液体静压转台系统油膜工作性能分析
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摘要
重载、大型、高速、精密、自动化、多功能的加工机床具有尺寸大、重量大、精度高等特点,是未来机床的发展趋势,其对结构、环境、控制等都提出了更高的要求。应用流体润滑技术的静压机床中,油膜的工作性能的优劣直接影响到整个机床运行的可靠性、寿命和经济指标。
本文以液体静压转台系统为研究对象,对油膜的工作性能进行了分析。建立了模拟液体静压转台内部三维流动的数学模型及边界条件,利用CFD原理,选用层流模型,数值研究了粘度和温—粘、压—粘关系对粘度的改变、圆形油腔几何特征对油膜工作性能的影响,并对比分析了牛顿流体和非牛顿流体工作性能的不同。具体内容为:
(1)分析计算了润滑油粘度对液体静压转台系统承载力及刚度的影响。在工作环境、油腔的几何尺寸等不变的条件下,随着润滑油粘度的增加,液体静压转台系统承载能力及刚度都逐渐增大;随着润滑油粘度的增加,油腔内的温升也相应增加。
(2)引入温—粘特性,分析了温度对液体静压转台系统承载力及刚度的影响。温-粘特性在很大程度上影响油腔内的承载能力、刚度和温升,在数值计算及工程设计中,不能忽略环境温度及液压机床自身摩擦生热对润滑油粘度的影响。
(3)引入压—粘特性,分析了压力对润滑油粘度、液体静压转台系统的承载力及刚度的影响。压-粘特性会增大润滑油的粘度,进而提高油膜的承载能力和刚度,尤其在重载、高压的条件下,不能忽略压力对润滑油特性的影响。
(4)分析了圆形油腔几何特征对液体静压转台系统工作性能的影响。减小油膜厚度和油腔深度、增加封油边宽度或扩大油腔内径等途径可以增大油腔承载能力;油腔深度较小的条件下,对上部工作转台的冲击作用会影响加工的稳定性。应该综合考虑承载能力、刚度以及工作台的稳定性进行圆形油腔几何尺寸的选择。
(5)对比计算了不同转速条件下,牛顿流体和非牛顿流体的润滑性能;分析计算了高剪切率条件下,牛顿流体与非牛顿流体工作性能的不同。与牛顿流体相比较,具有“剪切稀释”特性的非牛顿流体降低油腔的承载能力且稳定性较差,具有“剪切稠化”特性的非牛顿流体则与之相反;高速条件下,粘度大的润滑油或具有剪切稠化性质的润滑油具有更好工作性能的结论。
研究结果表明,在液体静压支承系统的研究和设计中,温—粘效应和压—粘效应的影响十分显著,不能忽略。可以通过改变油腔的几何特征增大油腔的承载能力及油膜刚度,以免除润滑油选择的局限性。同时,在润滑油的选择中,应确定润滑油的流变特性,保证油膜的工作性能。本文的研究结果对液体静压支承系统的油腔几何特征的设计及润滑油的选择有重要指导意义。
Heavy, large, high-speed, precision, automation, multi-function machine tools with large size, heavy, high precision properties is the trends of industries. It has higher requirements on its structure, the environment and control systems. The oil film's performance in fluid lubrication technology will directly affect the reliability of operation, life and economic indicators.
A 3-D model of hydrostatic turntable was set up to simulate the flow of oil film. Laminar flow model and the finite volume method are selected in the simulation by using FLUENT software and CFD theory. Influences of viscosity, temperature– viscosity relationship, pressure - viscosity relationship, round oil chamber’s geometry feature et al on oil film’s performance were investigated. The difference between Newtonian fluid and non-Newtonian fluid was also compared. Results are in the following:
(1) Influences of lubricant oil’s viscosity on hydrostatic bearing capacity and stiffness of the system were studied. It can be obtained in the conditions of other factors being constant that carrying capacity and stiffness of hydrostatic bearing system are increased with the augment of oil viscosity, meanwhile, oil cavity temperature also increased.
(2) Temperature’s effect considering the temperature - viscosity characteristics on carrying capacity and stiffness of hydrostatic bearing system was calculated. It is shown that the temperature - viscosity characteristics has great influence on the oil chamber’s carrying capacity, stiffness and temperature rise. It should not be ignored that the environmental temperature and the heat generated by friction’s influence on oil’s viscosity in the numerical simulation and engineering design.
(3) Pressure’s influence considering the pressure - viscosity characteristics on the carrying capacity and stiffness of hydrostatic bearing system was calculated. It is presented that the pressure - viscosity characteristics can change the oil chamber’s carrying capacity and stiffness. Especially in overload and high-pressure conditions, the pressure - viscosity characteristics should not be ignored.
(4) The geometric characteristics of the circular cavity’s influence on the performance of hydrostatic bearing system were analyzed. It is found that the carrying capacity of the oil chamber can be increased by decreasing film thickness and the depth of the oil chamber, or increasing the width of oil chamber’s oil seal edges and diameter of oil chamber. However, the turntable will have poor stability when the depth of the oil chamber is smaller. Therefore, carrying capacity, stiffness and stability should be taken into account in choosing the circular oil cavity’s geometry.
(5) The Newtonian fluid and non-Newtonian fluid’s performance were compared under different speed conditions. It is given that, with the high shear rate conditions, the Newtonian fluid and non-Newtonian fluid have different behaviors. In addition, the oil with high viscosity or the characteristic of shear thickening has a good performance in the high-speed conditions.
In the whole, Effects of temperature - viscosity and pressure - viscosity relationship are significant, and should not be ignored in hydrostatic support system’s research and design. Capacity of oil chamber and the oil film stiffness could be increased by changing the geometry characteristics of the oil chamber so as to remove the lubricant selection limitations. Meanwhile, the rheological property should be considered to ensure the film's performance in choosing the oil. Results on the hydrostatic bearing system have important guiding significance on oil cavity geometry’s design and the choice of lubricant oil.
本文以液体静压转台系统为研究对象,对油膜的工作性能进行了分析。建立了模拟液体静压转台内部三维流动的数学模型及边界条件,利用CFD原理,选用层流模型,数值研究了粘度和温—粘、压—粘关系对粘度的改变、圆形油腔几何特征对油膜工作性能的影响,并对比分析了牛顿流体和非牛顿流体工作性能的不同。具体内容为:
(1)分析计算了润滑油粘度对液体静压转台系统承载力及刚度的影响。在工作环境、油腔的几何尺寸等不变的条件下,随着润滑油粘度的增加,液体静压转台系统承载能力及刚度都逐渐增大;随着润滑油粘度的增加,油腔内的温升也相应增加。
(2)引入温—粘特性,分析了温度对液体静压转台系统承载力及刚度的影响。温-粘特性在很大程度上影响油腔内的承载能力、刚度和温升,在数值计算及工程设计中,不能忽略环境温度及液压机床自身摩擦生热对润滑油粘度的影响。
(3)引入压—粘特性,分析了压力对润滑油粘度、液体静压转台系统的承载力及刚度的影响。压-粘特性会增大润滑油的粘度,进而提高油膜的承载能力和刚度,尤其在重载、高压的条件下,不能忽略压力对润滑油特性的影响。
(4)分析了圆形油腔几何特征对液体静压转台系统工作性能的影响。减小油膜厚度和油腔深度、增加封油边宽度或扩大油腔内径等途径可以增大油腔承载能力;油腔深度较小的条件下,对上部工作转台的冲击作用会影响加工的稳定性。应该综合考虑承载能力、刚度以及工作台的稳定性进行圆形油腔几何尺寸的选择。
(5)对比计算了不同转速条件下,牛顿流体和非牛顿流体的润滑性能;分析计算了高剪切率条件下,牛顿流体与非牛顿流体工作性能的不同。与牛顿流体相比较,具有“剪切稀释”特性的非牛顿流体降低油腔的承载能力且稳定性较差,具有“剪切稠化”特性的非牛顿流体则与之相反;高速条件下,粘度大的润滑油或具有剪切稠化性质的润滑油具有更好工作性能的结论。
研究结果表明,在液体静压支承系统的研究和设计中,温—粘效应和压—粘效应的影响十分显著,不能忽略。可以通过改变油腔的几何特征增大油腔的承载能力及油膜刚度,以免除润滑油选择的局限性。同时,在润滑油的选择中,应确定润滑油的流变特性,保证油膜的工作性能。本文的研究结果对液体静压支承系统的油腔几何特征的设计及润滑油的选择有重要指导意义。
Heavy, large, high-speed, precision, automation, multi-function machine tools with large size, heavy, high precision properties is the trends of industries. It has higher requirements on its structure, the environment and control systems. The oil film's performance in fluid lubrication technology will directly affect the reliability of operation, life and economic indicators.
A 3-D model of hydrostatic turntable was set up to simulate the flow of oil film. Laminar flow model and the finite volume method are selected in the simulation by using FLUENT software and CFD theory. Influences of viscosity, temperature– viscosity relationship, pressure - viscosity relationship, round oil chamber’s geometry feature et al on oil film’s performance were investigated. The difference between Newtonian fluid and non-Newtonian fluid was also compared. Results are in the following:
(1) Influences of lubricant oil’s viscosity on hydrostatic bearing capacity and stiffness of the system were studied. It can be obtained in the conditions of other factors being constant that carrying capacity and stiffness of hydrostatic bearing system are increased with the augment of oil viscosity, meanwhile, oil cavity temperature also increased.
(2) Temperature’s effect considering the temperature - viscosity characteristics on carrying capacity and stiffness of hydrostatic bearing system was calculated. It is shown that the temperature - viscosity characteristics has great influence on the oil chamber’s carrying capacity, stiffness and temperature rise. It should not be ignored that the environmental temperature and the heat generated by friction’s influence on oil’s viscosity in the numerical simulation and engineering design.
(3) Pressure’s influence considering the pressure - viscosity characteristics on the carrying capacity and stiffness of hydrostatic bearing system was calculated. It is presented that the pressure - viscosity characteristics can change the oil chamber’s carrying capacity and stiffness. Especially in overload and high-pressure conditions, the pressure - viscosity characteristics should not be ignored.
(4) The geometric characteristics of the circular cavity’s influence on the performance of hydrostatic bearing system were analyzed. It is found that the carrying capacity of the oil chamber can be increased by decreasing film thickness and the depth of the oil chamber, or increasing the width of oil chamber’s oil seal edges and diameter of oil chamber. However, the turntable will have poor stability when the depth of the oil chamber is smaller. Therefore, carrying capacity, stiffness and stability should be taken into account in choosing the circular oil cavity’s geometry.
(5) The Newtonian fluid and non-Newtonian fluid’s performance were compared under different speed conditions. It is given that, with the high shear rate conditions, the Newtonian fluid and non-Newtonian fluid have different behaviors. In addition, the oil with high viscosity or the characteristic of shear thickening has a good performance in the high-speed conditions.
In the whole, Effects of temperature - viscosity and pressure - viscosity relationship are significant, and should not be ignored in hydrostatic support system’s research and design. Capacity of oil chamber and the oil film stiffness could be increased by changing the geometry characteristics of the oil chamber so as to remove the lubricant selection limitations. Meanwhile, the rheological property should be considered to ensure the film's performance in choosing the oil. Results on the hydrostatic bearing system have important guiding significance on oil cavity geometry’s design and the choice of lubricant oil.
引文
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69 R. Pit, H. Hervet, L. Leger. Direct Experimental Evidence of Slip in Hexadecane: Solid Interfaces. Physical Review Letters. 2000, (85):980~983.
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77刘红彬,孟永钢.基于区域分解法的纹理表面流体润滑分析——纹理分布模式的影响.摩擦学报. 2007, (11):555~561.
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