摘要
端面密封是一种轴向密封,又称机械端面密封,简称机械密封,是流体机械旋转轴密封最为主要的类型,是常用的旋转轴密封,与压盖软填料密封相比,具有泄漏量低,摩擦磨损小,使用寿命长、工作可靠、不需要日常维护等一系列优点,因此在现代工业生产中得到了广泛的应用。
动力卡盘属于自动定心卡盘,配以不同的动力装置(气缸、油缸或电机),便可组成气动卡盘、液压卡盘或电动卡盘。气缸或油缸装在机床主轴后端,用穿在主轴孔内的拉杆或拉管,推拉主轴前端卡盘体内的楔形套,由楔形套的轴向进退使3个卡爪同时径向移动。这种卡盘动作迅速,卡爪移动量小,适于在大批量生产中使用。从目前国内对液压动力卡盘的需求看,最高转速超过6000rpm的液压动力卡盘都需要从国外进口。主要原因之一是国内还不具备生产与液压动力卡盘配套的中空旋转油缸的技术。旋转油缸中固定部件和旋转部件之间的密封是限制此技术发展的瓶颈,鉴于其密封处于高界面滑速、高边界压差及高环境温度的工况,普通的接触式端面密封因高的pV值而难于胜任,因而这些部位的密封,应采用非接触型的动密封形式。
在西方发达国家动力卡盘占据了很大的市场,手动卡盘虽有一定市场,但需求不断下降,动力卡盘在国外特别在欧洲已被大量采用,主要应用在加工中高精度数控机床,普通机床采用数量也不断增加。我国在上世纪80年代中期,由于受当时生产条件限制,只能生产一种短圆柱型的具有普通转速、精度低的铸铁盘体的低档次产品。由于我国数控技术迅速发展要求将高速楔式动力卡盘和高速回转油缸配套使用在数控机床上。液压回转油缸是液压动力卡盘的动力源。当前,高速液压回转油缸的研究和产品在国内外未见报道,针对这一全新技术,作者进行了大量地理论分析和实验研究。
首先,在查阅大量国内外资料的基础上,分析了国内外端面油膜密封、变粘度流体流动特性和液压动力卡盘的研究与应用情况,指出了研究液压回转油缸的重要意义,明确了研究液压回转油缸的主要技术难点,在此基础上,提出了解决液压回转油缸技术难点所需的关键技术,确定了本文的主要研究内容。
在考虑粘度函数为常数和不为常数的两种情况下,给出了平面端面油膜密封缝隙流体的压力分布和摩擦转矩的计算公式,从而可以确定端面密封的开启力,并可以计算出功率损失。在不考虑粘度变化和考虑粘度变化两种情况下,对影响平面端面油膜缝隙流体的泄漏特性、粘性摩擦损失进行对比分析后,采用功率损失最小原则对平面端面油膜密封的端面间隙进行了优化,为液压回转油缸的结构设计及研制奠定坚实的理论基础。
介绍了深槽端面密封的工作机理,给出了圆弧深槽端面油膜密封的结构形式,在不考虑粘度变化和考虑粘度变化两种情况下,对影响圆弧深槽端面油膜缝隙流体的压力分布进行对比分析后,得到了圆弧深槽端面油膜密封缝隙流体的流体动力特性,为液压回转油缸的结构设计及研制奠定坚实的理论基础。当槽的数量在6个及以上时,转速对泄漏量的影响变得不太明显,而且泄漏量随转速的增加而减小,从而符合了“上游泵送”的理论。在动力粘度η不为常数,槽的数量为6,未开槽区域油膜厚度不变,转速在1000~10000rpm的情况下,当槽深度达到1mm的时候对摩擦转矩的影响不再明显。
在不考虑粘度变化和考虑粘度变化两种情况下,对影响圆弧浅槽端面油膜缝隙流体的压力分布进行对比分析后,得到了圆弧浅槽端面油膜密封缝隙流体的流体动力特性,为液压回转油缸的结构设计及研制奠定坚实的理论基础。当槽的数量在6个及以上时,转速对泄漏量的影响变得不太明显,而且泄漏量随转速的增加而减小,从而符合了“上游泵送”的理论。在动力粘度η不为常数,槽的数量为6,未开槽区域油膜厚度不变,转速在1000~10000rpm的情况下,当槽深度达到0.05mm的时候对摩擦转矩的影响不再明显。
仿真分析研究是现代各行业运用较多的研究手段,特别是数值仿真技术,它具有节约成本、节省时间等优点而被广泛采用。本文运用ANSYS软件对回转部件进行了模态分析,为液压回转油缸样机的实验奠定了基础;运动ADINA软件分析了平面、圆弧深槽、圆弧浅槽端面油膜密封缝隙流体的流体特性,验证了理论分析的正确性。
在端面油膜密封缝隙流体流动特性理论分析的基础上,对液压回转油缸样机进行了加工制造,并对样机进行了实验研究,结果表明:平面端面油膜密封、圆弧深槽端面油膜密封、圆弧浅槽端面油膜密封缝隙流体流动特性的理论分析是正确的,应用这些端面油膜密封技术的液压回转油缸可以满足高速动力卡盘的要求。
Face seal is a kind of radial face seal. It is also called mechanical face seal, mechanical seal for short. It is one of the main types of seal for sealing rotating axis in liquid machine. It is mainly used for axial seal. Compared to the soft wadding seal, the face seal has some advantages, such as low leakage, low friction, long longevity, stable running and simple maintenance. So this kind of face seal is widely used in modern industry.
Power chuck belongs to self-centering chuck. Connected with different power equipment (gas cylinder, hydraulic cylinder or electromotor), gas power chuck, hydraulic power chuck or electricity power chuck can be made up. The gas cylinder or hydraulic cylinder is installed at the back-end of principal axis of computer numerical control (CNC) machine as power source. Pulling pole or pipe is connected with rod of cylinder through the hole of the principle axis to pull or push the cuneiform set, which is installed in the chuck at the front-end of principle axis. The axial forward and backward action of the cuneiform set drives the radial movement of the three claws synchronously. This kind of power chuck works quickly and the displacement of claws is small. So it is suitable for volume-production. According to the national requirement, the hydraulic power chuck with rotating speed exceeding 6000 rpm needs to be imported from overseas. One of the main reasons is that there is no technology to produce hollow rotating hydraulic cylinder to mate the hydraulic power chuck. The seal between the rotating component and the fixed component restricts the development of this technology. Whereas the seal working under the condition of high slipping speed, high boundary pressure difference and high temperature, commonly used contact mechanical face seal can not satisfy the high pV value. So none-contact fleet spiral groove and deep circular groove oil film face mechanical seals should be adopted at this position.
Power chuck take up prodigious market in west developed country. Although manual chuck occupies some certain market, but the demand for it declines ceaselessly. Power chuck is widely adopted in CNC machine by overseas country, especially in Europe. The installment of power chuck on common machine is continually increasing. At the middle stage of 80 years last century, duing to the restrict of manufacture condition, our country can only produce one kind of short column, low speed, low precision chuck. To meet the high development speed of national CNC technology, high speed wedge power chuck and high speed rotating hydraulic cylinder are required to mate together on the CNC machine. The rotating hydraulic cylinder is the power source of power chuck. Currently the detailed report and research on high speed rotating hydraulic cylinder can not be found nationally and internationally. Amount of research and experiment of high speed rotating hydraulic cylinder have been carried out.
Firstly, after synthesizing a lot of relevant literatures and reference home and board, the author summarizes the research and applications of oil film face seal, flowing properies of fluid with variable viscosity and hydraulic power chuck, point out the great significance of the research and put forward the technology difficulties and the key technologies, above the question, main research matters have been confirmed.
Under the two conditions of not taking account of the variety and taking account of the variety of viscosity, the formula of pressure distribution and frictional torque is got. Thereby the openning force can be achieved. And the power loss can be calculated. Also under the two conditions of not taking account of the variety and taking account of the variety of viscosity, the leakage properties and frictional loss in the plane oil film face seal gap is contrastively analyzed. So the sealing gap is optimized through the least power loss principle. This theory establishes strong foundation for the structure design and manufacture of rotating hydraulic cylinder. The working principle and the structure shape of deep circular groove oil film face seal is put forward. Under the two conditions of not taking account of the variety and taking account of the variety of viscosity, the pressure distribution of fluid in the deep circular groove oil film face seal gap is contrastively analyzed. So the dynamic flowing characteristics of fluid in this kind of seal gap are achieved. This theory establishes strong foundation for the structure design and manufacture of rotating hydraulic cylinder. When the number of grooves reaches 6 or more, the influence of rotating speed on leakage becomes unobvious. Further more, as the increasing of the rotating speed, the leakage of the seal decreases. This is accord with the upstream pumping theory. Supposing the viscosity is variable, the number of groove is 6, the thickness of the un-grooved zone is not changed, the rotating speed varies among 1000~10000rpm, when the thickness of the grooved zone reaches 1mm, the influence on frictional torque becomes unobvious.
Under the two conditions of not taking account of the variety and taking account of the variety of viscosity, the pressure distribution of fluid in the fleet circular groove oil film face seal gap is contrastively analyzed. So the dynamic flowing characteristics of the fluid in this kind of seal gap are achieved. This theory establishes strong foundation for the structure design and manufacture of rotating hydraulic cylinder. When the number of grooves reaches 6 or more, the influence of rotating speed on leakage becomes unobvious. Further more, as the increasing of the rotating speed, the leakage of the seal decreases. This is accord with the upstream pumping theory. Supposing the viscosity is variable, the number of groove is 6, the thickness of the un-grooved zone is not changed, the rotating speed varies among 1000~10000rpm, when the thickness of the grooved zone reaches 0.05mm, the influence on frictional torque becomes unobvious.
Simulation research, especially numerical simulation research is one of the mainly used methods in modern industry. It is widely adopted cling to its low cost and saving time. The modes of rotating component are simulated using the ANSYS software, which establishes strong foundation for the structure design and manufacture of rotating hydraulic cylinder. The flowing characteristics of the fluid in the plane, deep circular groove, and fleet circular groove oil film face seal gap are simulated using ADINA software to confirm the correct of theoretical analysis.
After manufacturing the rotating hydraulic cylinder, experimental research on specimen have been done, results indicated that the theoretical analysis of the flowing properties of the fluid in the plane, deep circular groove, fleet circular groove oil film face seal gap are correct. Application of these three kinds of sealing technologies makes the rotating hydraulic cylinder satisfying the requirement of high speed power chuck.
引文
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