基于粘度可控水基润滑液的高速陶瓷滑动轴承主轴设计
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摘要
高速高精密主轴系统作为高速加工机床中的心脏部件,其性能的高低直接影响到高速加工机床的整体发展水平。现行的高速电主轴轴承技术中,滚动轴承较大的振动与噪声、磁力轴承过于复杂的控制系统以及气体轴承较低的承载能力限制了其进一步发展。本文设计完成了采用新型水基润滑液润滑的动静压陶瓷滑动轴承电主轴,并提出了一种基于润滑液粘度可控性,在现有制造水平下通过对粘度—轴承结构寻优从而实现主轴高性能的高速高精密主轴设计方法。根据上述构思,本文主要工作如下:
研制完成了用于高速精密滑动轴承的新型绿色水基润滑液。在确定润滑液主要组分后,采用正交试验方法确定了防锈添加剂组分配比,并测定了含不同浓度添加剂润滑液的温度—粘度特性以及其他物理性能。
为确定陶瓷滑动轴承摩擦副的制造材料,以及验证水基润滑液与工程陶瓷材料的匹配性能,开展了热压烧结Si3N4和反应烧结SiC陶瓷材料的摩擦磨损试验研究。结果表明,在不同的润滑情况下,SiC都表现出更高的极限承载能力、更好的跑合性能与更低的磨损率,而且生成了SiO2润滑膜并可有效改善摩擦磨损状况;同时水基润滑液与陶瓷材料匹配良好并表现出优良的润滑性能。
针对本课题独特的基于低粘度润滑液、多孔质节流器的流体动静压轴承,采用编程求解修正Reynolds方程并调用有限元分析软件的方法完成了高速水基润滑液润滑陶瓷轴承的TEHD数值理论计算与粘度、结构优化分析,最终确定了多孔质节流器、滑动轴承液腔相关结构尺寸与润滑液所需粘度;通过动力计算与液膜稳定性分析,算得轴心在小扰动下偏离平衡位置后的运动趋势为收敛。
在前述研究基础上,最终设计完成了基于粘度可控水基润滑液的高速高精度动静压陶瓷滑动轴承主轴系统。其轴承布局具有理论上高热稳定性并采用了全包容结构的陶瓷滑动轴承摩擦副;通过仿真计算及优化分析,确定了轴端外侧与真空夹紧机构相联接、内表面设计与HSK-C、HSK-D型刀柄相联接的结构并计算出了相应刀柄最佳预紧力。最后完成了循环润滑系统设计以及主轴—循环润滑系统的一体电气设计。
The high speed and highly accurate spindle system at the heart of a high speed machine tool directly influences the development and overall performance of that tool. The most common bearings of motorized spindle are the rolling bearing, magnetic bearing and the gas bearing. However, the vibrancy and noise of the rolling bearing, the excessively sophisticated control system of the magnetic bearing and the lower carrying power of the gas bearing restrict their further development. In this paper, a high speed and accuracy spindle system with hybrid ceramic bearing lubricated by new water based fluid is designed based on the method that on current manufacture technical level the match of theoretical rotary accuracy, rigidity and friction power can be optimized to play best performance of spindle with the controllable viscosity lubricant. The main work of this thesis can be summarized as follows:
A green and viscosity controllable water based fluid as lubricant of the high speed and highly accurate spindle is compounded. After main constituents of this lubricant established, the ratio of anti-rust additive can be determined with orthogonal test. On the one hand, the viscosity-temperature relationships and other physical properties of water based fluid with different additive concentration are also obtained in the test.
A series of friction and wear tests for hot pressed silicon Si3N4 and reaction sintering SiC are carried out in order to select the manufacture material of ceramics journal bearing and verify the matching performance of water-based fluid and engineering ceramics. The results present that under different lubricating condition SiC friction couples always have higher running-in properties and carrying capacity, smoother surface and lower wear rate, moreover SiO2 layer is more obviously formed and the friction coefficient of SiC will be reduced when SiO2 generates continuously. Besides the water based fluid can match ceramics materials well and exhibit good lubricity.
According to the special ceramic materials and the porous restrictor, which is applied for its high rigidity and excellent stability with vibration damping under certain conditions, the TEHD numerical calculation program for high speed hybrid bearing is compiled to solve modified Reynolds equation and thermal stress analysis with FORTRAN programe and finite element processor. After the optimization analysis, the viscosity of lubricant, the structure parameters of porous restrictor and fluid cavity of journal bearing can be deduced. Based on the dynamic calculation and stability analysis for lubricant film, when the rotor deviates the static balance position, its movement tendency is convergent, and the bearing can be regard as absolute stability according to relative criterion.
With the above results, the design for whole structure of spindle system with hybrid ceramic bearing lubricated by new water based fluid can be finished, and there possesses theoretical thermal stability of bearings distribution form and all-contain structure of ceramics journal bearing. Furthermore through the simulation and optimization analysis, the lateral of spindle end should be connected to the vacuum sucker and the inner surface should be combined with HSK-C and HSK-D tool-holder, meanwhile these pre-tightening forces are also optimized. Finally the design of circulating lubrication system and the electrical design of spindle and lubrication system are finished.
研制完成了用于高速精密滑动轴承的新型绿色水基润滑液。在确定润滑液主要组分后,采用正交试验方法确定了防锈添加剂组分配比,并测定了含不同浓度添加剂润滑液的温度—粘度特性以及其他物理性能。
为确定陶瓷滑动轴承摩擦副的制造材料,以及验证水基润滑液与工程陶瓷材料的匹配性能,开展了热压烧结Si3N4和反应烧结SiC陶瓷材料的摩擦磨损试验研究。结果表明,在不同的润滑情况下,SiC都表现出更高的极限承载能力、更好的跑合性能与更低的磨损率,而且生成了SiO2润滑膜并可有效改善摩擦磨损状况;同时水基润滑液与陶瓷材料匹配良好并表现出优良的润滑性能。
针对本课题独特的基于低粘度润滑液、多孔质节流器的流体动静压轴承,采用编程求解修正Reynolds方程并调用有限元分析软件的方法完成了高速水基润滑液润滑陶瓷轴承的TEHD数值理论计算与粘度、结构优化分析,最终确定了多孔质节流器、滑动轴承液腔相关结构尺寸与润滑液所需粘度;通过动力计算与液膜稳定性分析,算得轴心在小扰动下偏离平衡位置后的运动趋势为收敛。
在前述研究基础上,最终设计完成了基于粘度可控水基润滑液的高速高精度动静压陶瓷滑动轴承主轴系统。其轴承布局具有理论上高热稳定性并采用了全包容结构的陶瓷滑动轴承摩擦副;通过仿真计算及优化分析,确定了轴端外侧与真空夹紧机构相联接、内表面设计与HSK-C、HSK-D型刀柄相联接的结构并计算出了相应刀柄最佳预紧力。最后完成了循环润滑系统设计以及主轴—循环润滑系统的一体电气设计。
The high speed and highly accurate spindle system at the heart of a high speed machine tool directly influences the development and overall performance of that tool. The most common bearings of motorized spindle are the rolling bearing, magnetic bearing and the gas bearing. However, the vibrancy and noise of the rolling bearing, the excessively sophisticated control system of the magnetic bearing and the lower carrying power of the gas bearing restrict their further development. In this paper, a high speed and accuracy spindle system with hybrid ceramic bearing lubricated by new water based fluid is designed based on the method that on current manufacture technical level the match of theoretical rotary accuracy, rigidity and friction power can be optimized to play best performance of spindle with the controllable viscosity lubricant. The main work of this thesis can be summarized as follows:
A green and viscosity controllable water based fluid as lubricant of the high speed and highly accurate spindle is compounded. After main constituents of this lubricant established, the ratio of anti-rust additive can be determined with orthogonal test. On the one hand, the viscosity-temperature relationships and other physical properties of water based fluid with different additive concentration are also obtained in the test.
A series of friction and wear tests for hot pressed silicon Si3N4 and reaction sintering SiC are carried out in order to select the manufacture material of ceramics journal bearing and verify the matching performance of water-based fluid and engineering ceramics. The results present that under different lubricating condition SiC friction couples always have higher running-in properties and carrying capacity, smoother surface and lower wear rate, moreover SiO2 layer is more obviously formed and the friction coefficient of SiC will be reduced when SiO2 generates continuously. Besides the water based fluid can match ceramics materials well and exhibit good lubricity.
According to the special ceramic materials and the porous restrictor, which is applied for its high rigidity and excellent stability with vibration damping under certain conditions, the TEHD numerical calculation program for high speed hybrid bearing is compiled to solve modified Reynolds equation and thermal stress analysis with FORTRAN programe and finite element processor. After the optimization analysis, the viscosity of lubricant, the structure parameters of porous restrictor and fluid cavity of journal bearing can be deduced. Based on the dynamic calculation and stability analysis for lubricant film, when the rotor deviates the static balance position, its movement tendency is convergent, and the bearing can be regard as absolute stability according to relative criterion.
With the above results, the design for whole structure of spindle system with hybrid ceramic bearing lubricated by new water based fluid can be finished, and there possesses theoretical thermal stability of bearings distribution form and all-contain structure of ceramics journal bearing. Furthermore through the simulation and optimization analysis, the lateral of spindle end should be connected to the vacuum sucker and the inner surface should be combined with HSK-C and HSK-D tool-holder, meanwhile these pre-tightening forces are also optimized. Finally the design of circulating lubrication system and the electrical design of spindle and lubrication system are finished.
引文
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