换已烧毁的导卫,采用油气润滑之后更换时间间隔延长到数天或几个月。随后REBS油气润滑逐步扩展到了其它领域,尤其是工况恶劣的地方,用油气润滑可以解决其它润滑方式无法解决的问题。很多用户在采用油气润滑解决了令人头疼的润滑难题后也纷纷将工厂其它设备的润滑改为油气润滑。REBS油气润滑不只是在工况恶劣的情况下效果显著,在应用于常规非恶劣工况依然取得了理想的效果。有的用户甚至报告说,REBS油气润滑使用十年后竟然没有轴承和齿轮损坏,这不能不令人吃惊。     

油气润滑在特钢棒材短应力轧机上的运用

介绍特殊钢棒材短应力轧机上应用的油气润滑系统的结构及工作原理,探讨短应力轧机油气润滑系统的故障诊断与维护,分析油气润滑系统在短应力轧机上的应用效果,并提出需要改进的方面。结果表明,在短应力轧机上采用油气润滑效果良好,因润滑不良而烧轴承的现象大大减少;油气润滑润滑油利用率高,耗油量仅为油雾润滑的1/10~1/5。     

油气润滑技术在大功率精密磨削主轴中的应用

介绍了油气润滑基本原理,阐述了主轴油气润滑结构的设计原则,对公司大规格数控成形磨齿机磨削主轴采用油气润滑结构进行设计,对油气润滑技术进行了现场测试及应用验证。     

高速电主轴油气润滑参数优化系统及平台设计

油气润滑是高速电主轴最高效的冷却润滑方式,然而要达到最佳的润滑效果必须针对不同型号轴承以及不同工况设定准确的油气润滑参数,这就需要可靠的试验装备进行大量的试验分析。为此搭建模拟电主轴运行工况的实验平台,设计油气润滑系统并设计一种兼具油气混合器和油气分配器功能的油气混合分配器。试验结果表明：试验平台最佳的转速范围为0～30 000 r/min,满足高速机床主轴试验的转速要求;油气混合分配器供油误差满足±10%的行业标准,使用寿命达到12万次。因此搭建的试验平台和油气润滑系统对高速电主轴油气润滑参数的试验研究有较高的可靠性。     

CHARACTERISTCS OF FLUID FILM IN OPTIMIZED SPIRAL GROOVE MECHANICAL SEAL

In order to investigate the sealing performance variation resulted from the thermal deformation of the end faces, the equations to calculate the fluid film pressure distribution, the bearing force and the leakage rate are derived, for the fluid film both in parallel gap and in wedgy gap. The geometrical parameters of the sealing members are optimized by means of heat transfer analysis and complex method. The analysis results indicate that the shallow spiral grooves can generate hydrodynamic pressure while the rotating ring rotates and the bearing force of the fluid film in spiral groove end faces is much larger than that in the flat end faces. The deformation increases the bearing force of the fluid film in flat end faces, but it decreases the hydrodynamic pressure of the fluid film in spiral groove end faces. The gap dimensions which determine the characteristics of the fluid film is obtained by coupling analysis of the frictional heat and the thermal deformation in consideration of the equilibrium condition of the bearing force and the closing force. For different gap dimensions, the relationship between the closing force and the leakage rate is also investigated, based on which the leakage rate can be controlled by adjusting the closing force.     

CURING PROCESS OF PHOTOPOLYMER RESIN BOND DIAMOND TOOLS

Analytical simulation and corresponding proof-test are adopted to study the principle of the curing process of photopolymer resin diamond tools. The influence of the diamond as abrasives in photopolymer resin owing to the absorptivity of the diamond for the UV light on the photopolymer resin curing process is discussed. Based on the above, a kind of diamond tool—dicing blade is selected to analyze the curing process of photopolymer bond diamond tools. An analytical model of curing process is developed and a correlation curve between the depth of polymerization of the photopolymer resin diamond tools and the exposure time to represent the curing process of photopolymer bond dicing blade. A test is done to proof-test the validity of the analytical model and the correlation curve. The simulated data fit the experimental results, which demonstrates the analytical models and numerical algorithm are of high reliability. The analytical simulation method could possibly be used to optimize the curing cycle and improve the quality of the photopolymers resin bond diamond tools.     

交通荷载作用下桥梁结构参数识别方法

应用动力节点加载法,将作用在桥梁上的交通荷载转化为等效节点荷载,再用两步构造法识别结构物理参数.第1步,用Newmark-β方法变换结构运动方程,并用结构的加速度响应求得变换空间内的位移、速度和加速度响应;第2步,基于最小二乘原理,构造出变换空间内求解结构参数的递推式,进行结构物理参数识别.数值模拟结果表明,在交通荷载作用下,该方法能够快速、准确地进行桥梁结构参数识别.     

Effects of prebuckling deformations on the elastic flexural-torsional buckling of laterally fixed arches

The effect of the prebuckling in-plane deformations on the elastic flexural-torsional buckling of laterally fixed circular arches is studied in this paper. The finite strains and the energy equation for the flexural-torsional buckling of arches have been derived based on an accurate orthogonal rotation matrix. A closed form solution for the elastic flexural-torsional buckling resistance of laterally fixed arches in uniform bending, including the effects of the prebuckling deformations, is obtained. It is found that the notion that the prebuckling deformations increase the flexural-torsional buckling moment of an arch or of a beam is not necessarily correct for a laterally fixed arch or beam in uniform bending, in deference to a laterally pinned arch. When a laterally fixed arch is subjected to positive uniform bending, the effects of the prebuckling deformations decrease the buckling moment, and the reduction of the buckling moment increases with an increase of the included angle and of the out-of-plane slenderness ratio of the arch. When a laterally fixed arch is subjected to negative uniform bending, the effects of the prebuckling deformations decrease the absolute value of its buckling moment when the included angle is very small, but increase the absolute value of the buckling moment when the included angle exceeds a certain value. The increase in the absolute value of the buckling moment increases with an increase of the included angle and of the out-of-plane slenderness ratio of the arch. When the ratio of the out-of-plane to the in-plane second moments of area of the cross-section is not small, both the reduction of the buckling moment of a laterally fixed arch in positive uniform bending and the increase of the buckling moment of a laterally fixed arch in negative uniform bending, are substantial.     

PHENOMENON OF CARVED DRIVING WHEELS

A newly found phenomenon of carved driving wheels of a rear-wheel-drive tractor used in an airport is discussed. The circum of every driving wheel is damaged at three regions,which distribute regularly and uniformly. Everyday,the tractor tows a trailer which are times heavier than the tractor,and moves on the same road in the airport. The phenomenon is explained by the torsional self-excited vibration system of the powertrain. The simplified torsional vibration system is discribed by a 2-order ordinary differential equation,which has a limit circle. Experiments and numerical simulations show the followings: Because of the heavy trailer,the slip ratio of the tractor’s driving wheels is very large. Therefore,there is severe torsional self-excited vibration in the tractor’s drivetrain,and the self-excited vibration results in severe and regular fluctuations of the rear wheel’s velocity. The severe fluctuations in velocity fastens the damage of the driving wheels. At the same time,the time interval in which an arbitrary point in the circum of the driving wheel contacts with the road twice is two times more than the period of the torsional self-excited vibration,and this times explained the existence of three damaged regions. At last,it points out that the phenomenon can be avoided when the torsional damping is large enough.     

OPTIMIZATION METHOD ON IMPELLER MERIDIONAL CONTOUR AND 3D BLADE

An optimization method for 3D blade and meridional contour of centrifugal or mixed-flow impeller based on the 3D viscous computational fluid dynamics (CFD) analysis is proposed. The blade is indirectly parameterized using the angular momentum and calculated by inverse design method. The design variables are separated into two categories: the meridional contour design variables and the blade design variables. Firstly, only the blade is optimized using genetic algorithm with the meridional contour remained constant. The artificial neural network (ANN) techniques with the training sample data schemed according to design of experiment theory are adopted to construct the response relation between the blade design variables and the impeller performance. Then, based on the ANN approximated relation between the meridional contour design variables and impeller performance, the meridional contour is optimized. Fewer design variables and less calculation effort is required in this method that may be widely used in the optimization of three-dimension impellers. An optimized impeller in a mixed-flow pump, where the head and the efficiency are enhanced by 12.9% and 4.5% respectively, confirms the validity of this newly proposed method.     

On the Relation of Load to Average Gap in the Contact Between Surfaces with Longitudinal Roughness

A computer simulation model for the contact between longitudinally-oriented rough surfaces has been formulated. This model closely duplicates the actual surf ace contact deformation behavior by taking into account the elastic interactions between the asperities. There were no assumptions made about the shapes, or any deformation behavior of the asperities, except for their obeying the laws of elasticity. The plastic deformations on the high asperity peaks were taken into account by setting a ceiling on their contact pressures at the material hardness value. The simulations used real surface profiles which were digitized from unworn circumferentially ground steel surfaces. Each pair of these profiles was mathematically combined to form an equivalent rough profile pressing against an infinitely rigid flat and having the appropriately adjusted elastic modulus. A total of 28 different pairs of profiles were used in the simulations. Each contacting pair was subjected to 30 different load levels and the local contact pressures and deformations were calculated. The contact simulations yielded some important mathematical relationships between parameters, such as the real area of contact, average gap, and average asperity load through statistical curve fitting. Two analytical functions were generated to relate the average load to average gap and the real area of contact to load.     

运用改进残余力向量法的结构损伤识别研究

针对结构损伤识别时测试结构模态振型不完备的情况,采用了自由度凝聚方法进行模型凝聚,并给出了缩聚模型的残余力向量计算公式,证明了残余力向量对结构损伤单元的敏感性.为减小自由度凝聚及测量等因素带来的误差影响,提出了一种改进的残余力向量法.该方法首先通过测试损伤结构多阶模态得到残余力向量,并计算相对于损伤前结构的残余力向量得到残余力向量差矩阵,选取向量差矩阵各行元素中最大绝对值组成改进的残余力向量.损伤识别时,先运用改进的残余力向量确定可能损伤单元,再运用筛选法计算单元损伤程度.数值仿真算例说明,采用该方法只需结构的前几阶低阶频率和振型,就可以快速准确地识别出结构的损伤,显示了该方法具有较好的抗噪性.     

EFFECTS OF INJECTION STRATEGY ON D.I. DIESEL ENGINE COMBUSTION

Experiments are conducted to develop an understanding of how split injections can affect the combustion and emission characteristics of a D.I. diesel engine with a common-rail injection system. The ratio of the amount of fuel injected between two injection pulses and the injection interval is varied keeping the injected fuel quantity constant. Results show that under the 70D90-10 injection pattern, the engine achieves the lower NOx-smoke emissions and BSFC compared with the single injection pattern. The heat release rate and the temperature show that the split injections increase the initial premixed burn and retards the diffusion burn. With the balance of these two effects, the maximum in-cylinder temperature decreases while the 50% heat release point is held at almost the same crank angle. Therefore, both NOx emission and BSFC are improved while keeping the smoke emission at the same level.     

DESIGN AND CAD SYSTEM OF THE FOOL FOR DRILL FLUTE

Based on the principles of differential geometry and kinematics, a mathematical model is developed to describe the grinding wheel axial cross-section with the radial cross-section of the flute in a given drill under the basic engagement condition between the generating flute and the generated grinding wheel (or disk milling tool). The mathematical model is good for the flute in the radial cross-section consisting of three arcs. Furthermore, a CAD system is also developed to represent the axial cross-section of the grinding wheel (or disk milling tool). With the system, the grinding wheel (or disk milling tool) axial cross-section that corresponds to the three-arc flute cross section can be conveniently simulated. Through the grinding experiment of drill flutes, the method and the CAD system are proved to be feasible and reasonable.