固体颗粒杂质影响活塞环—缸套润滑、磨损的理论及试验装备研究
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摘要
活塞环-缸套是内燃机中最重要、最关键的运动副,对内燃机的动力性、经济性和可靠性有决定性的影响。本学位论文结合国家自然科学基金资助项目“磨料磨损过程数字仿真及其磨损机理研究”,结合云南省机械工业发展的强烈需求,旨在进一步提升云南省优势机械产品之一内燃机的产品质量,促进技术进步,增强市场竞争力。论文以活塞环-缸套摩擦副为研究对象,选择云内动力公司代表性产品4100型内燃机为具体工程对象,全面系统地研究了润滑油中固体颗粒杂质影响内燃机活塞环-缸套润滑、磨损的理论及其试验装备。论文的主要工作如下:
第一章,介绍了课题研究背景与意义,分别阐述了固体颗粒杂质对润滑、磨损影响的研究现状,活塞环-缸套摩擦学研究现状,固体颗粒杂质对活塞环-缸套润滑、磨损影响的研究现状,固体颗粒杂质检测系统的研究现状,活塞环-缸套摩擦副试验装备的研究现状。在此基础上,提出了论文的主要研究内容。
第二章,分析了润滑油中固体颗粒杂质形成原因,研究了固体颗粒杂质几何形态特征参数描述,得到了与固体颗粒实际形态比较符合且便于使用的几何形态描述参数,以润滑油中常见的固体颗粒杂质石英砂、氧化铝、氧化铁为分析对象,进行了几何形状参数测定实验。采用铁谱分析技术观察和分析了云内动力4100型内燃机润滑油中的颗粒杂质。研究了润滑油颗粒杂质的数量特征描述、检测方法以及浓度平衡理论,分析了固体颗粒杂质数量变化规律建模方法,重点研究了支持向量机建模理论,对使用中的云内4100型内燃机进行抽样,获得固体颗粒杂质浓度实验数据,并应用支持向量机理论实现了固体颗粒杂质数量变化规律的建模。
第三章,研究了固体颗粒对表面的作用数学模型,提出了一种针对固体颗粒的颗粒-表面接触数学模型,该模型考虑了弹性、弹塑性和塑性三种变形状态和在三种变形状态转化临界点的变形连续性和光滑性。根据润滑油中颗粒含量关系,建立了多个固体颗粒条件下的作用模型,实现了多个颗粒宏观作用的量化表达,为实际应用奠定了基础。最后,对固体颗粒与摩擦副表面作用进行了数值模拟研究:进行了固体颗粒微观接触过程的有限元分析,进行了固体颗粒冲击摩擦副表面过程的有限元分析,初步研究了基于分子动力学的微颗粒微观切削作用过程的数值模拟,进行了固体颗粒微观接触过程热效应有限元分析,从不同视角反映固体颗粒与摩擦副表面作用的变化过程和变化状态,探索了新的方法和手段。
第四章,从固体颗粒的存在而使润滑油变成了固-液两相流的角度出发,通过实验,研究了云内CD级40号专用柴油机润滑油,在含有三种类型的固体颗粒杂质时而引起润滑油粘度、闪点和燃点变化的两相流效应。重点讨论了活塞环-缸套润滑理论,在此基础上,建立了考虑颗粒杂质影响的活塞环-缸套润滑数学模型,分析了非线性二阶偏微分润滑模型的求解方法,为解决由于考虑了颗粒影响造成求解收敛更困难的难题,提出了解析解形式的活塞环-缸套润滑简化实用模型。针对云内动力4100型内燃机在进气、压缩、做功和排气整个实际工作行程中活塞环-缸套的润滑特性受颗粒杂质影响的情况进行了定量理论计算与分析。
第五章,分析了微切削作用机制和表面塑性变形机制的固体颗粒杂质机械效应。研究了综合两种机制的磨损模型,在此基础上,建立了固体颗粒对活塞环-缸套磨损的数学模型,并应用所建立的模型对云内动力4100型内燃机活塞环-缸套摩擦副进行了磨损量的理论计算分析,得到了内燃机在给定运行时间及颗粒条件下,活塞环、缸套的磨损量以及缸套不同位置的磨损量变化。
第六章,分析了固体颗粒杂质热效应及其可能引发粘着磨损的机理,研究了固体颗粒与接触表面的瞬时温度数学模型和固体颗粒热效应作用下产生粘着磨损的数学模型。在此基础上,分别建立了固体颗粒与缸套表面、固体颗粒与活塞环表面的瞬时温度数学模型以及热效应作用下活塞环-缸套发生粘着磨损的数学模型,并应用所建立的模型对云内动力4100型内燃机活塞环-缸套摩擦副进行了由于固体颗粒热效应而产生的局部温升的理论计算和粘着磨损理论计算,得到了内燃机在给定运行时间及颗粒条件下,缸套表面不同位置处和不同位置处的颗粒因热效应在压缩行程和膨胀作功行程中而产生的瞬时温度变化量,得到了缸套表面不同位置处因固体颗粒热效应而产生的粘着磨损量。
第七章,成功地应用旋转体视显微检测理论对润滑油中固体颗粒的三维外型进行检测,研究了润滑油中固体颗粒杂质三维外型微检测系统,验证了该系统对润滑油中固体颗粒的三维外型检测的可行性。研制了往复式活塞环-缸套试验机,该试验机采用模块化、积木式设计思想,配置可拆换的两部分装置:一是以内燃机实际使用的活塞环-缸套为摩擦副试件且能模拟实际运动形式的实验装置,二是可方便进行固体颗粒杂质影响活塞环-缸套润滑、磨损实验的装置。并基于国产低成本力控工控组态软件,开发了试验机数据采集与监测系统,在线测量与监控实验数据,实现对实验过程中数据变化的完全记录,弥补了同类试验装置不能自动监测实验数据的缺陷。
第八章,模拟4100型内燃机活塞环-缸套的实际运动形式,进行了润滑油含固体颗粒和不含固体颗粒时活塞环-缸套的摩擦磨损比较实验,研究了活塞环-缸套的摩擦力、磨损量、摩擦功耗等摩擦学特性以及与载荷、速度、时间等因素的关系,揭示了它们之间的相互关系规律和影响程度大小,总体分析了固体颗粒杂质的影响。然后根据固体颗粒影响活塞环-缸套润滑的理论研究,分别对试验机活塞环-缸套摩擦副试件在不同实验条件下应用理论模型计算润滑性能和活塞环、缸套试件的磨损量,与相应的实验数据进行对比分析,验证了理论的有效性和可信性。
第九章,对论文的主要研究工作和创新点作了总结,并对未来的研究工作进行了展望。
Piston ring and cylinder liner are important components in an internal combustion engine due to their crucial effects on internal combustion engine such as dynamic, economical efficiency, reliability and durability. Supported by the project of national nature science fund of china-"Study On Simulation And Mechanism Of Abrasive Wear Process", and meet development demand of mechanical industry and improve quality of engine products in Yunnan province, considered piston ring and cylinder liner of 4100 serial products of internal combustion engine as subject investigated, contaminant Solid particles in lubricant oil influencing lubrication and wear of piston ring and cylinder liner of internal combustion engine was systematically researched in this thesis.
In chapter 1, the background and significance of the research are introduced. The development trend and current research situations were expatiated, which included solid particle influencing lubrication and wear, piston ring and cylinder liner tribology, solid particle influencing lubricating and wear of piston ring and cylinder liner, solid particle detection and measuring system and testing equipment of piston ring and cylinder liner, and then the study contents of this dissertation were proposed.
In chapter 2, the origin of contaminant Solid particles in lubricant oil existing between piston ring and cylinder liner was explained, and solid particle geometric shape descriptor was studied, the shape descriptor got is according to real geometric shape. Shape measuring of general solid particle in lubricant oil such as SiO_2, Al_2O_3 and Fe_2O_3 was tested to verify the shape descriptor and geometric shape of solid particles come from lubricant oil samples of 4100 internal combustion engine of Yunnan province internal combustion engine company was analyzed and observed based on ferrography analysis experiments. The change trend in quantity of solid particle in lubricant oil, solid particles detecting technology and concentration balance theory were analyzed, model building methods of solid particle concentration change trend, particularly model by support vector machines theory were studied and used successfully to establish particle concentration change trend model of lubricant oil of 4100 internal combustion engine in use.
In chapter 3, based on contact analysis, a new contact model of solid particle and friction surface was put forward, which considered three deformation states such as elastic, plastic and elasto-plastic behavior, and deformation continuity law and smooth curve theory in state transition, and then the model of many solid particles was also established according to the quantity of solid particles in lubricant oil for macroscopic view. In order to disclose changing process and state and get intermediate data which are not be attained by current experiment, numerical simulation of solid particle acting on worn surface were researched, which were the finite element methods that were used to analyze micro contact process, impacting process and heat effect of solid particle on worn surface, and which is molecular dynamics simulation that was used to analyze micro cutting process of micro particle.
In chapter 4, on the view of two phase fluid due to lubricant oil containing solid particles, two phase effect that changed value of viscosity, flashing point and ignition point under condition of lubricant oil containing three different type solid particles were tested for Yunnan internal combustion engine company special lubricant oil of CD grade No.40. Based on lubrication theories of piston ring and cylinder liner researched mainly, the lubrication model that considered solid particle influencing lubrication of piston ring and cylinder liner was established, and then numerical solution method was introduced to solve the model of second-order partial differential equation. In order to solve the puzzle of convergence and conveniently compare two type lubrication condition of containing solid particles or not, a new simplification and utility lubrication model was established. On condition of lubricant oil containing solid particles lubrication performance of piston ring and cylinder liner in the four stroke of intake, compression, expansion and exhaust were calculated and analyzed for 4100 serial products of Yunnan internal combustion engine company.
In chapter 5, based on wear model of mechanical effect that combines micro cutting mechanism and plastic deform mechanism, the piston ring and cylinder liner wear model that considered solid particle influencing was established, and then piston ring wear, cylinder liner wear and wear distribution in cylinder liner on condition of given run time, concentration and size of solid particle were calculated and analyzed for 4100 serial products of Yunnan internal combustion engine company.
In chapter 6, the mechanism of adhere wear generated by heat effect was discussed, and the flashing contact temperature mathematical model for solid particle on friction surface and adhere wear volume model generated by solid particle heat effect were established, and then Instantaneous contact temperature mathematical model for solid particle on cylinder liner surface, solid particle on piston ring surface and adhere wear volume model of cylinder liner surface and piston ring surface which are generated by solid particle heat effect were also established. Using the theoretical models the piston ring and cylinder liner of 4100 serial products of Yunnan internal combustion engine company were calculated and analyzed on condition of given run time, concentration and size of solid particle. Instant contact temperature increment of cylinder liner surface and particle on different cylinder liner position generated by heat effect were got, and adhere wear volume distribution in cylinder liner generated by heat effect was got.
In chapter 7, micro measuring system for three-dimensional geometric shape measuring of solid particle in lubricant oil was successfully developed based on three dimension rotational stereo measuring theory and was tested that it is feasible. Aim at do special experiments of lubrication performance and wear effected by solid particles, Reciprocating type Piston ring and cylinder liner test machine was designed and developed, which comprises of two exchangeable components and can be use to simulate real movement of piston ring and cylinder liner in an internal combustion engine and do experiments of solid particles influencing lubrication and wear of piston ring and cylinder liner. Based on Likong industrial configuration software made in china the data collection and monitor system of testing machine was also developed, which can be used to measure and monitor experiment data on line and record changing data in experiment process. So shortage of similar test equipment that can not automatically monitor test data was remedied.
In chapter 8, simulated real movement of piston ring and cylinder liner of 4100 serial internal combustion engine, friction and wear of piston ring and cylinder liner on condition that lubricant oil containing solid particles or not were compared by experiments. The results show that solid particles influence tribological performance such as friction force, wear of piston ring and cylinder liner and friction loss. The relationship between tribological performance and load, velocity and run time was also investigated by experiments. Based on theory research achievement in advance chapters, applied theoretical models to calculate friction force related to lubrication performance and wear of specimen made from piston ring and cylinder liner under different experiment conditions in test machine, compared with corresponding test data, the theoretical models were proved that they are effective and confidence.
In chapter 9, the study contents and conclusions of the dissertation have been summarized and the further research works have been forecast.
第一章,介绍了课题研究背景与意义,分别阐述了固体颗粒杂质对润滑、磨损影响的研究现状,活塞环-缸套摩擦学研究现状,固体颗粒杂质对活塞环-缸套润滑、磨损影响的研究现状,固体颗粒杂质检测系统的研究现状,活塞环-缸套摩擦副试验装备的研究现状。在此基础上,提出了论文的主要研究内容。
第二章,分析了润滑油中固体颗粒杂质形成原因,研究了固体颗粒杂质几何形态特征参数描述,得到了与固体颗粒实际形态比较符合且便于使用的几何形态描述参数,以润滑油中常见的固体颗粒杂质石英砂、氧化铝、氧化铁为分析对象,进行了几何形状参数测定实验。采用铁谱分析技术观察和分析了云内动力4100型内燃机润滑油中的颗粒杂质。研究了润滑油颗粒杂质的数量特征描述、检测方法以及浓度平衡理论,分析了固体颗粒杂质数量变化规律建模方法,重点研究了支持向量机建模理论,对使用中的云内4100型内燃机进行抽样,获得固体颗粒杂质浓度实验数据,并应用支持向量机理论实现了固体颗粒杂质数量变化规律的建模。
第三章,研究了固体颗粒对表面的作用数学模型,提出了一种针对固体颗粒的颗粒-表面接触数学模型,该模型考虑了弹性、弹塑性和塑性三种变形状态和在三种变形状态转化临界点的变形连续性和光滑性。根据润滑油中颗粒含量关系,建立了多个固体颗粒条件下的作用模型,实现了多个颗粒宏观作用的量化表达,为实际应用奠定了基础。最后,对固体颗粒与摩擦副表面作用进行了数值模拟研究:进行了固体颗粒微观接触过程的有限元分析,进行了固体颗粒冲击摩擦副表面过程的有限元分析,初步研究了基于分子动力学的微颗粒微观切削作用过程的数值模拟,进行了固体颗粒微观接触过程热效应有限元分析,从不同视角反映固体颗粒与摩擦副表面作用的变化过程和变化状态,探索了新的方法和手段。
第四章,从固体颗粒的存在而使润滑油变成了固-液两相流的角度出发,通过实验,研究了云内CD级40号专用柴油机润滑油,在含有三种类型的固体颗粒杂质时而引起润滑油粘度、闪点和燃点变化的两相流效应。重点讨论了活塞环-缸套润滑理论,在此基础上,建立了考虑颗粒杂质影响的活塞环-缸套润滑数学模型,分析了非线性二阶偏微分润滑模型的求解方法,为解决由于考虑了颗粒影响造成求解收敛更困难的难题,提出了解析解形式的活塞环-缸套润滑简化实用模型。针对云内动力4100型内燃机在进气、压缩、做功和排气整个实际工作行程中活塞环-缸套的润滑特性受颗粒杂质影响的情况进行了定量理论计算与分析。
第五章,分析了微切削作用机制和表面塑性变形机制的固体颗粒杂质机械效应。研究了综合两种机制的磨损模型,在此基础上,建立了固体颗粒对活塞环-缸套磨损的数学模型,并应用所建立的模型对云内动力4100型内燃机活塞环-缸套摩擦副进行了磨损量的理论计算分析,得到了内燃机在给定运行时间及颗粒条件下,活塞环、缸套的磨损量以及缸套不同位置的磨损量变化。
第六章,分析了固体颗粒杂质热效应及其可能引发粘着磨损的机理,研究了固体颗粒与接触表面的瞬时温度数学模型和固体颗粒热效应作用下产生粘着磨损的数学模型。在此基础上,分别建立了固体颗粒与缸套表面、固体颗粒与活塞环表面的瞬时温度数学模型以及热效应作用下活塞环-缸套发生粘着磨损的数学模型,并应用所建立的模型对云内动力4100型内燃机活塞环-缸套摩擦副进行了由于固体颗粒热效应而产生的局部温升的理论计算和粘着磨损理论计算,得到了内燃机在给定运行时间及颗粒条件下,缸套表面不同位置处和不同位置处的颗粒因热效应在压缩行程和膨胀作功行程中而产生的瞬时温度变化量,得到了缸套表面不同位置处因固体颗粒热效应而产生的粘着磨损量。
第七章,成功地应用旋转体视显微检测理论对润滑油中固体颗粒的三维外型进行检测,研究了润滑油中固体颗粒杂质三维外型微检测系统,验证了该系统对润滑油中固体颗粒的三维外型检测的可行性。研制了往复式活塞环-缸套试验机,该试验机采用模块化、积木式设计思想,配置可拆换的两部分装置:一是以内燃机实际使用的活塞环-缸套为摩擦副试件且能模拟实际运动形式的实验装置,二是可方便进行固体颗粒杂质影响活塞环-缸套润滑、磨损实验的装置。并基于国产低成本力控工控组态软件,开发了试验机数据采集与监测系统,在线测量与监控实验数据,实现对实验过程中数据变化的完全记录,弥补了同类试验装置不能自动监测实验数据的缺陷。
第八章,模拟4100型内燃机活塞环-缸套的实际运动形式,进行了润滑油含固体颗粒和不含固体颗粒时活塞环-缸套的摩擦磨损比较实验,研究了活塞环-缸套的摩擦力、磨损量、摩擦功耗等摩擦学特性以及与载荷、速度、时间等因素的关系,揭示了它们之间的相互关系规律和影响程度大小,总体分析了固体颗粒杂质的影响。然后根据固体颗粒影响活塞环-缸套润滑的理论研究,分别对试验机活塞环-缸套摩擦副试件在不同实验条件下应用理论模型计算润滑性能和活塞环、缸套试件的磨损量,与相应的实验数据进行对比分析,验证了理论的有效性和可信性。
第九章,对论文的主要研究工作和创新点作了总结,并对未来的研究工作进行了展望。
Piston ring and cylinder liner are important components in an internal combustion engine due to their crucial effects on internal combustion engine such as dynamic, economical efficiency, reliability and durability. Supported by the project of national nature science fund of china-"Study On Simulation And Mechanism Of Abrasive Wear Process", and meet development demand of mechanical industry and improve quality of engine products in Yunnan province, considered piston ring and cylinder liner of 4100 serial products of internal combustion engine as subject investigated, contaminant Solid particles in lubricant oil influencing lubrication and wear of piston ring and cylinder liner of internal combustion engine was systematically researched in this thesis.
In chapter 1, the background and significance of the research are introduced. The development trend and current research situations were expatiated, which included solid particle influencing lubrication and wear, piston ring and cylinder liner tribology, solid particle influencing lubricating and wear of piston ring and cylinder liner, solid particle detection and measuring system and testing equipment of piston ring and cylinder liner, and then the study contents of this dissertation were proposed.
In chapter 2, the origin of contaminant Solid particles in lubricant oil existing between piston ring and cylinder liner was explained, and solid particle geometric shape descriptor was studied, the shape descriptor got is according to real geometric shape. Shape measuring of general solid particle in lubricant oil such as SiO_2, Al_2O_3 and Fe_2O_3 was tested to verify the shape descriptor and geometric shape of solid particles come from lubricant oil samples of 4100 internal combustion engine of Yunnan province internal combustion engine company was analyzed and observed based on ferrography analysis experiments. The change trend in quantity of solid particle in lubricant oil, solid particles detecting technology and concentration balance theory were analyzed, model building methods of solid particle concentration change trend, particularly model by support vector machines theory were studied and used successfully to establish particle concentration change trend model of lubricant oil of 4100 internal combustion engine in use.
In chapter 3, based on contact analysis, a new contact model of solid particle and friction surface was put forward, which considered three deformation states such as elastic, plastic and elasto-plastic behavior, and deformation continuity law and smooth curve theory in state transition, and then the model of many solid particles was also established according to the quantity of solid particles in lubricant oil for macroscopic view. In order to disclose changing process and state and get intermediate data which are not be attained by current experiment, numerical simulation of solid particle acting on worn surface were researched, which were the finite element methods that were used to analyze micro contact process, impacting process and heat effect of solid particle on worn surface, and which is molecular dynamics simulation that was used to analyze micro cutting process of micro particle.
In chapter 4, on the view of two phase fluid due to lubricant oil containing solid particles, two phase effect that changed value of viscosity, flashing point and ignition point under condition of lubricant oil containing three different type solid particles were tested for Yunnan internal combustion engine company special lubricant oil of CD grade No.40. Based on lubrication theories of piston ring and cylinder liner researched mainly, the lubrication model that considered solid particle influencing lubrication of piston ring and cylinder liner was established, and then numerical solution method was introduced to solve the model of second-order partial differential equation. In order to solve the puzzle of convergence and conveniently compare two type lubrication condition of containing solid particles or not, a new simplification and utility lubrication model was established. On condition of lubricant oil containing solid particles lubrication performance of piston ring and cylinder liner in the four stroke of intake, compression, expansion and exhaust were calculated and analyzed for 4100 serial products of Yunnan internal combustion engine company.
In chapter 5, based on wear model of mechanical effect that combines micro cutting mechanism and plastic deform mechanism, the piston ring and cylinder liner wear model that considered solid particle influencing was established, and then piston ring wear, cylinder liner wear and wear distribution in cylinder liner on condition of given run time, concentration and size of solid particle were calculated and analyzed for 4100 serial products of Yunnan internal combustion engine company.
In chapter 6, the mechanism of adhere wear generated by heat effect was discussed, and the flashing contact temperature mathematical model for solid particle on friction surface and adhere wear volume model generated by solid particle heat effect were established, and then Instantaneous contact temperature mathematical model for solid particle on cylinder liner surface, solid particle on piston ring surface and adhere wear volume model of cylinder liner surface and piston ring surface which are generated by solid particle heat effect were also established. Using the theoretical models the piston ring and cylinder liner of 4100 serial products of Yunnan internal combustion engine company were calculated and analyzed on condition of given run time, concentration and size of solid particle. Instant contact temperature increment of cylinder liner surface and particle on different cylinder liner position generated by heat effect were got, and adhere wear volume distribution in cylinder liner generated by heat effect was got.
In chapter 7, micro measuring system for three-dimensional geometric shape measuring of solid particle in lubricant oil was successfully developed based on three dimension rotational stereo measuring theory and was tested that it is feasible. Aim at do special experiments of lubrication performance and wear effected by solid particles, Reciprocating type Piston ring and cylinder liner test machine was designed and developed, which comprises of two exchangeable components and can be use to simulate real movement of piston ring and cylinder liner in an internal combustion engine and do experiments of solid particles influencing lubrication and wear of piston ring and cylinder liner. Based on Likong industrial configuration software made in china the data collection and monitor system of testing machine was also developed, which can be used to measure and monitor experiment data on line and record changing data in experiment process. So shortage of similar test equipment that can not automatically monitor test data was remedied.
In chapter 8, simulated real movement of piston ring and cylinder liner of 4100 serial internal combustion engine, friction and wear of piston ring and cylinder liner on condition that lubricant oil containing solid particles or not were compared by experiments. The results show that solid particles influence tribological performance such as friction force, wear of piston ring and cylinder liner and friction loss. The relationship between tribological performance and load, velocity and run time was also investigated by experiments. Based on theory research achievement in advance chapters, applied theoretical models to calculate friction force related to lubrication performance and wear of specimen made from piston ring and cylinder liner under different experiment conditions in test machine, compared with corresponding test data, the theoretical models were proved that they are effective and confidence.
In chapter 9, the study contents and conclusions of the dissertation have been summarized and the further research works have been forecast.
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