活塞系统二阶运动分析及表面形貌挤压效应研究
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摘要
本文以内燃机活塞—缸套系统为研究对象，对工作状态下活塞裙部二阶运动和混合润滑特性进行了研究；将表面织构技术应用于活塞裙部摩擦学分析，研究了微凹坑造型表面对活塞裙部摩擦性能和二阶运动的影响；设计了活塞裙部-缸套摩擦副的往复摩擦实验，间接验证了理论分析的正确性；研究了不同类型表面形貌对活塞裙部挤压油膜状态的影响。为改进活塞裙部摩擦学设计提供了理论依据。
研究了活塞裙部的热变形和机械变形问题，采用三维有限元进行了分析，得到了对应各个曲轴转角的活塞裙部热变形和机械变形数据，为进一步准确分析裙部的润滑特性提供了依据。
综合考虑了活塞裙部外形轮廓、表面波度和粗糙度、活塞裙部和缸套的热变形和机械变形等因素，建立了内燃机活塞裙部混合润滑数学模型。比较了冷态和工作状态下活塞二阶运动轨迹、最小油膜厚度以及摩擦力的不同。计算分析了工作状态下裙部横向型线和纵向型线对活塞裙部混合润滑特性的影响，给出了活塞裙部型线的优化设计方案。通过活塞仿真设计，研究了活塞裙部长度、活塞销偏心距、配缸间隙、径向缩减量等设计参数对活塞二阶运动和摩擦的影响，提出了一些活塞结构参数的设计准则。
结合表面织构技术、雷诺方程以及活塞动力学方程，建立了活塞裙部微凹坑表面润滑分析模型。分析比较了微坑深径比、直径和分布密度等裙部微凹坑表面特征参数对活塞裙部二阶运动和摩擦特性的影响，对最佳织构表面造型参数进行了探讨。
设计了活塞裙部-缸套摩擦副的往复摩擦实验，考察不同裙部微凹坑表面对活塞-缸套摩擦副的实际减摩效果。实验结果显示，对活塞裙部表面进行微坑织构化处理，可有效降低活塞裙部的摩擦系数，间接验证了理论分析的正确性。
研究了表面形貌的挤压效应。针对活塞裙部，建立了微凹坑表面挤压油膜特性流固耦合分析模型。采用欧拉/拉格朗日耦合算法对活塞裙部与缸套间的润滑油挤压过程进行流固耦合模拟分析，对挤压油膜受微凹坑直径、深径比、分布密度等微造型参数综合作用的影响情况进行研究，比较了不同类型表面形貌下挤压油膜承载能力的变化状况，得到了使挤压油膜具有最大承载能力的活塞裙部微凹坑结构参数。
The piston-cylinder system of an internal combustion engine is taken as the main researchobject in this paper. The characteristics of secondary motion and mixed lubrication of piston skirt isstudied in working condition. By applied surface texture technology to tribological analysis of pistonskirt, friction characteristics and secondary motion trajectory of dimple textured piston skirt isresearched through calculation and comparison. The tribological experiment on modelingpiston-cylinder friction pair is designed, and the validity of the theoretical analysis is verifiedindirectly. The effects of different type surface topography on characteristics of squeeze film ofpiston skirt are studied. The aim is to provide a set of quantitative design guidelines for tribologicaldesign of piston assembly.
The thermal and the mechanical deformation of piston skirt are calculated by three-dimensionalFEM analysis. The thermomechanical deformations data of piston skirt corresponding to the crankangle are obtained. The results provide good foundation for the further analyses of piston skirtlubrication.
A mathematical model for piston skirts in mixed lubrication is developed. It takes into accountthe effects of the topography of the skirt, surface waviness and roughness, thermal and mechanicaldeformation of both piston skirts and cylinder bore. The entire piston secondary motion trajectory,minimum film thickness, total friction forces of cold state and working condition are compared.The effects of the cross and the longitudinal piston skirt profile on mixed lubricating characters ofpiston skirt are analyzed during working condition and the optimum topography design scheme ofpiston skirt is proposed. By simulating design process of piston, the effects of design parameters onpiston secondary motion and friction are studied, such as piston skirt length, wrist pin offset, radialclearance between piston and cylinder bore, radial reduction of piston skirt, et al. The design criteriaof some piston structure parameters are proposed.
Combined with surface texture technology, the Reynolds equation and the kinetic equation ofthe piston, the lubrication analysis model for piston skirt with micro-pits is presented. The effects ofdimple depth over diameter ratio, diameter and area density on the piston secondary motion andfriction characteristics are evaluated and compared. The best texture surface modeling parameters ofpiston skirt is discussed.
A tribological experiment is designed for modeling piston-cylinder friction pair. The actualanti-friction effect of piston skirt with different micro-pits on piston-cylinder friction pair is studied.The experimental results show that the friction coefficient of piston skirt can be effectively reduced by treating piston skirt surface with micro-dimples. The validity of the theoretical analysis is verifiedindirectly.
Squeezing effect of surface topography is studied. A fluid-solid coupling analysis model isestablished for squeeze film between cylinder and piston skirt considering surface topography.Coupling Euler Lagrange algorithm is employed to simulate extrusion process of lubrication oilbetween piston skirt and cylinder. The comprehensive effects of dimple diameter, depth overdiameter ratio and area density on squeeze film are investigated. Comparing the changing conditionof squeeze film bearing capacity of different surface topography, structure parameters of micro-pitsfor piston skirt which lead to maximum carrying capacity of squeeze film is obtained.
研究了活塞裙部的热变形和机械变形问题，采用三维有限元进行了分析，得到了对应各个曲轴转角的活塞裙部热变形和机械变形数据，为进一步准确分析裙部的润滑特性提供了依据。
综合考虑了活塞裙部外形轮廓、表面波度和粗糙度、活塞裙部和缸套的热变形和机械变形等因素，建立了内燃机活塞裙部混合润滑数学模型。比较了冷态和工作状态下活塞二阶运动轨迹、最小油膜厚度以及摩擦力的不同。计算分析了工作状态下裙部横向型线和纵向型线对活塞裙部混合润滑特性的影响，给出了活塞裙部型线的优化设计方案。通过活塞仿真设计，研究了活塞裙部长度、活塞销偏心距、配缸间隙、径向缩减量等设计参数对活塞二阶运动和摩擦的影响，提出了一些活塞结构参数的设计准则。
结合表面织构技术、雷诺方程以及活塞动力学方程，建立了活塞裙部微凹坑表面润滑分析模型。分析比较了微坑深径比、直径和分布密度等裙部微凹坑表面特征参数对活塞裙部二阶运动和摩擦特性的影响，对最佳织构表面造型参数进行了探讨。
设计了活塞裙部-缸套摩擦副的往复摩擦实验，考察不同裙部微凹坑表面对活塞-缸套摩擦副的实际减摩效果。实验结果显示，对活塞裙部表面进行微坑织构化处理，可有效降低活塞裙部的摩擦系数，间接验证了理论分析的正确性。
研究了表面形貌的挤压效应。针对活塞裙部，建立了微凹坑表面挤压油膜特性流固耦合分析模型。采用欧拉/拉格朗日耦合算法对活塞裙部与缸套间的润滑油挤压过程进行流固耦合模拟分析，对挤压油膜受微凹坑直径、深径比、分布密度等微造型参数综合作用的影响情况进行研究，比较了不同类型表面形貌下挤压油膜承载能力的变化状况，得到了使挤压油膜具有最大承载能力的活塞裙部微凹坑结构参数。
The piston-cylinder system of an internal combustion engine is taken as the main researchobject in this paper. The characteristics of secondary motion and mixed lubrication of piston skirt isstudied in working condition. By applied surface texture technology to tribological analysis of pistonskirt, friction characteristics and secondary motion trajectory of dimple textured piston skirt isresearched through calculation and comparison. The tribological experiment on modelingpiston-cylinder friction pair is designed, and the validity of the theoretical analysis is verifiedindirectly. The effects of different type surface topography on characteristics of squeeze film ofpiston skirt are studied. The aim is to provide a set of quantitative design guidelines for tribologicaldesign of piston assembly.
The thermal and the mechanical deformation of piston skirt are calculated by three-dimensionalFEM analysis. The thermomechanical deformations data of piston skirt corresponding to the crankangle are obtained. The results provide good foundation for the further analyses of piston skirtlubrication.
A mathematical model for piston skirts in mixed lubrication is developed. It takes into accountthe effects of the topography of the skirt, surface waviness and roughness, thermal and mechanicaldeformation of both piston skirts and cylinder bore. The entire piston secondary motion trajectory,minimum film thickness, total friction forces of cold state and working condition are compared.The effects of the cross and the longitudinal piston skirt profile on mixed lubricating characters ofpiston skirt are analyzed during working condition and the optimum topography design scheme ofpiston skirt is proposed. By simulating design process of piston, the effects of design parameters onpiston secondary motion and friction are studied, such as piston skirt length, wrist pin offset, radialclearance between piston and cylinder bore, radial reduction of piston skirt, et al. The design criteriaof some piston structure parameters are proposed.
Combined with surface texture technology, the Reynolds equation and the kinetic equation ofthe piston, the lubrication analysis model for piston skirt with micro-pits is presented. The effects ofdimple depth over diameter ratio, diameter and area density on the piston secondary motion andfriction characteristics are evaluated and compared. The best texture surface modeling parameters ofpiston skirt is discussed.
A tribological experiment is designed for modeling piston-cylinder friction pair. The actualanti-friction effect of piston skirt with different micro-pits on piston-cylinder friction pair is studied.The experimental results show that the friction coefficient of piston skirt can be effectively reduced by treating piston skirt surface with micro-dimples. The validity of the theoretical analysis is verifiedindirectly.
Squeezing effect of surface topography is studied. A fluid-solid coupling analysis model isestablished for squeeze film between cylinder and piston skirt considering surface topography.Coupling Euler Lagrange algorithm is employed to simulate extrusion process of lubrication oilbetween piston skirt and cylinder. The comprehensive effects of dimple diameter, depth overdiameter ratio and area density on squeeze film are investigated. Comparing the changing conditionof squeeze film bearing capacity of different surface topography, structure parameters of micro-pitsfor piston skirt which lead to maximum carrying capacity of squeeze film is obtained.
引文
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