PTFE/PEEK聚合物涂层对活塞式全无油润滑压缩机活塞销润滑改进的研究
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摘要
PTFE/PEEK(聚四氟乙烯／聚醚醚酮)聚合物涂层具有独特的性质,如自润滑、低磨损、抗腐蚀、耐辐射和良好的化学稳定性等,有广泛的应用前景。随着人们要求更洁净的压缩气体,全无油润滑压缩机应运而生。现有的全无油润滑压缩机中,活塞销采用脂润滑。该润滑方式有其局限性,例如易失效、溢出及在真空环境易蒸发等,故不能完全满足全无油或稳定润滑的条件。因此,本文提出采用PTFE/PEEK涂层改进活塞销的润滑方式,提高全无油润滑压缩机工作性能及延伸其适用场合。
首先,设计一台全无油润滑压缩机的活塞组部分,以获得在SRV上进行PTFE/PEEK涂层试验的参数。
然后,采用粉末静电喷涂法制备PTFE/PEEK涂层,并运用正交试验设计法考察预热温度、涂层厚度和工作温度对PTFE/PEEK涂层性能的影响。结果表明：250℃预热基底,喷涂厚度100μm-150μm,在150℃温度下工作时,PTFE/PEEK涂层有着良好的摩擦学性能。随后考察了往复摩擦冲程的影响,发现在涂层厚度小于150μm的范围内,随着涂层厚度的增加,冲程对PTFE/PEEK涂层的摩擦系数影响越小,并且较大的冲程可获得更小的摩擦系数。
最后,运用ANSYS对PTFE/PEEK涂层进行模拟工作环境热分析。分别对比压缩机两级在活塞销固定和活塞销旋转两种定位方式下的活塞销温度分布,得出：低级的活塞列可以满足较优工作温度,而高级的则不能,且活塞销可旋转时,活塞销上温度的分布更均匀,利于减小集中热应力。本文的研究证明了使用PTFE/PEEK涂层的可行性,并且初步寻找到可应用于全无油活塞式压缩机活塞销涂层润滑的设计参数,为全无油润滑压缩机的设计提供新思路,新方法和延伸其使用场合,同时也为PTFE/PEEK涂层的应用提供参考。
PTFE/PEEK (Polytetrafluoroethylene/Polyetheretherketone) polymer coating has extensive prospect of application due to its unique hybrid properties, such as self-lubrication, high wear resistance, corrosion resistance, radiation resistance and great chemical stability. As higher demands of clean compressed air, the oil free compressor had come out. The wrist pins in this compressor are lubricated by grease which is limited in some cases, such as the failure and leakage of grease or evaporation in vacuum, so that they cannot meet good or stable lubrication totally. Therefore, in this thesis, PTFE/PEEK coating was invited to improve it by taking the place of grease for better performance of oil free compressor and expanding its scope of application.
Firstly, an oil free air compressor was designed to obtain the parameters for PTFE/PEEK coating tests on SRV tribometer.
Secondly, PTFE/PEEK coatings were prepared by electrostatic powder spraying method and factors were investigated on the preheating temperature, coating thickness and working temperature by the orthogonal experimental method. The results show that250℃preheating temperature,100μm-150μm coating thickness and150℃working temperature are better conditions for playing good performance of PTFE/PEEK coating. For the influence of stroke, in the range of coating thicknesses from20μm to150μm, the COF values are not influenced too much by strokes as the increasing of coating thickness, and bigger strokes can obtain lower COF values.
Finally, ANSYS was used to build a transient thermal model to analyze the temperature distribution in two working conditions-the fixed wrist pin and the rotated wrist pin. The results show that the first stage can meet the better conditions which are obtained by tribological tests, and the second stage cannot. Also, the temperature distribution becomes uniformity as wrist pin rotated, which can limit the thermal stress.
The conclusions in this thesis prove the feasibility of application of PTFE/PEEK coating, and provide a new design method of oil free compressor using polymer coating lubrication, and provide a reference of PTFE/PEEK coating application.
首先,设计一台全无油润滑压缩机的活塞组部分,以获得在SRV上进行PTFE/PEEK涂层试验的参数。
然后,采用粉末静电喷涂法制备PTFE/PEEK涂层,并运用正交试验设计法考察预热温度、涂层厚度和工作温度对PTFE/PEEK涂层性能的影响。结果表明：250℃预热基底,喷涂厚度100μm-150μm,在150℃温度下工作时,PTFE/PEEK涂层有着良好的摩擦学性能。随后考察了往复摩擦冲程的影响,发现在涂层厚度小于150μm的范围内,随着涂层厚度的增加,冲程对PTFE/PEEK涂层的摩擦系数影响越小,并且较大的冲程可获得更小的摩擦系数。
最后,运用ANSYS对PTFE/PEEK涂层进行模拟工作环境热分析。分别对比压缩机两级在活塞销固定和活塞销旋转两种定位方式下的活塞销温度分布,得出：低级的活塞列可以满足较优工作温度,而高级的则不能,且活塞销可旋转时,活塞销上温度的分布更均匀,利于减小集中热应力。本文的研究证明了使用PTFE/PEEK涂层的可行性,并且初步寻找到可应用于全无油活塞式压缩机活塞销涂层润滑的设计参数,为全无油润滑压缩机的设计提供新思路,新方法和延伸其使用场合,同时也为PTFE/PEEK涂层的应用提供参考。
PTFE/PEEK (Polytetrafluoroethylene/Polyetheretherketone) polymer coating has extensive prospect of application due to its unique hybrid properties, such as self-lubrication, high wear resistance, corrosion resistance, radiation resistance and great chemical stability. As higher demands of clean compressed air, the oil free compressor had come out. The wrist pins in this compressor are lubricated by grease which is limited in some cases, such as the failure and leakage of grease or evaporation in vacuum, so that they cannot meet good or stable lubrication totally. Therefore, in this thesis, PTFE/PEEK coating was invited to improve it by taking the place of grease for better performance of oil free compressor and expanding its scope of application.
Firstly, an oil free air compressor was designed to obtain the parameters for PTFE/PEEK coating tests on SRV tribometer.
Secondly, PTFE/PEEK coatings were prepared by electrostatic powder spraying method and factors were investigated on the preheating temperature, coating thickness and working temperature by the orthogonal experimental method. The results show that250℃preheating temperature,100μm-150μm coating thickness and150℃working temperature are better conditions for playing good performance of PTFE/PEEK coating. For the influence of stroke, in the range of coating thicknesses from20μm to150μm, the COF values are not influenced too much by strokes as the increasing of coating thickness, and bigger strokes can obtain lower COF values.
Finally, ANSYS was used to build a transient thermal model to analyze the temperature distribution in two working conditions-the fixed wrist pin and the rotated wrist pin. The results show that the first stage can meet the better conditions which are obtained by tribological tests, and the second stage cannot. Also, the temperature distribution becomes uniformity as wrist pin rotated, which can limit the thermal stress.
The conclusions in this thesis prove the feasibility of application of PTFE/PEEK coating, and provide a new design method of oil free compressor using polymer coating lubrication, and provide a reference of PTFE/PEEK coating application.
引文
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[4]Petrovicova E, Knight R, Schadler L S, Twardowski T E. Nylon 11/Silica Nanocomposite Coatings Applied by the HVOF Process. Mechanical and Barrier Properties[J]. Journal of Applied Polymer Science, 2000, 78:2272-2289
[5]Lathabai S, Ottmuller M, Fernandez I. Solid Particle Erosion Behavior of Thermal Sprayed Ceramin, Metallic and Polymer Coating[J]. Wear, 1998, 221:93-108
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[19]Briscoe B J, Yao L H, and Stolarski T A. The Friction and Wear of Polytetrafluorothylene-poly (ether ether ketone) Composites:An Initial Appraisal of The Optimum Composition[J]. Wear, 1986, 108:357-374
[20]Stuart B H. The Plasticization of Polymer Surfaces[D]. University of London, 1993
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[22]Lu Z P, Friedrich K. On Sliding Friction and Wear of PEEK and Its Composites[J]. Wear, 1995, 181-183:624-631
[23]Burris D L, Sawyer W G. A Low Friction and Ultra Low Wear Rate PEEK/PTFE Composite[J]. Wear, 2006(261):410-418
[24]Demas N G, Polycarpou A A. Tribological Performance of PTFE-based Coatings for Air-conditioning Compressors[J]. Surface & Coatings Technology, 2008(203):307-316
[25]Dascalescu D, Polychronopoulou K, Polycarpou A A. The Significance of Tribochemistry on The Performance of PTFE-based Coatings in CO2 Refrigerant Environment[J]. Surface & Coatings Technology, 2009(204):319-329
[26]Nunez E E, Yeo S M, Polychronopoulou K, Polycarpou A A. Tribological Study of High Bearing Blended Polymer-based Coatings for Air-conditioning and Refrigeration Compressors[J]. Surface & Coatings Technology, 2011(205):2994-3005
[27]Song H J, Zhang Z Z, Men X H. Super-hydrophobic PEEK/PTFE Composite Coating[J]. Applied Physics A:Materials Science & Processing, 2008(91):73-76
[28]Karnath M A. Frictional Characteristics of Thin Polytetrafluoroehylene Films Deposited on Glass by Hot Filament Chemical Vapor Deposition Method[D]. Northeastern University, 2008
[29]彭超群,黄伯云.喷射沉积技术[J].有色金属,2002,54(1)：12-15
[30]张济山,熊柏青,崔华.喷射成型快速凝固技术[M].北京：科学出版社,2008
[31]王迪生,崔天生,夏振鹏等.小型压缩机变转速的试验研究[J].流体工程,1985,(7)：13-17
[32]彭培英,彭宝成等.全无油润滑压缩机的试验研究[J].河北工业科技,2007,24(6)：332-334
[33]彭宝成,彭培英,朱玉峰.全无油压缩机设计中重要参数的合理选择[J].润滑与密封,2005,(1)：94-95
[34]王迪生,杨乐之.活塞式压缩机结构[M].北京：机械工业出版社,1988
[35]《活塞式压缩机设计》编写组.活塞式压缩机设计[M].北京：机械工业出版社,1974
[36]赵选民.试验设计方法[M].北京：科学出版社,2006
[37]杨子胥.正交表的构造[M].济南：山东人民出版社,1978
[38]http://sklt.tsinghua.edu.cn/index.php?option=com content&task=view&id=20&Itemid=80
[39]《机械工程材料性能数据手册》编委会.机械工程材料性能数据手册[M].北京：机械工业出版社,1994
[40]温诗铸,黄平.摩擦学原理(第3版)[M].北京：清华大学出版社,2008
[41]Wang J, Shi F G. Thickness Dependence of Elastic Modulus and Hardness of On-Wafer Low-k Ultrathin Polytetrafluoroehtylene Films[J]. Scripta Materialia, 2000(42):687-694
[42]田云德,秦世伦.复合材料等效弹性模量的改进混合律方法[J].西南交通大学学报,2005,40(6)：783-787
[43]董炎明,朱平平,徐世爱.高分子结构与性能[M].上海：华东理工大学出版社,2010
[44]http://info.coatings.hc360.com/2012/01/021150428928.shtml
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