微动接触中分形粗糙表面的温升分布研究

目的 研究不同分形参数下表面粗糙度对微动接触表面温升的影响。方法 通过创建Python脚本,将MATLAB中利用Weierstrass-Mandelbrot函数构造的分形表面轮廓坐标导入ABAQUS中,使用样条曲线拟合轮廓坐标,构建包含粗糙表面的二维柱面-平面接触模型,研究表面粗糙度、法向载荷、切向载荷以及材料属性对接触表面温升的影响规律。结果 微动接触状态下,温升在接触宽度方向上呈先增后减的趋势,且沿深度方向温升幅值逐渐减小。不同粗糙度的表面节点具有相似的温升分布历程,热影响区主要分布于接触区表层附近,并在此表层产生高的温度场。粗糙接触模型会出现局部温升峰值,同时剪切摩擦应力和接触压力分布具有离散性,与文献中已有结论一致。结论 接触表面温升幅值随着粗糙度的增大而增大。当表面粗糙度和法向载荷一定时,随着切向载荷幅值的增大,上试件的相对滑移距离和摩擦热产生率增加,引起温升幅值增大。考虑材料属性时,发现温升幅值大小与材料导热性密切相关,材料导热性能越好,接触表面温升幅值越小。     

基于随机过程的三维粗糙表面接触刚度研究

目的 建立三维粗糙表面法向接触刚度的有限元模型,研究法向接触刚度对粗糙度、自相关系数、弹性模量、屈服极限等参数的敏感性。方法 首先基于随机过程理论,采用二维数字滤波技术,生成满足Gauss分布和指数自相关函数的粗糙表面,建立三维粗糙表面接触有限元模型。然后根据结合面静位移与结合面受力关系推导出静刚度表达式,得到两粗糙表面的法向接触刚度。根据中心复合试验设计方法选取的样本点和有限元计算结果,建立二阶响应面模型。最终定义了临界自相关系数,并研究了临界自相关系数与其他参数的关系。结果 有限元计算得到的法向接触刚度结果合理,与试验结果相比最大误差不超过12.34%。弹性变形、塑性变形及真实接触面积随载荷的增加逐渐增大。法向接触刚度与粗糙度呈现负相关趋势,粗糙度不变时法向接触刚度随自相关系数的增大先增大后减小;法向接触刚度与弹性模量呈负相关趋势,法向接触刚度与屈服强度呈正相关趋势,且粗糙度的改变对法向接触刚度影响最大。当压力为200 MPa时,粗糙度、自相关系数、弹性模量、屈服极限分别为0.8 μm、18.91、240 GPa、355 MPa,法向接触刚度达到最大值121.53 MPa/mm,优化后接触面的法向接触刚度提高247%,并给出了临界自相关系数选取公式。结论 所建立模型正确、准确,为粗糙表面法向接触刚度计算提供一种有效方法,可为航空发动机安装边结构设计提供理论指导。     

基于微观接触模型的支撑基座刚度分析

针对支撑基座的竖直刚度计算问题,围绕如何提高有限元计算准确性,提出一种等效刚度模型替代宏观结构模型的分析方式,基于有限元法进行微观粗糙表面仿真和分析,利用积分思想计算等效刚度。通过轮廓扫描仪获取真实工件表面的形貌数据,重构符合高斯分布的微观粗糙表面,使用ANSYS软件仿真计算接触刚度,结果与不同理论接触模型对比,验证了有限元微观接触表面刚度的合理性。将宏观结构模型有限元计算刚度与等效刚度模型计算刚度对比,结果表明接触面的塑性变形和曲面的基体变形对刚度影响最大,为后续支撑系统的结构优化提供依据。     

表面粗糙峰坐标点云重构的金属-橡胶接触分析

目的 通过金属-橡胶微观接触面粗糙峰坐标点云重构,建立外部载荷与接触面积、微观接触状态之间的联系.方法 基于粗糙表面的自相关函数和高斯分布函数,获得金属-橡胶粗糙接触面数据点云坐标,利用ANSYS APDL方法,建立金属-橡胶接触模型,对两种表面粗糙度(分别为1.6μm和3.2μm)的4种接触情形进行有限元接触分析,确定模型的可靠性.结果 随着外部载荷的增加,经数据点云重构后的粗糙表面,其接触面积呈非线性增加.载荷较小时,外加载荷每增加0.1 MPa,接触面积增加约6％;大载荷时,外加载荷每增加0.1 MPa,接触面积增加约1.5％.接触状态中,滑移占比为12％左右,近场和粘着呈完全相反的变化趋势.结论 随着外加载荷的增加,界面的真实接触面积呈幂指关系增加.同一载荷下,真实接触面积随表面粗糙度的增加而减小;随着外加载荷的增加,界面间的接触状态由近场接触向粘着接触转变.接触面积和粘着状态是界面间磨损粒子的分布范围和大小的确定因素,对于准确描述载荷传递和随之发生的磨损过程有着重要意义.根据橡胶表面的应力分布和变形情况,解释了粘着接触状态促使橡胶一侧微凸体脱落成为磨损颗粒,证明磨粒磨损是刚柔接触界面的主要磨损形式.     

纳米级粗糙表面接触行为的分子动力学模拟

为了研究纳米级粗糙表面接触的微观机理,以金刚石为例,采用Tersoff势,用分子动力学方法研究了具有分形粗糙表面的刚性球形探头与弹性平面的接触过程.模拟结果显示,探头的表面形貌是影响趋近阶段粘附力的重要因素,分形维数越大,粘附力越大;探头的表面形貌对载荷-位移曲线也有影响,载荷较小时,探头表面粗糙形貌显著影响载荷的增长规律,载荷较大时,表面形貌对载荷-位移曲线变化的影响不再显著,载荷与位移线性增长;探头表面的纳米级粗糙峰,显著地影响了探头与基体之间的接触行为.但这种改变,并不会影响接触过程中真实接触面积与法向载荷间的线性关系.     

结合面卸载过程法向接触刚度修正统计模型

基于接触统计理论以及GW模型,考虑微凸体弹性接触变形和弹塑性接触变形的两个不同阶段以及卸载过程中有效曲率半径的变化,提出了法向接触载荷与表面平均分离距离之间新的关系,进而建立了固定结合面卸载过程法向接触刚度的统计模型.经过仿真分析,结果表明,卸载过程中的无量纲结合面法向接触刚度随着无量纲表面平均分离距离的增大而减小;不...     

考虑表面形貌的接触应力分析

目的 研究规则和实际表面形貌对二维平面线接触模型的影响.方法 基于线接触几何特性,考虑表面受载后的弹性变形特性,结合规则和实际粗糙表面的形貌特征,并考虑磨合对表面的影响,采用移动平均滤波方法对实际粗糙表面进行光滑处理,利用共轭梯度法,求解表面接触压力和摩擦力,计算二维平面内接触近场应力分布,同时采用修正的离散卷积快速傅里叶变换方法提高计算效率.对比验证二维接触模型的准确性,并对比规则和实际粗糙形貌表面受法向载荷和切向载荷时平面应力分布云图中的应力分布和大小.结果 圆面与圆形微凸体接触时,圆形凸体半径越小,最大Mises应力值越大,半径增大,最大Mises应力减小.多个圆形微凸体及正弦微凸体对应力分布影响类似.当考虑切向力时,会对应力分布云图中的应力分布形状和大小产生巨大影响.在相同平面表面形貌时,摩擦系数越大,Mises应力越大,并且应力沿摩擦力方向发生偏移.结论 数值模型能准确计算出粗糙平面的应力.当圆面与规则表面轮廓平面接触时,与光滑表面接触时相比,Mises应力分布呈现很大不同,微凸体越小,应力越集中;摩擦力会使接触压力和近场Mises应力产生偏移,摩擦系数越大,偏移越明显.当考虑实际粗糙表面时,在粗糙界面尖端接触区域产生应力集中.经过磨合表面采用平均滤波光滑处理后,粗糙界面尖端接触区域应力集中将大幅减小.     

考虑摩擦因素的粗糙曲面弹塑性分形接触修正模型研究

为了建立更为准确的接触分形模型,以传统的M-B模型为基础,通过引入接触比例系数,考虑摩擦情况下的临界接触面积式,并基于修正的曲面接触面积密度分布函数,推导考虑摩擦的粗糙曲面弹塑性分形接触修正模型。并以两圆柱接触体为例,建立两圆柱体实际接触面积与法向载荷之间的分形模型,研究影响该分形接触模型的相关参数的变化规律。通过在MATLAB中的仿真分析结果表明:当载荷一定时,随着分形维数的增加,真实接触面积呈现先上升后下降的趋势;增大摩擦系数或材料特性参数,有利于提高接触承载能力;粗糙度幅值参数对接触承载能力的影响不是线性关系,而是存在一个最优值,高于或低于此值都会导致接触承载能力下降。该分形模型提供了更为准确的实际接触面积与法向载荷之间的数值关系,为改善粗糙表面的承载能力提供理论参考。     

粗糙表面弹塑性加卸载多级接触模型

真实工程表面在微观尺度上都是粗糙的,它们之间的接触实际上是表面微凸体的接触,粗糙表面间的接触行为对接触部件的真实承载能力、摩擦磨损等性能都有重要影响,研究工程表面间的真实接触行为是摩擦学研究的主要内容之一。采用最小均方误差法得到表面轮廓抛物线拟合曲线,在最大限度近似原始表面轮廓的同时,该方法能够更好地适用于微凸体弹塑性接触加卸载模型。通过单个微凸体上的支承载荷将总体级别模型和微凸体级别模型相联系,建立粗糙表面多级接触加卸载模型。以柱面与平面接触为算例,将接触区域视为与圆柱母线平行的离散线条集合,得到微凸体法向变形量和粗糙表面真实接触面积,该模型可用于分析粗糙表面弹塑性加卸载的真实接触行为。     

载荷对高温合金GH4169/K417间接触热导影响

采用自主研制的带补偿加热的接触热导测试设备,对航空发动机用高温结构材料GH4169/K417间不同载荷(60~180MPa)和不同粗糙度下的接触热导进行试验研究。研究了载荷对其接触热导的影响行为,对比分析了有、无补偿加热条件下的接触热导测试结果。结果表明,带有补偿加热的接触热导测试装置能有效降低横向热流损失。不同粗糙度的GH4169/K417材料组合,接触热导随载荷变化规律一致,且粗糙度较大时接触热导值较大,两者的差值随载荷先增加后减小,主要与平行刀纹的界面啮合作用有关。     

表面工程系统接触力学模型

在任何严峻条件下现代机械运行中综合性能的迫切需求促进了许多先进表面工程技术的迅速发展。因而，设计者在结构设计时将有许多表面工程技术可以选择。但是，怎样为一种特定的应用选择一种最优化的表面工程方法对设计者来说又是一种挑战。为了这个目标，在现代多层表面接触理论的基础上建立起一种接触力学模型，考虑到了多层结构、真实表面粗糙度和摩擦影响。这种力学模型可以成功地预测表面工程结构的性能。文中首先回顾了赫兹接触理论的发展过程，然后讨论了伯明翰多层真实粗糙表面接触力学模型，并用实例示范了一系列关于动载荷下表面工程结构设计的主要步骤。     

双粗糙表面的微动磨损行为研究

目的 建立符合实际情况的粗糙表面微动磨损模型,准确揭示连接结构的磨损机理.方法 利用ABAQUS有限元软件中的UMESHMOTION子程序和能量耗散模型,建立粗糙表面的微动磨损模型,并探究不同表面粗糙度、材料和振动频率对粗糙表面微动磨损的影响.结果 在外部载荷、振动频率和材料相同的情况下,下试件表面粗糙度为0.2μm的...     

Ultrasonic measurement of contact stiffness and pressure distribution on spindle–holder taper interfaces

The measurement of contact characteristics of the spindle–holder taper interface is critical for the evaluation of the performance of a machine tool spindle system. In this study, an ultrasonic method was proposed to measure the contact stiffness and pressure distribution on the taper interface. The taper interface was scanned by an ultrasound transducer, and the nominal contact area was directly estimated from the resulting ultrasonic reflection coefficient. The normal stiffness distribution was determined by the spring-damper model from the reflection coefficient. On this basis, the distributed and global radial stiffness of the taper interface was calculated by the presented theoretical formulas. Meanwhile, a calibration curve was established to convert the ultrasonic reflection to contact pressure. Based on the proposed ultrasonic method, the effects of angle fitting error and clamping force were studied. The results show that the contact area, contact pressure and contact stiffness increase with the clamping force. As the angle fitting error increases, the contact area decreases, while the pressure and stiffness at the big end of the taper interface become much larger than these at the small end. In the meantime, the global radial stiffness increases first and then decreases. This result suggests that a larger angle fit error within the permissible range is better for the global radial stiffness. Moreover, the measured results confirm that a taper joint with an angle fit error larger than +36" is not suitable for practical application, because the contact pressure at the small end is too small. To compare with the ultrasonic method, the geometrical shape profiles of the contact surfaces were constructed, and FE models were also established for contact pressure predictions. The comparison shows that the ultrasound results are consistent with the surface shape profiles and the numerical predictions. Besides, one of the taper interfaces was measured three times with the same clamping force, and the results indicate that the repeatability of the proposed method is good.     

修饰不同微结构对疏水性表面浸润性的影响

目的研究修饰微结构对疏水性材料表面浸润性的影响并指导制备超疏水表面。方法基于有限元软件建立了水滴在修饰不同微结构的疏水性表面的润湿模型,通过水滴表观接触角衡量分析了疏水材料表面修饰单一粗糙结构和复合粗糙结构对疏水性提升的效果,利用硅树脂掺杂微粒制备了不同粗糙度的疏水性涂层,涂层固化后测试其实际接触角大小,并与仿真结果对比。结果仿真结果显示,对水滴接触角为100°的表面修饰单一粗糙结构后,由于微结构形成的凹槽滞留空气,阻碍了水滴在表面铺展,使得水滴在表面的接触角增大至133°。在原微结构基础上修饰更小一级的微结构后,水滴在表面的接触角达168°,材料表面达到超疏水效果。实验中,随涂层表面粗糙度的提升,水滴在表面的接触角逐渐增大,掺混两种微粒的疏水涂层固化后,表面形成复合微观结构,水滴接触角达162°,与仿真结果拟合较好。结论在疏水性表面修饰微结构可显著提升其表面疏水性,修饰复合结构后可达到超疏水效果,此方法可用于实际工程制备超疏水表面。     

Prediction of surface topography in lubricated sheet metal forming

This study develops new model that is suitable for predicting the surface topography of the products of lubricated sheet metal forming. In the lubrication analysis, a finite element model is derived for the average Reynolds equation, no matter whether the tooling surface comes into contact with workpeice surface or not. With regard to the asperity contact theory and surface parameter analysis, a novel model takes account of the smoothing, roughening and tool elastic microwedge effects on the surface of the workpiece. A model was combined with a finite element membrane code of axisymmetric stretch forming to predict the contact area ratio and the surface roughness. Numerical results revealed that the new model is consistent with the experimental results. The superiority of the new model over the conventional model is that it predicts the surface roughness more accurately during the lubricated sheet metal forming process.     

基于分形理论的粗糙齿面齿轮动力学研究

为研究齿面微观误差对齿轮动力学特性的影响,基于分形理论对粗糙表面进行分形表征。结合时变啮合刚度、静态传递误差以及齿面摩擦等因素,建立计及粗糙齿面的齿轮非线性动力学模型,研究齿面粗糙度、齿面摩擦及工况对齿轮动力学特性的影响。结果表明：粗糙度增大时,齿轮传动系统的动态传递误差增大,振动稳定性降低,动态性能逐步恶化;齿面摩擦会使齿轮副的动态传递误差和振动位移都增大,且摩擦对垂直啮合线方向的振动特性影响更明显;粗糙度对齿轮动力学特性的影响随工况变化而改变,结合工况合理地进行齿面精度设计,有利于进一步平衡加工成本与传动质量之间的问题。     

Temperature dependence of the ultrasonic transmission through electrical resistance heated imperfect metal–metal interfaces

Because of surface roughness, the area of contact between real surfaces is less than the geometrical area. For this reason the known rules of acoustic reflection and transmission have to be modified for real interfaces. Ultrasonic transmission through imperfect interfaces is commonly described in terms of the contact stiffness model which assumes distributed springs between the surfaces in contact [Proc. R. Soc. Lond. A 202 244; J. Acoust. Soc. Am. 89 (1991) 503ff; J. Acoust. Soc. Am. 68 1516; J. Nondestr. Eval. 4 177; J. Geophys. Res. 94 (1989) 17681ff].Several authors [Trans. ASME 123 8ff; J. Acoust. Soc. Am. 103 657ff; Ultrasonics 38 513] theoretically and experimentally show the pressure and frequency dependence of the ultrasonic transmission through such interfaces. Our paper will document, that the temperature of the interface has significant influence on the ultrasonic transmission as well.In the experimental approach, a CuSn8-rod was clamped between the electrodes of a resistance welding unit. Either longitudinally or transversally polarised ultrasonic pulses were generated by a transmitter built in the upper electrode. The transmitted ultrasonic signal was subsequently detected by the receiver integrated in the lower electrode. After the welding current was turned on, a strong decrease in ultrasonic transmission has been observed due to resistance heating of the interfaces between the welding electrodes and the rod.To explain this extraordinary strong temperature effect, a simple quasistatic analytical thermal–electrical model of the contacting area was used to give a rough estimation of the maximum interfacial temperature and the temperature distribution during the flow of the welding current. In a second step, the temperature dependence of the material data in the acoustic contact stiffness model was used to calculate the changes in ultrasonic transmission caused by the welding current. It is shown, that the observed decrease in ultrasonic transmission with increasing temperature is mainly caused by the temperature dependence of the elastic constants of the metals and is much stronger than expected for ideal interfaces.The calculated ultrasonic transmission is in very good agreement with the experimental data and seems to be interpreted correctly by the acoustic contact stiffness model.     

A method for stiffness tuning of machine tool supports considering contact stiffness

A methodology for tuning the stiffness of machine tool supports is described based on a stiffness model using the contact stiffness approach. Using this model, the mathematical relationship between the load of the support and its stiffness is established. The relationship is separated into three regions. When the total stiffness of all supports is maximized, the load must be tuned so that the stiffness–support load relationship is in the critical region, whereby the contact stiffness is slightly larger than the bulk stiffness. Correspondingly, a placement method of supports is proposed that increases their stiffness without anchor bolts. The effectiveness of the proposed method is verified in two experiments. In the first experiment, the natural frequency of a small machine tool prototype is compared for several placements of three supports. The lowest natural frequency of the machine tool under the proposed placement scheme is maximized. In the second experiment, the proposed method is applied to increase the lowest natural frequency of a horizontal milling machine. The lowest natural frequency with a distinct arrangement of three supports is increased by 15–55%, compared to other popular placements of these three supports. The experimental results show that the proposed placement method is effective for enhancing the stiffness of machine tool supports.