高速高低温双滚子试验机的研制
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摘要
在航空航天和高新工程等复杂技术领域,揭示高温、低温、交变温度、高速重载等导致的极端温度环境下,摩擦副表面结构、润滑性能演变、摩擦副损伤和润滑失效行为之间的本质规律,建立面向航空航天、高新工程应用的润滑抗磨损材料的设计和评价方法成为行业发展的基础科学问题。
本文研制了高速高低温双滚子试验机系统,可用于高速重载、高温、低温、润滑、表面状态对高速摩擦副的性能影响及机理研究。
确定了试验机系统设计方案。整个系统由试验台机械系统、润滑系统、温度工况模拟、动力装置、加载系统以及测试控制系统组成。并根据机械系统方案完成了试验机系统的机械结构设计。
利用Solidworks完成了双滚子试验机的三维建模,用ANSYS对试验机进行了动静特性分析。针对不同等级的温度工况,进行了试验机机体的热—应力耦合分析,与静力分析相比,应力场分布发生了很大变化,热应力已经成为影响最大应力的主要因素。根据分析结果,更换试验机机体材料为QT400-18。完成试验机机体及轴系的模态分析,发现在试验机极限转速范围内存在共振频率。通过合理设计滚子试件的结构,提高活动轴承座与下底座连接的配合精度,可避免试验机工作在危险频率内。
确定了测控系统方案,采用上位机、下位机联合实现对系统的测试与控制。用PLC完成下位机软件编程,对试验机进行直接控制及监测。上位机的主控软件由组态王、VB等软件的混合编程完成,将组态王设计的组态模块作为测控软件的核心,可调用振动监测程序、PLC程序,实现系统的运行控制、数据采集与分析、监测报警等功能。完成电气系统的电路图设计,合理选择元器件,搭建了测控系统的硬件平台,并对系统进行了抗干扰的处理。
对试验机系统进行安装及测控系统的性能测试,并验证了测控系统的准确性、稳定性。
In the fields of aerospace, astronautics and high-tech engineering, it wouldbe the basal science subject of the industry development that revealing the lawsof nature among surface structure of friction pairs, evolution of lubrication,injury of friction pairs and lubrication failure, under the influence of extremetemperature condition which is caused by high temperature, low temperature,alternating temperature, high speed and heavy load, basing the design andevaluate methods of lubrication and friction material which would be used in thefields of aerospace,astronautics and high-tech engineering.
High speed and high-low temperature two rollers testrig is developed in thispaper, which can be used for performanceand mechanism study of friction pairsunder the influence of high speed ,heavy load, high temperature, low temperature,lubrication and surface state.
The scheme design of the whole test system is established. The test benchiscomposed of mechanical structure, lubrication system, simulation system oftemperature conditions, power unit, loading system and monitoring and controlsystem. Mechanical structure deign of the tester is completed according to thescheme of the structure.
The 3-D module of the tester is finished by SolidWorks, of which the staticand dynamic analysis is developed by ANSYS. Compare thermal-stress analysiswith static analysis, great changes of the body’s Stress contour have taken place.Thermal stress becomes the principle factor affecting the maximum stress.According to thermal-stress analysis for different temperature conditions,QT400-18 is chosen as the material of the body. Accomplish modal analysis ofboth body and shafting and get the resonance frequency in tester’s ultimate speed.The machine can work avoiding resonance frequency with rational design ofroller sample. The matching precision between flexible housing and tester bodyshould be improved.
The scheme of the monitoring and control system is established, that themonitoring and control of system is realized by both host computer and slavecomputer. PLC program can directly control the tester. The upper computer software is developed by mixed programming method of VB and KINGVIEW.Configuration module as the core of the software system, which is designed byKINGVIEW, could call vibration monitoring program and PLC program andrealize the control and monitoring alarm functions of tester.Design the electricalcircuit diagram. By choosing the reasonable electronic components, assemble thehardware system.And further more, present somemeasures of anti-interference.
Accomplish the assemblage of mechanical structure. Debug the control andmonitoring system. Furthermore, feasibilityof the system is verified
本文研制了高速高低温双滚子试验机系统,可用于高速重载、高温、低温、润滑、表面状态对高速摩擦副的性能影响及机理研究。
确定了试验机系统设计方案。整个系统由试验台机械系统、润滑系统、温度工况模拟、动力装置、加载系统以及测试控制系统组成。并根据机械系统方案完成了试验机系统的机械结构设计。
利用Solidworks完成了双滚子试验机的三维建模,用ANSYS对试验机进行了动静特性分析。针对不同等级的温度工况,进行了试验机机体的热—应力耦合分析,与静力分析相比,应力场分布发生了很大变化,热应力已经成为影响最大应力的主要因素。根据分析结果,更换试验机机体材料为QT400-18。完成试验机机体及轴系的模态分析,发现在试验机极限转速范围内存在共振频率。通过合理设计滚子试件的结构,提高活动轴承座与下底座连接的配合精度,可避免试验机工作在危险频率内。
确定了测控系统方案,采用上位机、下位机联合实现对系统的测试与控制。用PLC完成下位机软件编程,对试验机进行直接控制及监测。上位机的主控软件由组态王、VB等软件的混合编程完成,将组态王设计的组态模块作为测控软件的核心,可调用振动监测程序、PLC程序,实现系统的运行控制、数据采集与分析、监测报警等功能。完成电气系统的电路图设计,合理选择元器件,搭建了测控系统的硬件平台,并对系统进行了抗干扰的处理。
对试验机系统进行安装及测控系统的性能测试,并验证了测控系统的准确性、稳定性。
In the fields of aerospace, astronautics and high-tech engineering, it wouldbe the basal science subject of the industry development that revealing the lawsof nature among surface structure of friction pairs, evolution of lubrication,injury of friction pairs and lubrication failure, under the influence of extremetemperature condition which is caused by high temperature, low temperature,alternating temperature, high speed and heavy load, basing the design andevaluate methods of lubrication and friction material which would be used in thefields of aerospace,astronautics and high-tech engineering.
High speed and high-low temperature two rollers testrig is developed in thispaper, which can be used for performanceand mechanism study of friction pairsunder the influence of high speed ,heavy load, high temperature, low temperature,lubrication and surface state.
The scheme design of the whole test system is established. The test benchiscomposed of mechanical structure, lubrication system, simulation system oftemperature conditions, power unit, loading system and monitoring and controlsystem. Mechanical structure deign of the tester is completed according to thescheme of the structure.
The 3-D module of the tester is finished by SolidWorks, of which the staticand dynamic analysis is developed by ANSYS. Compare thermal-stress analysiswith static analysis, great changes of the body’s Stress contour have taken place.Thermal stress becomes the principle factor affecting the maximum stress.According to thermal-stress analysis for different temperature conditions,QT400-18 is chosen as the material of the body. Accomplish modal analysis ofboth body and shafting and get the resonance frequency in tester’s ultimate speed.The machine can work avoiding resonance frequency with rational design ofroller sample. The matching precision between flexible housing and tester bodyshould be improved.
The scheme of the monitoring and control system is established, that themonitoring and control of system is realized by both host computer and slavecomputer. PLC program can directly control the tester. The upper computer software is developed by mixed programming method of VB and KINGVIEW.Configuration module as the core of the software system, which is designed byKINGVIEW, could call vibration monitoring program and PLC program andrealize the control and monitoring alarm functions of tester.Design the electricalcircuit diagram. By choosing the reasonable electronic components, assemble thehardware system.And further more, present somemeasures of anti-interference.
Accomplish the assemblage of mechanical structure. Debug the control andmonitoring system. Furthermore, feasibilityof the system is verified
引文
1陈卓君、徐宝信.摩擦学试验方法的研究及发展.机械设计与制造.1999,6:62-63
2 M.J.O’Brien. Failure analysis of three Si3N4 balls used in hybrid bearings.Engineeringfailureanalysis.2003(10):43-473
3王黎钦、李秀娟.涡喷发动机高温高速轴承失效机理及改进措施.机械科学与技术.2002,21(6):963-965
4张永振、邱明。高速干摩擦条件下铝基复合材料的摩擦磨损行为研究.摩擦学学报.2005,25(4):333-336
5乔玉林、徐滨士. Fe-Cr-Ni耐磨涂层的摩擦性能及作用机理.机械工程学报.2002,38(5):18-21
6 Soemantri S. Some Aspects of Abrasive Wear at Elevated Temperatures. Wear.1985,104:338-344
7 Fischer A. construction of A New wear Tester for elevated Temperatures andFirst Results of Sliding Abrasion Tests. Wear of material: InternationalConferenceonWearofMaterials.1989:729-734
8 M.Kalin,J.Vizintin . A rolling-contact device that uses the ball-on-flat testingprinciple.WEAR.2004,256:335-341
9 B. Subramonian, Bikramjit Basu. Development of a high-speed cryogenictribometer: Design concept and experimental results. Materials Science andEngineering.2006,A415:72-79
10宋宝玉,古乐. SY-1型真空摩擦磨损试验机的研制.润滑与密封。2004(1):61-62
11徐双满、曾昭翔.往复式摩擦磨损试验机的研制.机车车辆工艺. 1997(6):22-2412李霞,许志庆,杨勇.高速摩擦磨损试验机的总体设计.中国仪器仪表.2003(10):19-21
13 Kim, Kitae. Design and development of a high-speed bearing testapparatus.JournalofTesting&Evaluation.1998,26(4):301~305
14 M. S. Stephen. Performance of a Hybrid Cylindrical Roller Bearing.LubricationEngineering.1997,48(8):665~672
15 Y.Shoda, S. Ijuin. The Performance of a Hybrid Ceramic Ball-Bearing underHigh-Speed Conditions with The under Race Lubrication Method. TribologyTransactions.1997,40(7):676~684
16 Zatarain.M, lejardi. E, Egana. F. Modular synthesis of machine tools. Annals oftheCIRP,1998,47(1):333-336
17 Heisel.U, Feinauer.A . Dynamic Influence on Workpiece Quality in HighSpeedMilling.AnnalsoftheCIRP,1999,48(1):321-324
18 Ramezanali Mahdavinejad. Finite element analysis of machine and workpieceinstability in turning. International Journal of Machine tools & Manufacture,2005,(45):753-760
19 Jin Kyung Choi, Dai Gil Lee. Thermal characteristics of the spindle bearingsystem withagearlocatedonthebearingspan. International Journal ofMachineTool&Manufacture,1998(38):1017-1030
20 Chi- Wei Lin, Jay F. Tu, Joe Kamman. An integrated thermo-mechanicaldynamicmodeltocharacterizemotorizedmachinetoolspindlesduringveryhighspeed rotation. International Journal of Machine tools & Manufacture, 2003,(43):1035-1050
21尤国英.某燃气轮机试验台的动态特性研究.燃气轮机技术. 2000,13(3):37-41
22杨成云,林腾蛟等.增速箱系统固有特性和动态响应分析.中国机械工程。2003,14(5):380-382
23晋兵营,李冠锋等。YT4135Z柴油机机体动态响应分析。内燃机工程。2005,26(2):58-60
24张俊红,蓝军,倪广建。车用柴油机机体及油底壳的动态特性分析。中国机械工程2004,15(16):1433-1436
25刘晓东、吴入军.车床主轴箱模态分析。机械设计与制造。2007(2):24-25
26孙雅洲,王蕊等.微型机床的结构动态特性分析。2005(1):94-95
27胡秋,何东林.数控机床电主轴单元热-结构特性动态分析.组合机床与自动化加工技术.2006(12):5-7
28王东方,潘琼瑶等.柴油机气缸盖多场耦合三维有限元分析.力学季刊.2006,26(3):511-516
29向东湖、唐群国.新型摩擦磨损试验机测试系统开发.机械与电子.2005(2):74-76
30将建忠,赵永武.摩擦磨损试验机计算机辅助测试系统的设计与实现.江南大学学报.2005,4(2):187-190
31李鸽鹏、邓建春. PLC在电喷发动机试验台架控制系统中的应用.电子元器件应用.2006,8(11):47-49
32王世博、葛世荣.牵引滚动摩擦实验机的研制.矿山机械.2007,35(1):96-98
33 Jia Shuo, Duan Zhengang. Application of RSView Configuration Software inChlorine Dosing and Ammonia Dosing System. the First InternationalSymposiumonTestAutomation&Instrumentation. 2006:1872-1875
34纪玉龙、徐久军等.新型缸套-活塞零部件摩擦磨损试验机及其测控系统.润滑与密封.2006(11):177-180
35梅宏斌.滚动轴承振动监测与诊断理论·方法·系统.机械工业出版社.1995年
36潘新安,苏学成等.有限元前处理技术的研究与应用.煤矿机械.2007,28(4):68-70
37董爱花,孙平. YZ4105柴油机机体温度场的测量和三维数值模拟.拖拉机与农用运输机械.2007,34(1):50-52
38胡友安,李晓东等.涡壳温度场和热应力的有限元分析.机械强度.2007,29(1):130-134
39赵丽娟,刘宏梅. ANSYS在矿用减速器箱体应力分析中的应用.矿业研究与开发.2007,27(1):52-54
40舒敏,洪荣晶.高速铣齿机床主轴箱结构的有限元法分析.机械.2005,32(6):27-29
41曹凤利,李国璋,傅建平。基于有限元的履带车辆变速箱体强度分析.机械工程师.2006(7):108-110
42杨文硕,满志强.齿轮减速箱体的结构力学分析.哈尔滨科学技术大学学报.1995,19(3):94-98
43 I.U.Ojalvo. proper use of lanczos vectors for large elgenvalue problems.Computers&Structure.1985,20:115-120.
44 Zhi-gang Su,Pei-hong Wang. Experimental investigation of vibration signal ofan industrial tubular ball mill: Monitoring and diagnosing. MineralsEngineering.2008,1:1-9
45 M. Ramirez, Rodolfo Haber. Fuzzy control of a multiple hearth furnace.COMPUTERSININDUSTRY.2004,54:105-113
46 A.M.F. Fileti. Experimental investigations on fuzzy logic for process control.CONTROLENGINEERINGPRACTICE.2007,15:1149-1160
47陶永华.新型PID控制及其应用.北京:机械工业出版社,2002:1~8
48 J.Pineyro, A.Klempnow, V.lescano. Effectiveness of new spectral tools in theanomaly detection of rolling element bearings. Journal of Alloys andCompounds.2000,310:276-279
49 j.P.Dron, L.Rasolofondraibe, F.Bolaers. High-resolution methods in vibratoryanalysis: application to ball bearing monitoring and production machine.InternationalJournalofSolidsandStructures.2001,38:4293-4313
2 M.J.O’Brien. Failure analysis of three Si3N4 balls used in hybrid bearings.Engineeringfailureanalysis.2003(10):43-473
3王黎钦、李秀娟.涡喷发动机高温高速轴承失效机理及改进措施.机械科学与技术.2002,21(6):963-965
4张永振、邱明。高速干摩擦条件下铝基复合材料的摩擦磨损行为研究.摩擦学学报.2005,25(4):333-336
5乔玉林、徐滨士. Fe-Cr-Ni耐磨涂层的摩擦性能及作用机理.机械工程学报.2002,38(5):18-21
6 Soemantri S. Some Aspects of Abrasive Wear at Elevated Temperatures. Wear.1985,104:338-344
7 Fischer A. construction of A New wear Tester for elevated Temperatures andFirst Results of Sliding Abrasion Tests. Wear of material: InternationalConferenceonWearofMaterials.1989:729-734
8 M.Kalin,J.Vizintin . A rolling-contact device that uses the ball-on-flat testingprinciple.WEAR.2004,256:335-341
9 B. Subramonian, Bikramjit Basu. Development of a high-speed cryogenictribometer: Design concept and experimental results. Materials Science andEngineering.2006,A415:72-79
10宋宝玉,古乐. SY-1型真空摩擦磨损试验机的研制.润滑与密封。2004(1):61-62
11徐双满、曾昭翔.往复式摩擦磨损试验机的研制.机车车辆工艺. 1997(6):22-2412李霞,许志庆,杨勇.高速摩擦磨损试验机的总体设计.中国仪器仪表.2003(10):19-21
13 Kim, Kitae. Design and development of a high-speed bearing testapparatus.JournalofTesting&Evaluation.1998,26(4):301~305
14 M. S. Stephen. Performance of a Hybrid Cylindrical Roller Bearing.LubricationEngineering.1997,48(8):665~672
15 Y.Shoda, S. Ijuin. The Performance of a Hybrid Ceramic Ball-Bearing underHigh-Speed Conditions with The under Race Lubrication Method. TribologyTransactions.1997,40(7):676~684
16 Zatarain.M, lejardi. E, Egana. F. Modular synthesis of machine tools. Annals oftheCIRP,1998,47(1):333-336
17 Heisel.U, Feinauer.A . Dynamic Influence on Workpiece Quality in HighSpeedMilling.AnnalsoftheCIRP,1999,48(1):321-324
18 Ramezanali Mahdavinejad. Finite element analysis of machine and workpieceinstability in turning. International Journal of Machine tools & Manufacture,2005,(45):753-760
19 Jin Kyung Choi, Dai Gil Lee. Thermal characteristics of the spindle bearingsystem withagearlocatedonthebearingspan. International Journal ofMachineTool&Manufacture,1998(38):1017-1030
20 Chi- Wei Lin, Jay F. Tu, Joe Kamman. An integrated thermo-mechanicaldynamicmodeltocharacterizemotorizedmachinetoolspindlesduringveryhighspeed rotation. International Journal of Machine tools & Manufacture, 2003,(43):1035-1050
21尤国英.某燃气轮机试验台的动态特性研究.燃气轮机技术. 2000,13(3):37-41
22杨成云,林腾蛟等.增速箱系统固有特性和动态响应分析.中国机械工程。2003,14(5):380-382
23晋兵营,李冠锋等。YT4135Z柴油机机体动态响应分析。内燃机工程。2005,26(2):58-60
24张俊红,蓝军,倪广建。车用柴油机机体及油底壳的动态特性分析。中国机械工程2004,15(16):1433-1436
25刘晓东、吴入军.车床主轴箱模态分析。机械设计与制造。2007(2):24-25
26孙雅洲,王蕊等.微型机床的结构动态特性分析。2005(1):94-95
27胡秋,何东林.数控机床电主轴单元热-结构特性动态分析.组合机床与自动化加工技术.2006(12):5-7
28王东方,潘琼瑶等.柴油机气缸盖多场耦合三维有限元分析.力学季刊.2006,26(3):511-516
29向东湖、唐群国.新型摩擦磨损试验机测试系统开发.机械与电子.2005(2):74-76
30将建忠,赵永武.摩擦磨损试验机计算机辅助测试系统的设计与实现.江南大学学报.2005,4(2):187-190
31李鸽鹏、邓建春. PLC在电喷发动机试验台架控制系统中的应用.电子元器件应用.2006,8(11):47-49
32王世博、葛世荣.牵引滚动摩擦实验机的研制.矿山机械.2007,35(1):96-98
33 Jia Shuo, Duan Zhengang. Application of RSView Configuration Software inChlorine Dosing and Ammonia Dosing System. the First InternationalSymposiumonTestAutomation&Instrumentation. 2006:1872-1875
34纪玉龙、徐久军等.新型缸套-活塞零部件摩擦磨损试验机及其测控系统.润滑与密封.2006(11):177-180
35梅宏斌.滚动轴承振动监测与诊断理论·方法·系统.机械工业出版社.1995年
36潘新安,苏学成等.有限元前处理技术的研究与应用.煤矿机械.2007,28(4):68-70
37董爱花,孙平. YZ4105柴油机机体温度场的测量和三维数值模拟.拖拉机与农用运输机械.2007,34(1):50-52
38胡友安,李晓东等.涡壳温度场和热应力的有限元分析.机械强度.2007,29(1):130-134
39赵丽娟,刘宏梅. ANSYS在矿用减速器箱体应力分析中的应用.矿业研究与开发.2007,27(1):52-54
40舒敏,洪荣晶.高速铣齿机床主轴箱结构的有限元法分析.机械.2005,32(6):27-29
41曹凤利,李国璋,傅建平。基于有限元的履带车辆变速箱体强度分析.机械工程师.2006(7):108-110
42杨文硕,满志强.齿轮减速箱体的结构力学分析.哈尔滨科学技术大学学报.1995,19(3):94-98
43 I.U.Ojalvo. proper use of lanczos vectors for large elgenvalue problems.Computers&Structure.1985,20:115-120.
44 Zhi-gang Su,Pei-hong Wang. Experimental investigation of vibration signal ofan industrial tubular ball mill: Monitoring and diagnosing. MineralsEngineering.2008,1:1-9
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