摘要
针对高强化柴油机燃烧室主要结构件在高温重载条件下拉缸倾向严重等摩擦磨损问题,研究了缸套-活塞环摩擦副的摩擦状态转化机制,从摩擦状态转化表征方法和摩擦状态转化规律两个方面展开讨论与分析。
(1)建立了摩擦状态转化实验方法和表征方法。分别采用载荷级、温度级、速度级和贫油等四种实验方案,以摩擦状态宏观特征参量(摩擦力)为表征参数,以对摩擦状态转化的敏感性为评价标准,建立了以贫油实验方案为基准的摩擦状态转化实验方法,以模拟高强化柴油机发生拉缸的过程。以摩擦力为参量,基于混沌处理方法建立描述摩擦状态转化过程的分析模型,提取混沌吸引子作为有效表征摩擦状态转化的特征参数。依据不同摩擦状态摩擦副所具有的表面形貌特征,建立摩擦副表面形貌取向特征和各向分形特征与其所处摩擦状态的对应关系,并以系列图谱的形式表征,最终获得了摩擦副工况条件-摩擦状态-特征参数-特征形貌间的系统关联关系。
(2)获得了缸套-活塞环典型配副的摩擦状态转化规律。通过优化设计的摩擦副系统贫油实验,采用特征参数和特征形貌表征方法,研究了载荷、温度等因素对铸铁/氮化铬、铸铁/喷钼、铸铁/CKS、镀铬/氮化铬、镀铬/喷钼、氮化/喷钼、氮化/CKS、复合镀/喷钼等高强化柴油机典型配副的抗拉缸性能影响规律,其中复合镀/喷钼配对副具有优异的抗拉缸性能。通过分析润滑油对止点附近摩擦特性的影响,可以看出镀铬/氮化铬配对副与润滑油RP-4652D之间存在“温度缝隙”低速区域滑动速度的微小变化带来了止点附近润滑特性的明显改变。当载荷为10MPa,滑动速度小于0.4mm/s时,润滑油中的添加剂ZDDP会显著减小摩擦力；滑动速度大于0.4mm/s时,添加剂ZDDP对减小摩擦力的影响减弱。当载荷为20MPa时,添加剂ZDDP在试验速度范围内对减小摩擦力的影响不明显。在贫油润滑状态下,当凹槽内储存的润滑油无法向平台结构区域供给润滑油时,摩擦表面吸附膜/化学反应膜/分解膜会逐渐消耗直至发生微凸体黏着。各配对副黏着磨损区域的共同特点是极压反应膜保护作用减弱,摩擦副材料发生黏着转移,表面形貌取向特征增强,精细复杂结构减少,分形维数值趋近于1左右。可以从设计具有梯度结构的摩擦副,保持摩擦副表面形貌各向高分形维数,提升摩擦副材料与润滑油的协同性等三方面改善摩擦副的抗黏着性能,提高高强化柴油机抗拉缸性能。
总之,本文从摩擦学、动力学、材料学三个方面较为系统地研究了混合润滑状态转化至严重黏着磨损的摩擦状态转化机制,为高强化柴油机缸套-活塞环摩擦副的抗拉缸性能控制提供了科学依据,对缸套-活塞环摩擦表面的设计提供了理论支持。此研究不仅对于高强化柴油机缸套-活塞环样件研制具有重要的工程意义,而且对丰富摩擦学理论具有重要的学术意义。
In order to study the cylinder liner scuffing problems of heavy duty diesel engine, this dissertation focuses on the friction condition transiton (FCT) mechanism between piston ring and cylinder liner (PRCL) in terms of the FCT characterization methods and FCT rules. The following conclusions are drawn:
Firstly, the FCT experimental methods and characterization methods are investigated. Through the varied loads, speeds, temperatures experiments as well as the starvation experiments, friction force is measured to judge the sensitivity of different experimental methods, then the starved lubrication experiments are optimized to analog the FCT process at the PRCL interface with the piston ring reciprocating liner test rig. Chaos theory is used to extract the transient features. It is based on the assumption that the chaos theory can characterize the nonlinear dynamic behavior of friction phenomenon. It allows for describing the dynamic behavior of the tribological process with the attractors in phase space. The attractors represent irregular behaviors of friction force in different strokes from chaos to order. It has three main patterns under starved lubrication conditions. As the projection of attractors on the phase space coordinate exceeds a limit, it indicates the onset and progression of scuffing. The autocorrelation function and profile dimension distribution are used to characterize the surface morphology. From lubricant starvation to the adhesive wear conditions, surface orientation gradually strengthens with the increasing amplitude of autocorrelation function. Moreover, the decreasing profile fractal dimensions in every direction indicate the fine or detailed structures constantly reduce. It can gain the relationship among the working conditions-friction condition-characteristic parameters-topographic features.
Secondly, the FCT rules of PRCL are acquired. Through the starvation experiments, the influence of loads, temperatures and lubricants on FCT can be acquired with the characteristic parameters and topographic features method. Composited plated cylinder liner with the molybdenum-sprayed piston ring has the best anti-scuffing properties among the friction pairs. The lubricant temperature gap is existed between tribological surfaces (Chrome-plated cylinder liner and the CrN piston ring) and lubricant RP-4652D. For the lubrication problems near the PRCL top dead centre (TDC), it investigates friction force vs. sliding speed characteristics of lubricant under different loads and lubrication conditions. Minor speed change obviously varies the lubrication characteristic near TDC. When the load is10MPa, ZDDP additives reduce friction force at sliding speeds less than0.4mm/s. As the sliding speeds greater than0.4mm/s, the influence of ZDDP additives to the lubricating film shear characteristics become weakened. When the load is20MPa, ZDDP additives don't obviously reduce friction force at slow sliding speed.
Thirdly, when the grooves can't supply the stored lubricant to the structure of the platform area, adsorption film/chemical reaction film/decomposition film will be gradually consumed until the asperities adhesion happen under the starvation condition. The adhesive wear areas have some common features,such as the weakened extreme pressure protection film, the transfered adhesive friction pair materials, the enhancement of surface morphology orientation feature, the reduced the fined complex structure with fractal dimension value closing to about1. It can design the gradient structures, keep the fined complex tribological surface and upgrade the compatibility between tribological surface and lubricant to improve the anti-adhesive properties of tribological surfaces and anti-scuffing perforemance of heavy duty diesel engine
Finally, the dissertation systematically studies the transient mechanisms from mixed lubrication to scuffing wear of heavy duty diesel engine with the tribology, dynamics and materials science method. Scientific basis and theoretical supports are provided to the design and anti-scuffing control of the PRCL tribological surface. It is of considerable academic and engineering values to the PRCL samples develpoment and tribology theory.
引文
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