钢表面凹坑纹理的制备及摩擦学性能研究
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摘要
摩擦副表面纹理形貌的合理设计和制备,将有效提高摩擦副的摩擦、润滑和抗磨损性能。本课题在广泛查阅文献资料的基础上,设计合理的试验方案,结合数值分析的手段,着重就摩擦副表面凹坑纹理的制备、表征及摩擦与润滑性能的几个关键问题进行了探讨。
首先,探讨表面纹理结构的摩擦磨损性能,一般广泛采用面-面接触的滑动摩擦试验形式,而上、下试样组成的摩擦副端面调整一直是比较困难的问题。本文通过设计一种自适应夹头装置,可以带动被固定的试样实现任意方向的自由微动,使滑动摩擦过程中摩擦副保持全面接触并自动适应接触区表面状况的变化。与普通夹头装置的对比试验数据表明,可以显著提高摩擦试验数据的稳定性和重复性,从而更加准确地反映摩擦副间的最初表面状态,使摩擦磨损数据更加准确,为接下来研究摩擦副表面形貌结构对于摩擦磨损性能的影响提供了试验保障。
其次,本文探讨了两种简单实用的表面凹坑纹理结构制备工艺方法,一种是压丸表面凹坑纹理制备工艺方法,该工艺方法可以方便快捷地通过变换压丸力而可获得深度尺寸和截面(口径)尺寸同时变化且二者的比值即深径比也随之变化的一系列规则凹坑,获得毫米至亚毫米级的表面规则压丸凹坑纹理结构;另一种是喷砂表面纹理制备工艺方法,该工艺方法可以方便快捷地通过变换砂粒大小、喷砂距离、喷射压力、喷射角度等喷砂工艺参数调节喷砂表面的粗糙度,获得微米至亚微米级的表面非规则喷砂凹坑纹理结构。这两种简单实用的表面纹理结构制备工艺方法经济实用,操作简单,在深入研究其几何表征及对于摩擦与润滑性能影响机制的基础上便于向工业应用推广使用。
对于毫米至亚毫米级的大尺度规则压丸凹坑纹理,其口径尺寸的大小一方面决定着整个表面粗糙度的增大程度,另一方面也决定着扑捉磨屑和磨粒的容易程度,而凹坑深度尺寸则决定着流体润滑状态下的润滑膜的厚度及润滑膜动压力。因此,应该使用深径比这一参数来综合考虑两个几何参数对于摩擦磨损的影响。在流体润滑状态下,深径比相对较大的凹坑纹理更容易使试样表面获得较大的动压力和承载力,具有相对较大的临界载荷。而最低的摩擦系数值,则要根据所施加的载荷大小来确定,一般而言,低载时,深径比相对较小的压丸试样具有更小的摩擦系数值,而重载时,深径比相对较大的压丸试样具有更小的摩擦系数值。
对于微米至亚微米级尺度的非规则喷砂凹坑纹理,可以用粗糙度来进行几何表征。粗糙度值决定着最低的摩擦系数和最高承载能力。合适的粗糙度值(本文Ra为3.92μm左右)可以使润滑介质具有相对较小的表观润湿角和成膜性,此时摩擦副间容易取得相对最低的摩擦系数;而粗糙度值不在一个合适的范围内(本文Ra大于或小于3.92μm的范围)润滑介质具有相对较高表观润湿角,在液固结合处容易夹杂更多含量的气相,且机油润滑膜更厚,或机油液滴的曲率半径更大,此时摩擦副间具有更高的承载能力。
再次,本文通过各项脉冲激光的工艺参数的匹配,制备了四种类型的激光表面纹理形貌,丰富了激光与物质相互作用机理的理论。
激光表面纹理的制备过程是一个复杂的激光与物质相互作用的冶金物理化学过程。通过脉冲波形(高斯波形)、脉冲宽度、脉冲能量、离焦量及激光扫描速度等各项脉冲激光的工艺参数的匹配,可以分别得到乳突结构的表面纹理结构凹坑结构的表面纹理结构。采用超快激光还可以得到周期性波纹结构和包含有微米级乳突、亚微米级凹坑和短小波纹的多尺度复合结构。其中,乳突结构处于组织梯度分布的多尺度的复合结构状态,从结构和组织方面有了优异的摩擦、磨损和润湿性等表面性能的保证;本文试验条件下所得的激光凹坑结构尺度在200μm口径和100μm深度下,在较低的Hersey数时,凹坑纹理的引入不利于摩擦系数的降低,而只有在较大的Hersey数时,凹坑纹理的引入才有利于摩擦副的润滑与摩擦学性能的提高。且此时,网格状的凹坑纹理试样具有最低的摩擦系数和最低的磨损量,但从磨损痕迹来看,网格状的凹坑纹理试样始终没有进入完全的流体润滑状态。采用超快激光且在低于材料损伤阈值的较低辐照能量下,可以在材料表面得到比较规则的周期性的波纹结构,在超过材料损伤阈值的较高辐照能量下,可以在材料表面获得包含有微米级乳突、亚微米级凹坑和短小波纹的多尺度复合结构。上述两种典型的表面结构都表现出疏水性,且多尺度复合结构较规则的周期性波纹结构具有更大的表观润湿角度,表现出超疏水的性能。
本文最后采用数值模拟方法研究了矩形微坑纹理表面润滑膜形成的机理以及几何参数对纹理表面润滑性能的影响,模拟结果显示:空化和惯性力是纹理表面润滑膜形成的两种重要机理,而且当纹理的深径比较小时,空化占主导,深径比较大时,惯性力占主导,惯性力的作用同时使得空化的发生减弱,有利于纹理表面承载能力的提高;纹理的几何参数对其润滑性能有重要的影响,微坑的深度、长度、纹理的面积占有率、入口区域、出口区域的长度等对纹理表面的承载能力都有一定的影响规律。
本文有图88幅,表12个,公式14个,参考文献150篇。
Rational design and fabrication of surface structure in friction pairs will effectively enhance the pairs’frictional, lubricating and wear-resistant properties. This paper, based on extensive literature documentations, the rational experimental program design and numerical analysis combination, mainly in order to discuss on the following key issues: the fabrication and characterization of friction pairs as well as frictional and lubricating properties.
First, this paper designed a self-adapted holder, which can make fixed samples swing in any direction, can keep friction pairs full contact and adapt the change of the contacting surface in the process of sliding friction. Compared with the ordinary holder, it showed test data become more stable and repeatable. This can exactly reflect the original surface state between friction pairs and make the data more accurate. What’s more, this helps the following research on how friction pairs’surface structure effect friction and wear properties.
Second, this paper discussed two simple and practical methods to fabricate surface structure. One is surface dimple-textured by pellet-pressing, which is a convenient and economical way of getting millimeter or sub-millimeter scale dimple-textured surface structure , and another is surface texturing by sandblast, which is a convenient and economical way of getting micron or submicron scale irregular surface structure which had no fixed geometry but a certain roughness. These two methods are economical, practical and easy-operated so that they can be promoted to industrial applications after deep research on their geometric representation and influence to frictional and lubricating properties.
Third, this paper fabricated four kinds of laser surface structures. Protuberance surface structure and concave surface structure were prepared by common laser respectively. Using ultrafast laser we can also find periodic corrugated structure and micro-mastoid, submicron-pits and short corrugated multi-scale composite structure. With metallographic microstructures gradient distribution complex structure, protuberance surface structure had excellent tribology, wear and wettability properties. Concave surface structure could get excellent tribology and lubrication properties when the Hersey number is bigger.
Finally, this paper simulated how different micro-pit parameters under test conditions affect the load capacity. Simulation results which are basically consistent with experimental results show that there is an optimum depth to diameter ratio that is 0.025.
In this paper, there are 88 figures, 12 tables, 14 formulas and 150 reference articles.
首先,探讨表面纹理结构的摩擦磨损性能,一般广泛采用面-面接触的滑动摩擦试验形式,而上、下试样组成的摩擦副端面调整一直是比较困难的问题。本文通过设计一种自适应夹头装置,可以带动被固定的试样实现任意方向的自由微动,使滑动摩擦过程中摩擦副保持全面接触并自动适应接触区表面状况的变化。与普通夹头装置的对比试验数据表明,可以显著提高摩擦试验数据的稳定性和重复性,从而更加准确地反映摩擦副间的最初表面状态,使摩擦磨损数据更加准确,为接下来研究摩擦副表面形貌结构对于摩擦磨损性能的影响提供了试验保障。
其次,本文探讨了两种简单实用的表面凹坑纹理结构制备工艺方法,一种是压丸表面凹坑纹理制备工艺方法,该工艺方法可以方便快捷地通过变换压丸力而可获得深度尺寸和截面(口径)尺寸同时变化且二者的比值即深径比也随之变化的一系列规则凹坑,获得毫米至亚毫米级的表面规则压丸凹坑纹理结构;另一种是喷砂表面纹理制备工艺方法,该工艺方法可以方便快捷地通过变换砂粒大小、喷砂距离、喷射压力、喷射角度等喷砂工艺参数调节喷砂表面的粗糙度,获得微米至亚微米级的表面非规则喷砂凹坑纹理结构。这两种简单实用的表面纹理结构制备工艺方法经济实用,操作简单,在深入研究其几何表征及对于摩擦与润滑性能影响机制的基础上便于向工业应用推广使用。
对于毫米至亚毫米级的大尺度规则压丸凹坑纹理,其口径尺寸的大小一方面决定着整个表面粗糙度的增大程度,另一方面也决定着扑捉磨屑和磨粒的容易程度,而凹坑深度尺寸则决定着流体润滑状态下的润滑膜的厚度及润滑膜动压力。因此,应该使用深径比这一参数来综合考虑两个几何参数对于摩擦磨损的影响。在流体润滑状态下,深径比相对较大的凹坑纹理更容易使试样表面获得较大的动压力和承载力,具有相对较大的临界载荷。而最低的摩擦系数值,则要根据所施加的载荷大小来确定,一般而言,低载时,深径比相对较小的压丸试样具有更小的摩擦系数值,而重载时,深径比相对较大的压丸试样具有更小的摩擦系数值。
对于微米至亚微米级尺度的非规则喷砂凹坑纹理,可以用粗糙度来进行几何表征。粗糙度值决定着最低的摩擦系数和最高承载能力。合适的粗糙度值(本文Ra为3.92μm左右)可以使润滑介质具有相对较小的表观润湿角和成膜性,此时摩擦副间容易取得相对最低的摩擦系数;而粗糙度值不在一个合适的范围内(本文Ra大于或小于3.92μm的范围)润滑介质具有相对较高表观润湿角,在液固结合处容易夹杂更多含量的气相,且机油润滑膜更厚,或机油液滴的曲率半径更大,此时摩擦副间具有更高的承载能力。
再次,本文通过各项脉冲激光的工艺参数的匹配,制备了四种类型的激光表面纹理形貌,丰富了激光与物质相互作用机理的理论。
激光表面纹理的制备过程是一个复杂的激光与物质相互作用的冶金物理化学过程。通过脉冲波形(高斯波形)、脉冲宽度、脉冲能量、离焦量及激光扫描速度等各项脉冲激光的工艺参数的匹配,可以分别得到乳突结构的表面纹理结构凹坑结构的表面纹理结构。采用超快激光还可以得到周期性波纹结构和包含有微米级乳突、亚微米级凹坑和短小波纹的多尺度复合结构。其中,乳突结构处于组织梯度分布的多尺度的复合结构状态,从结构和组织方面有了优异的摩擦、磨损和润湿性等表面性能的保证;本文试验条件下所得的激光凹坑结构尺度在200μm口径和100μm深度下,在较低的Hersey数时,凹坑纹理的引入不利于摩擦系数的降低,而只有在较大的Hersey数时,凹坑纹理的引入才有利于摩擦副的润滑与摩擦学性能的提高。且此时,网格状的凹坑纹理试样具有最低的摩擦系数和最低的磨损量,但从磨损痕迹来看,网格状的凹坑纹理试样始终没有进入完全的流体润滑状态。采用超快激光且在低于材料损伤阈值的较低辐照能量下,可以在材料表面得到比较规则的周期性的波纹结构,在超过材料损伤阈值的较高辐照能量下,可以在材料表面获得包含有微米级乳突、亚微米级凹坑和短小波纹的多尺度复合结构。上述两种典型的表面结构都表现出疏水性,且多尺度复合结构较规则的周期性波纹结构具有更大的表观润湿角度,表现出超疏水的性能。
本文最后采用数值模拟方法研究了矩形微坑纹理表面润滑膜形成的机理以及几何参数对纹理表面润滑性能的影响,模拟结果显示:空化和惯性力是纹理表面润滑膜形成的两种重要机理,而且当纹理的深径比较小时,空化占主导,深径比较大时,惯性力占主导,惯性力的作用同时使得空化的发生减弱,有利于纹理表面承载能力的提高;纹理的几何参数对其润滑性能有重要的影响,微坑的深度、长度、纹理的面积占有率、入口区域、出口区域的长度等对纹理表面的承载能力都有一定的影响规律。
本文有图88幅,表12个,公式14个,参考文献150篇。
Rational design and fabrication of surface structure in friction pairs will effectively enhance the pairs’frictional, lubricating and wear-resistant properties. This paper, based on extensive literature documentations, the rational experimental program design and numerical analysis combination, mainly in order to discuss on the following key issues: the fabrication and characterization of friction pairs as well as frictional and lubricating properties.
First, this paper designed a self-adapted holder, which can make fixed samples swing in any direction, can keep friction pairs full contact and adapt the change of the contacting surface in the process of sliding friction. Compared with the ordinary holder, it showed test data become more stable and repeatable. This can exactly reflect the original surface state between friction pairs and make the data more accurate. What’s more, this helps the following research on how friction pairs’surface structure effect friction and wear properties.
Second, this paper discussed two simple and practical methods to fabricate surface structure. One is surface dimple-textured by pellet-pressing, which is a convenient and economical way of getting millimeter or sub-millimeter scale dimple-textured surface structure , and another is surface texturing by sandblast, which is a convenient and economical way of getting micron or submicron scale irregular surface structure which had no fixed geometry but a certain roughness. These two methods are economical, practical and easy-operated so that they can be promoted to industrial applications after deep research on their geometric representation and influence to frictional and lubricating properties.
Third, this paper fabricated four kinds of laser surface structures. Protuberance surface structure and concave surface structure were prepared by common laser respectively. Using ultrafast laser we can also find periodic corrugated structure and micro-mastoid, submicron-pits and short corrugated multi-scale composite structure. With metallographic microstructures gradient distribution complex structure, protuberance surface structure had excellent tribology, wear and wettability properties. Concave surface structure could get excellent tribology and lubrication properties when the Hersey number is bigger.
Finally, this paper simulated how different micro-pit parameters under test conditions affect the load capacity. Simulation results which are basically consistent with experimental results show that there is an optimum depth to diameter ratio that is 0.025.
In this paper, there are 88 figures, 12 tables, 14 formulas and 150 reference articles.
引文
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