柴油机硅油减振器减振机理及匹配仿真技术研究
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摘要
扭转振动是柴油机轴系运行时出现的一种振动形式,严重的扭转振动可能造成柴油机不能正常工作,甚至导致柴油机轴系的疲劳破坏。对于在重型运输和工程机械车辆上使用的重型车载柴油机,由于采用高增压、高速,机器的单位体积输出功率得到大幅度地提高,也加剧了轴系的扭转振动。在柴油机轴系上安装扭振减振器是减小扭转振动的重要方式,合理地设计与匹配扭振减振器对降低柴油机轴系扭转振动的振幅、减少扭转振动危害、降低振动噪声和提高车辆舒适性都有着非常重要的意义。
硅油扭振减振器结构简单且减振效率高,相对于其他结构形式的减振器有着较大的优势,因此在柴油机轴系扭振减振方面的应用非常广泛。但是,目前硅油减振器匹配设计计算技术和方法并没有跟上现代柴油机技术发展的步伐,仍然沿用20世纪40年代B.I.C.E.R.A(英国内燃机协会)提出的传统理论和经验公式,设计匹配的减振器需要反复不断地通过台架实验测试来修正和改进设计才能达到预期的减振效果要求。
现代柴油机的发展要求在尽量短的时间内设计开发承载能力足够高、工作稳定可靠的减振器。因此对硅油减振器匹配计算和设计方法进行深入细致的研究,提高匹配设计的准确性和可靠性具有十分重要的意义。本课题以高分子材料流变学、非牛顿流体力学、热力学、振动力学和柴油机动力学等理论为基础,在硅油流变特性实验研究之上,结合硅油减振器实际工作特点,进行减振机理分析和研究,建立基于非牛顿流体的柴油机硅油减振器的动态平衡匹配计算方法,形成较为准确和可靠的减振器匹配计算和优化设计方法。同时,利用现有的三维建模、多体动力学和有限元仿真计算软件,为工程实际应用提供基于多体动力学的柴油机曲轴系统和硅油减振器的扭转振动仿真计算的方法,作为产品设计验证的辅助手段,缩短产品开发的周期。论文的主要工作如下：
1)以非牛顿流体力学、流变学、热力学、振动力学等为理论基础,借助高级扩展旋转式流变仪等仪器进行硅油的流变试验,建立了硅油的力学模型及其非线性本构方程。
2)开展了硅油减振器的阻尼系数、粘性摩擦阻力矩、减振器的发热量和散热量计算方法的研究。
3)通过分析硅油减振器工作过程中影响其工作性能的温度、转速、硅油粘度和振动幅值等参数的内在联系,研究模拟减振器热平衡建立过程的数值计算方法,提出了一种接近于减振器实际运行工况的动态平衡匹配计算方法,该方法能有效地提高匹配计算的准确性和效率。
4)进行柴油机曲轴系统多体动力学的三维建模、边界和约束条件的设定,通过仿真计算得到了柴油机曲轴系统的瞬时转速信号,实现了对柴油机轴系扭转振动和减振器减振性能的分析。
5)从硅油减振器的结构特点和设计要求出发,考虑系统动力性、经济性和可靠性等因素,建立了扭振减振器的多目标优化设计模型,采用遗传算法进行了产品的匹配计算和设计优化,实现了减振器系统主要参数的优化配置,使产品的综合性能达到最优。
6)通过柴油机台架试验,进行了轴系的扭转振动和硅油减振器表面温度测试,验证了减振器动态匹配和仿真计算方法的正确性。
The torsional vibration of the diesel shaft sysytem inevitably exists when the diesel engine running, if this harmful vibration not suppressed, the machinery equipment is not working properly, even lead to the fatigue failure of the diesel engine shaft especially for the heavy-vehicle diesel engine used in the heavy transport and construction machinery vehicles, highly pressurized, high-speed characteristics, often the same volume of diesel engine's load compared the previous model has been increased several times.the more its own strengthen indicators is improved,the more the shafting torsional vibration is inevitably serious. Installing the torsional vibration damper is the main way to reduce the diesel engine shafting torsional vibration, the torsional vibration damper reasonably designed and matched,has a very important significance to reduce the diesel engine shafting torsional vibration amplitude, to avoid the torsional vibration hazards, to reduce the noise and improve the vehicle comfort.
The silicone-oil dampers are simple-structure and high efficiency relative to the other structures of the shock absorber used in the diesel engine shafting torsional vibration-absorted aspect. But the slicone-oil dampers did not keep up with the pace on the development of the modern diesel engine technology, the matching design and calculation of the torsional dampers currently mainly follow the previous theoretical and empirical formula (B.I.C.E.R.A), it is lack of the reliable computing method to the damper matching design, to match the shock absorber with the original design method does often not have the desired damping effect.
The development of the modern diesel engines, however, requires the carrying capacity of a high enough reliable shock absorber. Therefore, to do in-depth and meticulous research on the torsional dampers matching calculation and design methods has great valueble in the engineering application. This topic is intended to the rheology of the polymer materials, the non-Newtonian fluid mechanics, thermodynamics, vibration mechanics and diesel engine dynamics as the theoretical basis, the silicone-oil on top of the rheological properties of the experimental study, the actual work characteristics, the combined with the torsional dampers for the damping Mechanism analysis and the research, to establish the diesel engine dynamic equilibrium match of the damper,to form a more accurate and reliable matching calculation and optimization of the the design method based on the non-Newtonian fluid. Also taking advantage of the existing three-dimensional modeling by the multi-body dynamics and the finite element simulation software, to provide of the diesel crankshaft multibody dynamics systems and the torsional dampers torsional vibration simulation-based method for the practical engineering application, as an adjunct of the product design verification, to shorten the product development cycle. The main work of the paper is as follows:
1) Based on the non-Newtonian fluid mechanics, rheology, thermodynamics, vibration mechanics, Accoding to the silicone-oil rheological test instrument with the advanced extension rheometer, to construct the silicone-oil fluid mechanics model and this constitutive equation.
2) On the basis of the study of the mechanical properties of the silicone-oil damper combined with the diesel engine crankshaft torsional vibration principle, to construct the calculation method to the damping coefficient, the viscous friction moment, the heat production and heat dissipation about the damper.
3) In the study on the basis of the silicone-oil damping mechanism, combined with the silicone-oil shock absorber works, through the analysis of the damper temperature to affect their work performance, speed rate, silicone-oil viscosity, and the vibration amplitude at the same time the parameters such as the intrinsic Contact the study simulated damper thermal balance established the process numerical methods, the establishment of a dynamic balance of operating conditions close to the actual damper matching calculation method to improve the accuracy and efficiency of/the matching calculation.
4) To construct the three-dimensional model of a diesel engine crankshaft system and themulti-body dynamics model, then set the boundaries and constraints, do the simulation calculation, to get the instantaneous speed of the diesel engine crankshaft system for the spectral analysis, and the torsional vibration calculation analysis of the crankshaft system.
5) From the silicone-oil damper structural features and design requirements, regardless of the dynamic performance, the economy and reliability factors, the establishment of a multi-objective optimization of the torsional vibration damper design models,to construct a multi-objective optimization model, using the genetic algorithms for the design optimization,to achive the optimization of the main parameters damper system configuration, in order to achieve the integrated optimal performance of its products.
6) Through The diesel engine bench test, to get the shafting torsional vibration amplitude and the torsional dampers surface temperature, can verify the accuracy of the matching simulation method.
硅油扭振减振器结构简单且减振效率高,相对于其他结构形式的减振器有着较大的优势,因此在柴油机轴系扭振减振方面的应用非常广泛。但是,目前硅油减振器匹配设计计算技术和方法并没有跟上现代柴油机技术发展的步伐,仍然沿用20世纪40年代B.I.C.E.R.A(英国内燃机协会)提出的传统理论和经验公式,设计匹配的减振器需要反复不断地通过台架实验测试来修正和改进设计才能达到预期的减振效果要求。
现代柴油机的发展要求在尽量短的时间内设计开发承载能力足够高、工作稳定可靠的减振器。因此对硅油减振器匹配计算和设计方法进行深入细致的研究,提高匹配设计的准确性和可靠性具有十分重要的意义。本课题以高分子材料流变学、非牛顿流体力学、热力学、振动力学和柴油机动力学等理论为基础,在硅油流变特性实验研究之上,结合硅油减振器实际工作特点,进行减振机理分析和研究,建立基于非牛顿流体的柴油机硅油减振器的动态平衡匹配计算方法,形成较为准确和可靠的减振器匹配计算和优化设计方法。同时,利用现有的三维建模、多体动力学和有限元仿真计算软件,为工程实际应用提供基于多体动力学的柴油机曲轴系统和硅油减振器的扭转振动仿真计算的方法,作为产品设计验证的辅助手段,缩短产品开发的周期。论文的主要工作如下：
1)以非牛顿流体力学、流变学、热力学、振动力学等为理论基础,借助高级扩展旋转式流变仪等仪器进行硅油的流变试验,建立了硅油的力学模型及其非线性本构方程。
2)开展了硅油减振器的阻尼系数、粘性摩擦阻力矩、减振器的发热量和散热量计算方法的研究。
3)通过分析硅油减振器工作过程中影响其工作性能的温度、转速、硅油粘度和振动幅值等参数的内在联系,研究模拟减振器热平衡建立过程的数值计算方法,提出了一种接近于减振器实际运行工况的动态平衡匹配计算方法,该方法能有效地提高匹配计算的准确性和效率。
4)进行柴油机曲轴系统多体动力学的三维建模、边界和约束条件的设定,通过仿真计算得到了柴油机曲轴系统的瞬时转速信号,实现了对柴油机轴系扭转振动和减振器减振性能的分析。
5)从硅油减振器的结构特点和设计要求出发,考虑系统动力性、经济性和可靠性等因素,建立了扭振减振器的多目标优化设计模型,采用遗传算法进行了产品的匹配计算和设计优化,实现了减振器系统主要参数的优化配置,使产品的综合性能达到最优。
6)通过柴油机台架试验,进行了轴系的扭转振动和硅油减振器表面温度测试,验证了减振器动态匹配和仿真计算方法的正确性。
The torsional vibration of the diesel shaft sysytem inevitably exists when the diesel engine running, if this harmful vibration not suppressed, the machinery equipment is not working properly, even lead to the fatigue failure of the diesel engine shaft especially for the heavy-vehicle diesel engine used in the heavy transport and construction machinery vehicles, highly pressurized, high-speed characteristics, often the same volume of diesel engine's load compared the previous model has been increased several times.the more its own strengthen indicators is improved,the more the shafting torsional vibration is inevitably serious. Installing the torsional vibration damper is the main way to reduce the diesel engine shafting torsional vibration, the torsional vibration damper reasonably designed and matched,has a very important significance to reduce the diesel engine shafting torsional vibration amplitude, to avoid the torsional vibration hazards, to reduce the noise and improve the vehicle comfort.
The silicone-oil dampers are simple-structure and high efficiency relative to the other structures of the shock absorber used in the diesel engine shafting torsional vibration-absorted aspect. But the slicone-oil dampers did not keep up with the pace on the development of the modern diesel engine technology, the matching design and calculation of the torsional dampers currently mainly follow the previous theoretical and empirical formula (B.I.C.E.R.A), it is lack of the reliable computing method to the damper matching design, to match the shock absorber with the original design method does often not have the desired damping effect.
The development of the modern diesel engines, however, requires the carrying capacity of a high enough reliable shock absorber. Therefore, to do in-depth and meticulous research on the torsional dampers matching calculation and design methods has great valueble in the engineering application. This topic is intended to the rheology of the polymer materials, the non-Newtonian fluid mechanics, thermodynamics, vibration mechanics and diesel engine dynamics as the theoretical basis, the silicone-oil on top of the rheological properties of the experimental study, the actual work characteristics, the combined with the torsional dampers for the damping Mechanism analysis and the research, to establish the diesel engine dynamic equilibrium match of the damper,to form a more accurate and reliable matching calculation and optimization of the the design method based on the non-Newtonian fluid. Also taking advantage of the existing three-dimensional modeling by the multi-body dynamics and the finite element simulation software, to provide of the diesel crankshaft multibody dynamics systems and the torsional dampers torsional vibration simulation-based method for the practical engineering application, as an adjunct of the product design verification, to shorten the product development cycle. The main work of the paper is as follows:
1) Based on the non-Newtonian fluid mechanics, rheology, thermodynamics, vibration mechanics, Accoding to the silicone-oil rheological test instrument with the advanced extension rheometer, to construct the silicone-oil fluid mechanics model and this constitutive equation.
2) On the basis of the study of the mechanical properties of the silicone-oil damper combined with the diesel engine crankshaft torsional vibration principle, to construct the calculation method to the damping coefficient, the viscous friction moment, the heat production and heat dissipation about the damper.
3) In the study on the basis of the silicone-oil damping mechanism, combined with the silicone-oil shock absorber works, through the analysis of the damper temperature to affect their work performance, speed rate, silicone-oil viscosity, and the vibration amplitude at the same time the parameters such as the intrinsic Contact the study simulated damper thermal balance established the process numerical methods, the establishment of a dynamic balance of operating conditions close to the actual damper matching calculation method to improve the accuracy and efficiency of/the matching calculation.
4) To construct the three-dimensional model of a diesel engine crankshaft system and themulti-body dynamics model, then set the boundaries and constraints, do the simulation calculation, to get the instantaneous speed of the diesel engine crankshaft system for the spectral analysis, and the torsional vibration calculation analysis of the crankshaft system.
5) From the silicone-oil damper structural features and design requirements, regardless of the dynamic performance, the economy and reliability factors, the establishment of a multi-objective optimization of the torsional vibration damper design models,to construct a multi-objective optimization model, using the genetic algorithms for the design optimization,to achive the optimization of the main parameters damper system configuration, in order to achieve the integrated optimal performance of its products.
6) Through The diesel engine bench test, to get the shafting torsional vibration amplitude and the torsional dampers surface temperature, can verify the accuracy of the matching simulation method.
引文
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