船用湿式多片摩擦离合器耦合分析及试验研究
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摘要
船用湿式多片摩擦离合器在较高速度时容易发生滑摩或油膜剪切发热问题,这不仅与摩擦片内部温度场、位移场有关,还与润滑及冷却介质的流场有关。本文提出基于两方程湍流模型分析湿式多片摩擦离合器复杂油路流场的方法,以及基于流体能量守恒方程分析润滑油剪切作用下摩擦片副温度场的方法,开展离合器空转状态润滑油路流场分析、摩擦片副热-流和热-结构分析,接排过程摩擦片组瞬态热-结构耦合分析,并进行试验研究,揭示润滑油油路结构、摩擦片油槽结构及离合器使用工况等因素对摩擦离合器发热的影响规律,对低发热、高寿命、高可靠的离合器设计具有重要的理论意义及工程应用价值。
本文项目来源于重庆市科技攻关计划项目“高性能船舶用齿轮箱系统关键技术及产业化”(CSTC:2007AB3030)及“船用湿式多片摩擦离合器关键技术及产业化”(CSTC:2008AC3102)。针对船用齿轮箱中的湿式多片摩擦离合器进行耦合分析及实验研究。主要研究工作如下:
①综合考虑离合器的结构和使用工况,基于原有结构建立了湿式多片摩擦离合器油路流场的参数化有限元分析模型,研究湿式多片摩擦离合器的油路结构对摩擦片间润滑油压力分布的影响,并提出了五种油路结构的改进方案;针对离合器的不同使用工况进行油路流场分析,研究入口流量和润滑油温度对摩擦片间润滑油压力分布的影响。
②基于流体能量守恒方程,建立摩擦片副中润滑油热-流耦合分析模型,研究离合器空转速度、油量、摩擦片油槽形式及片间间隙对润滑油温度的影响;而后对摩擦片进行热-结构耦合分析,以研究离合器空转时润滑油流量、油槽形式等对摩擦片变形的影响。
③针对船用湿式摩擦离合器调压阀的阀体结构及椭球形阀芯形状,建立调压阀内流道流体动力学有限元分析模型,对调压阀内流道的流场进行数值仿真,得出不同阀芯开口度下的压力云图、速度矢量图以及阀口油压曲线,同时分析了不同工作油温对阀件内流道流场的影响。
④构建带径向油槽和螺旋油槽的摩擦片三维实体模型和瞬态传热有限元模型,分析离合器接排过程中单片摩擦片的瞬态温度场,得出接排过程中摩擦片的温度云图及最高温度随时间变化曲线,并研究油槽宽度对摩擦片温度分布的影响;考虑摩擦片与摩擦片座、对偶片与离合器齿轮间花键副摩擦力作用,分析了摩擦片副间的正压力和花键齿间摩擦力的分布规律;而后建立多对摩擦片副的热弹接触有限元分析模型,通过瞬态热-结构耦合分析,得出接排过程中摩擦片组温度云图及分布规律,同时分析了摩擦片的热弹变形及片间接触压力。
⑤搭建了船用齿轮箱综合性能试验台,进行了二级调压阀压力试验研究,得出不同开口度的工作油压曲线;针对原始结构及五种改进油路结构、摩擦片不同间隙及油槽参数进行了试验研究,得出了不同油路结构、摩擦片间隙、油槽参数以及进油流量、温度等对入口压力、出油温度的影响规律。试验数据与分析结果吻合良好。
Slipping friction and overheating caused by shearing of oil film were common problems when wet multi-plate friction clutches were disengagement in high speed. The causes of these problems were about not only inner temperature of the clutch and displacement of the disks, but also the flow field of the lubricant. A method based on two-equation turbulence model to analyze the complex flow field of the clutch was proposed, associating with the analysis of temperature field of disks, which was based on the energy conservation of the flow field, the numerical simulation and experimental study of the flow field of lubricant, together with the thermal fluid and thermal structure of the disks in disengaged operation and the thermal structure of the friction disks in engaging process were carried out. After research the influence of the structure of the oil way, the shape of the oil groove and operating conditions on the heating problems of the disks were summarized. Therefore, it has great theory significance and important engineering values to design clutches with low-heat, long-life and high-reliability.
The topic of this thesis was drawn from scientific and technological project --- key technologies and industrialization of high-performance marine gearbox of Chongqing (CSTC: 2007AB3030) and key technologies and industrialization of marine wet multi-plate friction clutch (CSTC: 2008AC3102). The research work of numerical analysis and experimental study of the coupled of the wet multi-plate friction clutches could be summarized as follows:
(1) With comprehensive consideration of the structure and operating conditions of the clutch, the parameterized finite model of original oil way was established and the influence of the structure of oil way on the lubricant pressure distribution in the clearances of the disks was studied, five modified structures were presented, and then the flow field analysis with different import velocity and oil temperature of lubricant in different operating conditions were analyzed.
(2) The thermal analysis of lubricant of clutch was analyzed based on the energy conservation of flow. The influence of disengagement speed, inlet flow rate, type of oil grooves and width of the clearances between the disks on the lubricant temperature and after that the deformation of the disks was presented.
(3) According to the structure of pressure-regulating vale in marine wet multi-plate friction clutch and the shape of its ellipsoidal spool, the oil way model of pressure-regulating valve was established and analyzed. Then after numerical simulation of the oil way, the pressure isograms at three different opening positions, the velocity vector diagram and lubricant pressure in the inlet of the vale could be displayed, and the influence of different lubricant temperature on the flow field were specified.
(4) The friction plate solid and transient heat transfer finite model with spiral and radial oil groove was established, and the transient thermal field in the engaging process of single clutch was analyzed. The temperature contour and the curves of maximum temperature-time history of friction plate were displayed. After comparison the influence of groove width on the temperature distribution was specified. Considering the friction factor on the spline of the friction disks and disk blocks, the steel disks and clutch gear, the friction force distribution between the disks and the gears of spline could be analyzed. According to the establishment the thermal-elastic model of all disks and transient analysis of thermal structure of the disks, the temperature contour and distribution between the disks in engaging process was displayed, together with the thermal-elastic deformation and contact pressure.
(5) The general performance test bench of gearbox was established, and the experiment of the two-stage pressure-regulating valve was done, the lubricant pressure curves at different opening positions were recorded. According to the original structure and five modified structures, width of the clearances between the disks and parameter of oil grooves, the experimental study was carried out, and the influences of different oil structure, clearances between the disks, parameter of oil grooves, inlet flow rate and temperature on inlet pressure and outlet temperature were got. The result of test and analysis show good agreement.
本文项目来源于重庆市科技攻关计划项目“高性能船舶用齿轮箱系统关键技术及产业化”(CSTC:2007AB3030)及“船用湿式多片摩擦离合器关键技术及产业化”(CSTC:2008AC3102)。针对船用齿轮箱中的湿式多片摩擦离合器进行耦合分析及实验研究。主要研究工作如下:
①综合考虑离合器的结构和使用工况,基于原有结构建立了湿式多片摩擦离合器油路流场的参数化有限元分析模型,研究湿式多片摩擦离合器的油路结构对摩擦片间润滑油压力分布的影响,并提出了五种油路结构的改进方案;针对离合器的不同使用工况进行油路流场分析,研究入口流量和润滑油温度对摩擦片间润滑油压力分布的影响。
②基于流体能量守恒方程,建立摩擦片副中润滑油热-流耦合分析模型,研究离合器空转速度、油量、摩擦片油槽形式及片间间隙对润滑油温度的影响;而后对摩擦片进行热-结构耦合分析,以研究离合器空转时润滑油流量、油槽形式等对摩擦片变形的影响。
③针对船用湿式摩擦离合器调压阀的阀体结构及椭球形阀芯形状,建立调压阀内流道流体动力学有限元分析模型,对调压阀内流道的流场进行数值仿真,得出不同阀芯开口度下的压力云图、速度矢量图以及阀口油压曲线,同时分析了不同工作油温对阀件内流道流场的影响。
④构建带径向油槽和螺旋油槽的摩擦片三维实体模型和瞬态传热有限元模型,分析离合器接排过程中单片摩擦片的瞬态温度场,得出接排过程中摩擦片的温度云图及最高温度随时间变化曲线,并研究油槽宽度对摩擦片温度分布的影响;考虑摩擦片与摩擦片座、对偶片与离合器齿轮间花键副摩擦力作用,分析了摩擦片副间的正压力和花键齿间摩擦力的分布规律;而后建立多对摩擦片副的热弹接触有限元分析模型,通过瞬态热-结构耦合分析,得出接排过程中摩擦片组温度云图及分布规律,同时分析了摩擦片的热弹变形及片间接触压力。
⑤搭建了船用齿轮箱综合性能试验台,进行了二级调压阀压力试验研究,得出不同开口度的工作油压曲线;针对原始结构及五种改进油路结构、摩擦片不同间隙及油槽参数进行了试验研究,得出了不同油路结构、摩擦片间隙、油槽参数以及进油流量、温度等对入口压力、出油温度的影响规律。试验数据与分析结果吻合良好。
Slipping friction and overheating caused by shearing of oil film were common problems when wet multi-plate friction clutches were disengagement in high speed. The causes of these problems were about not only inner temperature of the clutch and displacement of the disks, but also the flow field of the lubricant. A method based on two-equation turbulence model to analyze the complex flow field of the clutch was proposed, associating with the analysis of temperature field of disks, which was based on the energy conservation of the flow field, the numerical simulation and experimental study of the flow field of lubricant, together with the thermal fluid and thermal structure of the disks in disengaged operation and the thermal structure of the friction disks in engaging process were carried out. After research the influence of the structure of the oil way, the shape of the oil groove and operating conditions on the heating problems of the disks were summarized. Therefore, it has great theory significance and important engineering values to design clutches with low-heat, long-life and high-reliability.
The topic of this thesis was drawn from scientific and technological project --- key technologies and industrialization of high-performance marine gearbox of Chongqing (CSTC: 2007AB3030) and key technologies and industrialization of marine wet multi-plate friction clutch (CSTC: 2008AC3102). The research work of numerical analysis and experimental study of the coupled of the wet multi-plate friction clutches could be summarized as follows:
(1) With comprehensive consideration of the structure and operating conditions of the clutch, the parameterized finite model of original oil way was established and the influence of the structure of oil way on the lubricant pressure distribution in the clearances of the disks was studied, five modified structures were presented, and then the flow field analysis with different import velocity and oil temperature of lubricant in different operating conditions were analyzed.
(2) The thermal analysis of lubricant of clutch was analyzed based on the energy conservation of flow. The influence of disengagement speed, inlet flow rate, type of oil grooves and width of the clearances between the disks on the lubricant temperature and after that the deformation of the disks was presented.
(3) According to the structure of pressure-regulating vale in marine wet multi-plate friction clutch and the shape of its ellipsoidal spool, the oil way model of pressure-regulating valve was established and analyzed. Then after numerical simulation of the oil way, the pressure isograms at three different opening positions, the velocity vector diagram and lubricant pressure in the inlet of the vale could be displayed, and the influence of different lubricant temperature on the flow field were specified.
(4) The friction plate solid and transient heat transfer finite model with spiral and radial oil groove was established, and the transient thermal field in the engaging process of single clutch was analyzed. The temperature contour and the curves of maximum temperature-time history of friction plate were displayed. After comparison the influence of groove width on the temperature distribution was specified. Considering the friction factor on the spline of the friction disks and disk blocks, the steel disks and clutch gear, the friction force distribution between the disks and the gears of spline could be analyzed. According to the establishment the thermal-elastic model of all disks and transient analysis of thermal structure of the disks, the temperature contour and distribution between the disks in engaging process was displayed, together with the thermal-elastic deformation and contact pressure.
(5) The general performance test bench of gearbox was established, and the experiment of the two-stage pressure-regulating valve was done, the lubricant pressure curves at different opening positions were recorded. According to the original structure and five modified structures, width of the clearances between the disks and parameter of oil grooves, the experimental study was carried out, and the influences of different oil structure, clearances between the disks, parameter of oil grooves, inlet flow rate and temperature on inlet pressure and outlet temperature were got. The result of test and analysis show good agreement.
引文
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