柴油机曲轴轴系强度和主轴承润滑仿真研究
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摘要
内燃机曲轴一轴承系统是内燃机的关键部件,其摩擦学、动力学性能分析和强度刚度计算是内燃机设计必须面临的问题,直接影响到内燃机工作的可靠性和耐久性。然而,长期以来,由于曲轴一轴承系统特殊的结构形式和复杂的受力状况,理论研究难度较大,其摩擦学性能、动力学行为的分析和强度刚度计算是在各自独立的领域里分别进行的。实际上,内燃机在运转时,各种机械行为是同时发生互相影响的。因此,进行曲轴一轴承系统摩擦学、动力学、刚度和强度耦合研究、提高曲轴一轴承系统理论分析的准确性,具有重要的理论意义和现实的应用价值。多体动力学和有限元法的发展使得较精确地分析曲轴动力学响应问题成为可能。
本文运用有限元法和多体动力学仿真相结合的方法,对CA4D32柴油机曲轴轴系进行动力学分析仿真,其主要研究内容为:通过建立合理的柴油机曲轴轴系多体动力学模型,完成一个工作周期内的仿真,得到曲轴在实际工作周期内所表现出的动力响应特性,然后运用有限元分析软件对曲轴进行瞬态动力学分析。
首先针对具体产品结构特点以及后续的功能分析特点来决定曲轴轴系模型的简化程度,建立了CA4D32柴油机轴系俩种有限元模型,根据下文多体动力学模型的需要建立了轴系缩减有限元模型,在此基础上建立了轴系多体动力学分析模型。然后通过轴系的有限元模态分析与厂方实验数据结果的对比,论证了轴系有限元模型的合理性。接着通过EXCITE多体动力学仿真,进行了柴油机额定转速下的正常工况下包括曲柄销受力、轴系自由端扭转位移、曲轴位移量、转速波动等参数的多体动力学分析,得到曲轴在实际工作周期内所表现出的动力响应特性,进一步验证多体动力学模型的正确性。同时进行轴承载荷分析,得到最小油膜厚度、最大油膜压力、主轴承轴心轨迹等,对主轴承的润滑状况进行分析,得到3#主轴承的润滑状况最为恶劣,需要优化处理。最后对曲轴进行应力应变分析,并与传统有限元法比较。计算表明,曲轴的最大应力在其许用应力范围内,且变形小,曲轴的刚度足够。不同时段最大应力均发生在主轴颈和曲柄臂连接处,因此主轴颈和曲柄臂连接处是结构设计和优化的重点。多体动力学结合有限元法的使用为曲轴的精确仿真,创新设计,改型设计及优化设计提供了强有力的技术保证。
Crankshaft bearing system is one of the most important components in Internal Combustion Engines (ICE). The analysis on dynamics, tribology, stiffness and strength for the crankshaft bearing system has to be done when engineers design a 1C engine. It directly affects reliability and durability of the engine. The multidisciplinary performance such as dynamics tribology stiffness and strength have been researched independently in the extent of respective discipline for a long period of time because crankshaft has a complex geometric structure and the crankshaft bearing system is applied by a complicated variable load. The multidisciplinary performances of the system happen simultaneously and affect each other as engine works. The coupling study on dynamics tribology stiffness and strength is very important both in theoretical and practice sense. The Multi-body system Dynamics and the finite element analysis make the precise analysis of crankshaft being true.
A method that combined finite element method with multi-body dynamics simulation is applied to carry on dynamics analysis simulation on the CA4D32 diesel engine crankshaft system in this article. Its main research content is: Establishes reasonable diesel engine crankshaft system dynamics model, completes the simulation in an action cycle, and obtains the power response characteristic which displays in one operation cycle. Then it carries on the transient dynamics analysis on crankshaft using finite element analysis software.
First, in view of the concrete product unique features as well as the following functional analysis characteristic simplify the crankshaft system. The two kinds of CA4D32 diesel engine shafting models according to different simplified degrees are created. shafting condensed models used for the following multi-body dynamics model are established, and the multi-body dynamics model is also created. Then, the result of shafting model analysis is contracted with factory experiment data. It proves the shafting models are reasonable. According to the results of EXCITE multi-body dynamics simulation, The multi-body dynamics analysis of the diesel engine shafting, which consists of crank force, torsional displacement of the shafting free end, shafting displacement, speed motion and so on, is implemented. Obtaining the power response characteristic which displays in one operation cycle proves the multi-body dynamics model reasonable further. Simultaneously carries on the bearing load analysis, and obtains the minimum oil film thickness, the peak oil film pressure, orbital path of main bearings and so on. The lubrication condition of main bearings is analyzed. We can know lubrication condition of the third main bearing is bad, which needs optimization. Last, it carries on the transient analysis of the crankshaft, and comparison with the traditional finite element method. The results indicate that, the maximum stress of the crankshaft is within its allowable scope, the rigidity of crankshaft is enough and the distortion is slight. The maximum stress of different time interval is all occurred on the joints of main journal and connecting rod journal. Therefore, the joints are important points in the structural design and optimization. Using multi-body dynamics and 3D finite element method, has provided the powerful technical guarantee for precise dynamics simulation of crankshaft, and the innovation design, the modification design and the optimized design.
本文运用有限元法和多体动力学仿真相结合的方法,对CA4D32柴油机曲轴轴系进行动力学分析仿真,其主要研究内容为:通过建立合理的柴油机曲轴轴系多体动力学模型,完成一个工作周期内的仿真,得到曲轴在实际工作周期内所表现出的动力响应特性,然后运用有限元分析软件对曲轴进行瞬态动力学分析。
首先针对具体产品结构特点以及后续的功能分析特点来决定曲轴轴系模型的简化程度,建立了CA4D32柴油机轴系俩种有限元模型,根据下文多体动力学模型的需要建立了轴系缩减有限元模型,在此基础上建立了轴系多体动力学分析模型。然后通过轴系的有限元模态分析与厂方实验数据结果的对比,论证了轴系有限元模型的合理性。接着通过EXCITE多体动力学仿真,进行了柴油机额定转速下的正常工况下包括曲柄销受力、轴系自由端扭转位移、曲轴位移量、转速波动等参数的多体动力学分析,得到曲轴在实际工作周期内所表现出的动力响应特性,进一步验证多体动力学模型的正确性。同时进行轴承载荷分析,得到最小油膜厚度、最大油膜压力、主轴承轴心轨迹等,对主轴承的润滑状况进行分析,得到3#主轴承的润滑状况最为恶劣,需要优化处理。最后对曲轴进行应力应变分析,并与传统有限元法比较。计算表明,曲轴的最大应力在其许用应力范围内,且变形小,曲轴的刚度足够。不同时段最大应力均发生在主轴颈和曲柄臂连接处,因此主轴颈和曲柄臂连接处是结构设计和优化的重点。多体动力学结合有限元法的使用为曲轴的精确仿真,创新设计,改型设计及优化设计提供了强有力的技术保证。
Crankshaft bearing system is one of the most important components in Internal Combustion Engines (ICE). The analysis on dynamics, tribology, stiffness and strength for the crankshaft bearing system has to be done when engineers design a 1C engine. It directly affects reliability and durability of the engine. The multidisciplinary performance such as dynamics tribology stiffness and strength have been researched independently in the extent of respective discipline for a long period of time because crankshaft has a complex geometric structure and the crankshaft bearing system is applied by a complicated variable load. The multidisciplinary performances of the system happen simultaneously and affect each other as engine works. The coupling study on dynamics tribology stiffness and strength is very important both in theoretical and practice sense. The Multi-body system Dynamics and the finite element analysis make the precise analysis of crankshaft being true.
A method that combined finite element method with multi-body dynamics simulation is applied to carry on dynamics analysis simulation on the CA4D32 diesel engine crankshaft system in this article. Its main research content is: Establishes reasonable diesel engine crankshaft system dynamics model, completes the simulation in an action cycle, and obtains the power response characteristic which displays in one operation cycle. Then it carries on the transient dynamics analysis on crankshaft using finite element analysis software.
First, in view of the concrete product unique features as well as the following functional analysis characteristic simplify the crankshaft system. The two kinds of CA4D32 diesel engine shafting models according to different simplified degrees are created. shafting condensed models used for the following multi-body dynamics model are established, and the multi-body dynamics model is also created. Then, the result of shafting model analysis is contracted with factory experiment data. It proves the shafting models are reasonable. According to the results of EXCITE multi-body dynamics simulation, The multi-body dynamics analysis of the diesel engine shafting, which consists of crank force, torsional displacement of the shafting free end, shafting displacement, speed motion and so on, is implemented. Obtaining the power response characteristic which displays in one operation cycle proves the multi-body dynamics model reasonable further. Simultaneously carries on the bearing load analysis, and obtains the minimum oil film thickness, the peak oil film pressure, orbital path of main bearings and so on. The lubrication condition of main bearings is analyzed. We can know lubrication condition of the third main bearing is bad, which needs optimization. Last, it carries on the transient analysis of the crankshaft, and comparison with the traditional finite element method. The results indicate that, the maximum stress of the crankshaft is within its allowable scope, the rigidity of crankshaft is enough and the distortion is slight. The maximum stress of different time interval is all occurred on the joints of main journal and connecting rod journal. Therefore, the joints are important points in the structural design and optimization. Using multi-body dynamics and 3D finite element method, has provided the powerful technical guarantee for precise dynamics simulation of crankshaft, and the innovation design, the modification design and the optimized design.
引文
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