表面相互作用下表面形貌表征及微造型表面润滑分析
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摘要
表面形貌对零件的功能及零件装配后设备的整体工作性能、效率和使用寿命有很大影响。面向功能的表面形貌表征是实现表面设计与评定的基础,目前的表面形貌表征多针对单一表面进行,而对相互作用的表面形貌表征较少。由于任何机械产品都有一个“运动保证功能”,必然要涉及到两个相对运动的表面,也就是通常所说的运动副或摩擦副,两表面间不可避免会发生相互作用。本文分析了体现表面相互作用的表面三维参数:实体接触面积比、封闭与开放空体面积比,研究了两表面相互作用过程中表面形貌变化情况,并延伸出两个重要参数——最大封闭空体面积比和封闭空体体积。文中应用MATLAB软件结合数学形态学数字图像处理给出了详细的参数计算方法,并应用于分析各种实际表面和模拟表面。
为了进一步研究表面形貌的摩擦润滑特性,本文针对具有规则微凹坑的激光微造型缸套表面,基于润滑理论模型,分析了表面形貌几何参数对缸套/活塞环系统摩擦润滑性能的影响,进而为摩擦副表面的微观几何形貌优化设计提供理论依据。
Surface topography has tremendous influence on the components function and the performance, the efficiency and the service life of equipment. Function oriented characterization surface topography is the basis of design and evaluation of surface topography. At present, surface characterization mainly aims at the single surface, and few at interacting surface. As any mechanical products have a "motion guarantee function", inevitably two surfaces in relative motion must be concerned, which also known as tribopair, interaction inevitably occurs between two surfaces. This paper analyzed 3D surface characterizing parameters which manifest the interaction of the surface: real contact area ratio, closed and open void area ratio, studied the change situation of surface topography in surface interaction process, and extended two key parameters--maximum closed void area ratio and closed void volume. The the detailed computational method of above parameters by using MATLB software and mathematics morphology digital image processing is given, and real surface topography and simulated surface topography are characterized.
In order to further research the friction and lubrication performance of surface topography, based on theoretical lubricating models, aimed at cylinder surface with regular micro pores, the friction and lubrication performance of cylinder / piston ring system is analyzed, and the influence of surface micro geometry shape parameters is given, this work provide theoretical basis for the optimization design of microscopic geometry of tribopair surface.
为了进一步研究表面形貌的摩擦润滑特性,本文针对具有规则微凹坑的激光微造型缸套表面,基于润滑理论模型,分析了表面形貌几何参数对缸套/活塞环系统摩擦润滑性能的影响,进而为摩擦副表面的微观几何形貌优化设计提供理论依据。
Surface topography has tremendous influence on the components function and the performance, the efficiency and the service life of equipment. Function oriented characterization surface topography is the basis of design and evaluation of surface topography. At present, surface characterization mainly aims at the single surface, and few at interacting surface. As any mechanical products have a "motion guarantee function", inevitably two surfaces in relative motion must be concerned, which also known as tribopair, interaction inevitably occurs between two surfaces. This paper analyzed 3D surface characterizing parameters which manifest the interaction of the surface: real contact area ratio, closed and open void area ratio, studied the change situation of surface topography in surface interaction process, and extended two key parameters--maximum closed void area ratio and closed void volume. The the detailed computational method of above parameters by using MATLB software and mathematics morphology digital image processing is given, and real surface topography and simulated surface topography are characterized.
In order to further research the friction and lubrication performance of surface topography, based on theoretical lubricating models, aimed at cylinder surface with regular micro pores, the friction and lubrication performance of cylinder / piston ring system is analyzed, and the influence of surface micro geometry shape parameters is given, this work provide theoretical basis for the optimization design of microscopic geometry of tribopair surface.
引文
[1]刘小君,方新燕,刘焜,桂长林.产品性能与加工表面质量设计.合肥工业大学学报(自然科学版),2005,28(7):781-783.
[2]冯秀.表面形貌的研究现状及发展趋势.润滑与密封,2006,174(2):168-170.
[3]李惠芬,蒋向前,李柱.基于高斯滤波的稳健工程表面评定方法.华中科技大学学报,2002,30(8):43-45.
[4]曾文涵,谢铁邦,蒋向前,李柱.表面粗糙度的稳健提取方法研究.中国机械工程,2004,15(2):127-130.
[5]Dong W P,Sullivan P J,Stout K J.Comprehensive study of parameters for characterization 3-D surface topography-Ⅲ.Wear,1994,178(1):29-43.
[6]Thomas A P,Thomas T R.Engineering surface as fractals,fractal aspects ofmaterials.Pittsburgh:Materials Research Society,1986:75-77.
[7]Majumdar A,Bhushan B.Fractalmodel of elastic plastic contact between rough surfaces.Tram of ASME,1991,113(1):1-11.
[8]Majumdar A,Bhushan B.Role of fractal geometry in roughness characterization and contact mechanics of surfaces.ASME Journal of Tribology,1990,172:205-206.
[9]Vandenberg S,Osborne C F.Digital image processing techniques,fractal dimensionality and scale-space applied to surface roughness.Wear,1992,159:17-30.
[10]Zhou G Y,Leu M C,eta.Fractal geometry model for wear prediction.Wear,1993,170:1-14.
[11]Srinivasan R S,Wood.Fractal based geometric tolerancing in mechanical design.Proc of ASME DTM Conference,1992:107-115.
[12]Srinivasan R S.A form tolerancing theory using fractals and wavelets.J of Mech Design,1997,119:185-192.
[13]葛世荣,K Tonder.粗糙表面的分形特征与分形表达研究.摩擦学学报.1997,17(1):73-80.
[14]葛世荣,索双富.表面轮廓分形维数计算方法的研究.摩擦学学报,1997,17(4):354-362.
[15]陈国安,葛世荣,张晓云.磨合过程中表面形貌变化的分形表征.润滑与密封.1999(2):55-56.
[16]葛世荣,陈国安.磨合表面形貌变化的特征粗糙度参数表征.中国矿业大学学报,1999,28(3):204-207.
[17]李丽伟,董申,程凯.表面微观形貌定量表征中几种新方法的应用.中国 机械工程,2002,13(19):1072-1075.
[18]费斌,蒋庄德.工程粗糙表面粘着磨损的分形学研究.摩擦学学报,1999,19(1):78-82.
[19]冯丽,谢沛霖.基于分形几何的表面微观形貌模拟及粘着弹性接触计算研究.润滑与密封,2007,32(6):74-77.
[20]李小兵,刘莹.表面分形表征方法比较.南昌大学学报(理学版),2006,30(1):84-86
[21]陈庆虎,李柱.表面粗糙度评定的小波基准线.计量学报,1998,(10):254-257.
[22]陈庆虎,李柱.表面粗糙度提取的小波频谱法[J].机械工程学报,1999,(3):41-43.
[23]陈庆虎,周轶尘.表面奇异特征的小波提取.武汉交通科技大学学报,1999,23(4):343-346.
[24]陈庆虎,谢峰,谢铁邦等.小波滤波的频率结构分析及其在表面形貌分析中的应用.武汉交通科技大学学报,1998,(122):231-23.
[25]宋康,蒋庄德,李兵.基于小波函数迭代的外圆磨削表面分形分析.计量学报,2004,7:211-214.
[26]王安良,杨春信.评价机械加工表面形貌的小波变换方法.机械工程学报,2001,37(8):65-74.
[27]S H Lee,H Zahouani,R Caterini,T G.mathia.Morphological characterization of engineered surfaces by wavelet transform.Tools Manufact,1998,38(5):581-589.
[28]郭百巍,陈大融.结合小波分析和分水岭分割法的微观表面形貌分析方法.中国机械工程,2007,18(17):2043-2047.
[29]杨练根,谢铁邦,蒋向前,等.表面形貌的Motif评定方法及其发展.中国机械工程,2002,21(3):1862-1865.
[30]Barre F,Lopez J.Watershed Lines and Catchment Basins:a New 3D-Motif Method.Tools & Manufacture,2000,40(8):1171-1184.
[31]Chen C-C A,Liu W-C,Duffle N A.A surface topography model for automated surface finishing.Int Journal of Machine Tools &Manufacture,1998,38(5/6):543-550.
[32]Zahouani H.Spectral and 3D motifs identification of anisotropic topographical components.Analysis and filtering of anisotropic patterns by morphological rose approach.Int J Mach Tools & Manufact,1998,38(5/6):615-623.
[33]Dr Pawl,J Scott.Foundations of topological characterization of surface texture.ToolsManufact,1998,38(5):559-566.
[34]李志强,陈小安,杨学恒,韩贤武.三维motif方法及其对微观形貌的表征.重庆大学学报(自然科学版),2006,29(11):10-13.
[35]ISO/TC213 N756.New work item proposal[S].2005.
[36]Snegovsky F P,Buljuk N G.Study of Lubrication of Sliding Bearings with Microcavities on Journals.Friction and Wear,1983,4(2):321-328.
[37]Lai T W.Development of Non-Contacting Spiral Groove Liquid Face Seals.Lubrication Engineering,1994,50(8):625-640.
[38]Etsion I,Burstein L.A Model for Mechanical Seals with Regular Micro-surface Structure.Tribol Trans,1996,39(3):677-683.
[39]Kligerman Y,Etsion I.Analysis of the Hydrodynamic Effects in a Surface Textured Circumferential Gas Seal.Tribology Transactions,2001,44(3):472-478.
[40]Siripuram R,Stephens L S.Effect of Deterministic Asperity Geometry on Hydrodynamic Lubrication.Tribol,2004,126(7):527-534.
[41]于新奇,彭培英,王振辉,蔡仁良.激光加工多孔密封端面的摩擦性能试验研究.润滑与密封,2006,(8):34-37.
[42]韩中领,汪家道,陈大融.不同凹坑深度在乏油润滑状态下的减阻实验.润滑与密封,2007,32(3):18-20.
[43]Pfestorf M,Engel U,Geiger M.3D-surface parameter and their application determinstic sheets.Int.J.Tools Manufact,1998,88(5-6):607-614.
[44]Sobis T,Engel U,Geiger M.Atheoretical Study on Wear Simulation in Metal Forming Processes.J.Mater.Process.Technol,1992,34(1-4):33-40.
[45]Weidel S,Engel U.Surface characterization in forming processes by functional 3D parameters.Int J Adv ManufTechnol,2007,33:130-136.
[46]王家文,李仰军.MATLAB7.0图形图像处理.国防工业出版社,2006.
[47]章毓晋.图象工程.清华大学出版社,2004.
[48]苏金明,王永利.MATLAB图形图像.电子工业出版社,2005.
[49]崔屹.图像处理与分析——数学形态学方法及应用.科学出版社,2000.
[50]Meiler M,PfestorfM,Geigerb M,Merklein M.The use of dry film lubricants in aluminum sheet metal forming.Wear,2003,255(7—12):1455-1462.
[51]李伯奎,刘远伟.机械加工表面承载和储油性能研究.淮阴工学院学报,2004,13(1):39-42.
[52]Miltsios,G.K,Patterson D.J.,Papanastastasiou T.C..Solution of the Lubrication Problem and Calculation of the Friction Force on the Piston Rings.ASME,J.Tribol.,1989,111:635-641.
[53]Patir N,Cheng H S.An Average Flow Model for Determining Effects of Three-Dimensional Roughness on Partial Hydrodynamic Lubrication.ASME,1978,100:12-14.
[54]温诗铸,黄平.摩擦学原理.北京:清华大学出版社,1990.
[55]符永宏,陆化才,华希俊等。激光微珩磨缸套润滑耐磨性能理论分析。内燃机学报,2006,24(6):559-564.
[56]Rode S.A mixed friction model for dynamically loaded contacts with application to piston ring lubrication.Proc.of the 7th Leeds-Lyon Symposium on Tribology,Lyon,1980,262.
[2]冯秀.表面形貌的研究现状及发展趋势.润滑与密封,2006,174(2):168-170.
[3]李惠芬,蒋向前,李柱.基于高斯滤波的稳健工程表面评定方法.华中科技大学学报,2002,30(8):43-45.
[4]曾文涵,谢铁邦,蒋向前,李柱.表面粗糙度的稳健提取方法研究.中国机械工程,2004,15(2):127-130.
[5]Dong W P,Sullivan P J,Stout K J.Comprehensive study of parameters for characterization 3-D surface topography-Ⅲ.Wear,1994,178(1):29-43.
[6]Thomas A P,Thomas T R.Engineering surface as fractals,fractal aspects ofmaterials.Pittsburgh:Materials Research Society,1986:75-77.
[7]Majumdar A,Bhushan B.Fractalmodel of elastic plastic contact between rough surfaces.Tram of ASME,1991,113(1):1-11.
[8]Majumdar A,Bhushan B.Role of fractal geometry in roughness characterization and contact mechanics of surfaces.ASME Journal of Tribology,1990,172:205-206.
[9]Vandenberg S,Osborne C F.Digital image processing techniques,fractal dimensionality and scale-space applied to surface roughness.Wear,1992,159:17-30.
[10]Zhou G Y,Leu M C,eta.Fractal geometry model for wear prediction.Wear,1993,170:1-14.
[11]Srinivasan R S,Wood.Fractal based geometric tolerancing in mechanical design.Proc of ASME DTM Conference,1992:107-115.
[12]Srinivasan R S.A form tolerancing theory using fractals and wavelets.J of Mech Design,1997,119:185-192.
[13]葛世荣,K Tonder.粗糙表面的分形特征与分形表达研究.摩擦学学报.1997,17(1):73-80.
[14]葛世荣,索双富.表面轮廓分形维数计算方法的研究.摩擦学学报,1997,17(4):354-362.
[15]陈国安,葛世荣,张晓云.磨合过程中表面形貌变化的分形表征.润滑与密封.1999(2):55-56.
[16]葛世荣,陈国安.磨合表面形貌变化的特征粗糙度参数表征.中国矿业大学学报,1999,28(3):204-207.
[17]李丽伟,董申,程凯.表面微观形貌定量表征中几种新方法的应用.中国 机械工程,2002,13(19):1072-1075.
[18]费斌,蒋庄德.工程粗糙表面粘着磨损的分形学研究.摩擦学学报,1999,19(1):78-82.
[19]冯丽,谢沛霖.基于分形几何的表面微观形貌模拟及粘着弹性接触计算研究.润滑与密封,2007,32(6):74-77.
[20]李小兵,刘莹.表面分形表征方法比较.南昌大学学报(理学版),2006,30(1):84-86
[21]陈庆虎,李柱.表面粗糙度评定的小波基准线.计量学报,1998,(10):254-257.
[22]陈庆虎,李柱.表面粗糙度提取的小波频谱法[J].机械工程学报,1999,(3):41-43.
[23]陈庆虎,周轶尘.表面奇异特征的小波提取.武汉交通科技大学学报,1999,23(4):343-346.
[24]陈庆虎,谢峰,谢铁邦等.小波滤波的频率结构分析及其在表面形貌分析中的应用.武汉交通科技大学学报,1998,(122):231-23.
[25]宋康,蒋庄德,李兵.基于小波函数迭代的外圆磨削表面分形分析.计量学报,2004,7:211-214.
[26]王安良,杨春信.评价机械加工表面形貌的小波变换方法.机械工程学报,2001,37(8):65-74.
[27]S H Lee,H Zahouani,R Caterini,T G.mathia.Morphological characterization of engineered surfaces by wavelet transform.Tools Manufact,1998,38(5):581-589.
[28]郭百巍,陈大融.结合小波分析和分水岭分割法的微观表面形貌分析方法.中国机械工程,2007,18(17):2043-2047.
[29]杨练根,谢铁邦,蒋向前,等.表面形貌的Motif评定方法及其发展.中国机械工程,2002,21(3):1862-1865.
[30]Barre F,Lopez J.Watershed Lines and Catchment Basins:a New 3D-Motif Method.Tools & Manufacture,2000,40(8):1171-1184.
[31]Chen C-C A,Liu W-C,Duffle N A.A surface topography model for automated surface finishing.Int Journal of Machine Tools &Manufacture,1998,38(5/6):543-550.
[32]Zahouani H.Spectral and 3D motifs identification of anisotropic topographical components.Analysis and filtering of anisotropic patterns by morphological rose approach.Int J Mach Tools & Manufact,1998,38(5/6):615-623.
[33]Dr Pawl,J Scott.Foundations of topological characterization of surface texture.ToolsManufact,1998,38(5):559-566.
[34]李志强,陈小安,杨学恒,韩贤武.三维motif方法及其对微观形貌的表征.重庆大学学报(自然科学版),2006,29(11):10-13.
[35]ISO/TC213 N756.New work item proposal[S].2005.
[36]Snegovsky F P,Buljuk N G.Study of Lubrication of Sliding Bearings with Microcavities on Journals.Friction and Wear,1983,4(2):321-328.
[37]Lai T W.Development of Non-Contacting Spiral Groove Liquid Face Seals.Lubrication Engineering,1994,50(8):625-640.
[38]Etsion I,Burstein L.A Model for Mechanical Seals with Regular Micro-surface Structure.Tribol Trans,1996,39(3):677-683.
[39]Kligerman Y,Etsion I.Analysis of the Hydrodynamic Effects in a Surface Textured Circumferential Gas Seal.Tribology Transactions,2001,44(3):472-478.
[40]Siripuram R,Stephens L S.Effect of Deterministic Asperity Geometry on Hydrodynamic Lubrication.Tribol,2004,126(7):527-534.
[41]于新奇,彭培英,王振辉,蔡仁良.激光加工多孔密封端面的摩擦性能试验研究.润滑与密封,2006,(8):34-37.
[42]韩中领,汪家道,陈大融.不同凹坑深度在乏油润滑状态下的减阻实验.润滑与密封,2007,32(3):18-20.
[43]Pfestorf M,Engel U,Geiger M.3D-surface parameter and their application determinstic sheets.Int.J.Tools Manufact,1998,88(5-6):607-614.
[44]Sobis T,Engel U,Geiger M.Atheoretical Study on Wear Simulation in Metal Forming Processes.J.Mater.Process.Technol,1992,34(1-4):33-40.
[45]Weidel S,Engel U.Surface characterization in forming processes by functional 3D parameters.Int J Adv ManufTechnol,2007,33:130-136.
[46]王家文,李仰军.MATLAB7.0图形图像处理.国防工业出版社,2006.
[47]章毓晋.图象工程.清华大学出版社,2004.
[48]苏金明,王永利.MATLAB图形图像.电子工业出版社,2005.
[49]崔屹.图像处理与分析——数学形态学方法及应用.科学出版社,2000.
[50]Meiler M,PfestorfM,Geigerb M,Merklein M.The use of dry film lubricants in aluminum sheet metal forming.Wear,2003,255(7—12):1455-1462.
[51]李伯奎,刘远伟.机械加工表面承载和储油性能研究.淮阴工学院学报,2004,13(1):39-42.
[52]Miltsios,G.K,Patterson D.J.,Papanastastasiou T.C..Solution of the Lubrication Problem and Calculation of the Friction Force on the Piston Rings.ASME,J.Tribol.,1989,111:635-641.
[53]Patir N,Cheng H S.An Average Flow Model for Determining Effects of Three-Dimensional Roughness on Partial Hydrodynamic Lubrication.ASME,1978,100:12-14.
[54]温诗铸,黄平.摩擦学原理.北京:清华大学出版社,1990.
[55]符永宏,陆化才,华希俊等。激光微珩磨缸套润滑耐磨性能理论分析。内燃机学报,2006,24(6):559-564.
[56]Rode S.A mixed friction model for dynamically loaded contacts with application to piston ring lubrication.Proc.of the 7th Leeds-Lyon Symposium on Tribology,Lyon,1980,262.