汽车轮毂轴承脂润滑理论与润滑失效机理研究
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摘要
随着工业技术的不断发展，零部件高温、重载和高速剪切的使用工况已经十分普遍，从而对润滑剂的性能和相关理论研究的要求也越来越高。经过大量学者的共同努力，对于润滑油及其润滑理论的理论研究，在面、线和点接触的润滑理论以及试验测试装置研制方面都取得了较多成果，并从宏观和微观两个方向全面研究了润滑油润滑机理，对润滑油的应用产生了积极影响。汽车轮毂轴承作为汽车关键零部件，通常采用润滑脂作为润滑剂，而润滑脂由于其特殊的结构和性质，在实际应用和理论研究方面均与润滑油具有较大的差别。目前，润滑脂相关研究主要侧重于应用方面，即高性能润滑脂和相关添加剂的研制，而方法主要是依据经验和大量的试验研究，相关研究尚处于较不完善阶段。因此，探讨润滑脂的润滑机理和完善润滑脂润滑理论，并将相关的理论研究结果应用于实际应用中，尚有许多问题亟需解决。
本文首先从推导一般形式脂润滑Reynolds方程出发，针对轮毂轴承失效统计分析中出现的润滑失效，分析了润滑因素在轴承寿命和使用性能中所起的作用；然后归纳总结出了轮毂轴承润滑失效最终的表现形式，即滚道表面缺陷和润滑脂中存在杂质颗粒；最后，通过理论计算和试验方法，研究了表面缺陷和固体颗粒对脂润滑弹流润滑的影响。因此，本文对脂润滑弹性流体动力润滑理论的研究，轴承失效分析以及润滑脂添加剂的应用具有一定的指导意义。本文的研究工作主要有以下几个方面：
1、推导了适用于润滑脂润滑Reynolds方程的普遍形式，针对不同脂润滑问题给出了相对应的脂润滑方程简化形式。
2、对失效轮毂轴承进行了统计，并分析了润滑对轮毂轴承寿命的影响以及由于润滑不良导致的几种轮毂轴承失效形式。针对内圈随轴转动、外圈固定的轮毂轴承，出现内圈相比于外圈疲劳破坏和磨损更为严重的现象，利用脂润滑弹流理论进行了解释。
3、研究了表面缺陷对脂润滑弹流润滑油膜压力和油膜厚度的影响，并通过实验方法对数值计算结果的正确性进行了验证。采用数值计算方法分析了滚道表面出现凹坑和凸起时，其尺寸和位置对线接触和点接触脂润滑弹流润滑油膜压力和油膜厚度分布的影响，并通过对轮毂轴承表面凹坑和凸起的边缘和中心进行电镜扫描和能谱元素分析证明了数值计算结果的正确性。
4、详细推导了润滑脂存在固体颗粒时的线接触和点接触脂润滑Reynolds方程。利用试验方法和统计学理论分析了轮毂轴承润滑脂中杂质颗粒的来源以及颗粒数量与颗粒粒径的关系，并在此基础上分析了固体颗粒中心位置、速度和尺寸对线接触脂润滑弹流润滑油膜的影响以及固体颗粒速度和尺寸对点接触脂润滑弹流润滑油膜的影响。
5、分析了不同物理属性、不同粒径和质量分数的微纳米颗粒对润滑脂润滑性能的影响。为避免润滑脂添加剂对试验结果的影响，自制了一种不含添加剂的复合锂基润滑脂作为基础脂，给出了基础脂的配方和制备工艺流程。并在基础脂中加入不同粒径、质量分数的硬质脆性颗粒SiO2和软质塑性颗粒Cu作为试验样品，利用四球摩擦磨损试验机测试了润滑脂样品的摩擦系数和试验温度随时间变化的关系。
With the development of industrial, harsh conditions are widely exists in machinecomponents, for example: high temperature，over loading and high speed shearing,therebythe demands on lubricant properties and relative theory research increasingly high. After alarge number of scholars efforts, the lubrication theory and measuring apparatus for slidersurface contact, line contact and point contact problems of liquid lubrication had beenresolved well; furthermore, comprehensive investigation on the lubrication mechanism fromthe macro and micro sides respectively, all these works made a positive influence on theapplication of liquid lubricant. As a main part of automotive, wheel hub bearings usuallyadopt grease for the lubricant, due to the special structure and property, the distinguishes ofapplication and theory study for grease are noticeable which compared to liquid lubricant. Atpresent, the study of grease puts particular emphasis on application sides, such asdevelopment of high-performance grease and relatively additive, the methods ordinarilyaccording to the experience and lots of experiment investigations. Consequently, discussingthe lubrication mechanism and perfect the lubrication theory of grease, and applying thetheory study conclusions to practices, there are a lot of problems still need to be resovled.
Firstly, a generalized form of Reynolds equation for grease lubrication is derived, andaims at the lubrication failure which discovered in the statistical analysis of the failured wheelhub bearings, the effects of lubrication factor on bearing life and capability are analyzed. Then,the final expression forms of lubrication failure for wheel hub bearing are summarized:defects on race-way and solid particles in grease. Finally, the influences of defect and solidparticles on grease EHL are discussed by theory and experimental method. Consequently, thispaper may perfect the study of grease EHL theory, and guide the analysis of bearing failureand application of grease additive. The research works of this paper mainly consist offollowing parts:
1、A generalized form of Reynolds equation for grease lubrication is derived, andaccording to the different grease lubrication problems, put out the correspongding greaselubrication equation.
2、The failure wheel hub bearings are counted, the effects of lubrication on bearing lifeand several failure modes which caused by the undesirable lubrication are analyzed. Used thegrease EHL analysis the phenomenon that for the outer ring fixed, inner ring rotating with theshaft ball bearing type, the inner ring race-way compared with the outer ring race-way ismore likely to appearance wear and fatigue failure.
3、The effect of surface defects on film pressure and thickness of grease EHL areanalyzed, and the correctness of numerical calculation is proved by experimental methods.Theeffect of dents and bumps in the race-way surface on the distribution of film pressure andthickness for line contact and point contact grease EHL are analyzed by numerical calculationmethod, include the size and location of the dents and bumps.Furthermore, through the SEMand EDS analyzing for the edge and core of surface dent and bump to proving the correctnessof numerical calculation.
4、The Reynolds equation of line contact and point contact grease EHL for exist a solidparticle in grease is detailed derived. The source of solid particles in wheel hub bearing grease,and the relationship between the particle number and diameter are analyzed by experimentalmethod and statistical theory. The effect of center location, velocity and size of solid particleon line contact grease EHL, and the velocity and size of solid particle on point contact greaseEHL are analyzed.
5、The influence of different physical property, diameter and massfraction of submicroparticle on lubricating property of grease are analyzed. In order to prevent the influence ofgrease additive on the experiment results, self-made a lithium complex grease withoutadditive, and offer the formula and preparation process. The test samples are the grease whichmixed by brittle particle SiO2and ductile particle Cu with different diameter and massfraction,and the friction coefficient and the relationship between the test temperature and times ofsamples are tested by used four-ball tester.
本文首先从推导一般形式脂润滑Reynolds方程出发，针对轮毂轴承失效统计分析中出现的润滑失效，分析了润滑因素在轴承寿命和使用性能中所起的作用；然后归纳总结出了轮毂轴承润滑失效最终的表现形式，即滚道表面缺陷和润滑脂中存在杂质颗粒；最后，通过理论计算和试验方法，研究了表面缺陷和固体颗粒对脂润滑弹流润滑的影响。因此，本文对脂润滑弹性流体动力润滑理论的研究，轴承失效分析以及润滑脂添加剂的应用具有一定的指导意义。本文的研究工作主要有以下几个方面：
1、推导了适用于润滑脂润滑Reynolds方程的普遍形式，针对不同脂润滑问题给出了相对应的脂润滑方程简化形式。
2、对失效轮毂轴承进行了统计，并分析了润滑对轮毂轴承寿命的影响以及由于润滑不良导致的几种轮毂轴承失效形式。针对内圈随轴转动、外圈固定的轮毂轴承，出现内圈相比于外圈疲劳破坏和磨损更为严重的现象，利用脂润滑弹流理论进行了解释。
3、研究了表面缺陷对脂润滑弹流润滑油膜压力和油膜厚度的影响，并通过实验方法对数值计算结果的正确性进行了验证。采用数值计算方法分析了滚道表面出现凹坑和凸起时，其尺寸和位置对线接触和点接触脂润滑弹流润滑油膜压力和油膜厚度分布的影响，并通过对轮毂轴承表面凹坑和凸起的边缘和中心进行电镜扫描和能谱元素分析证明了数值计算结果的正确性。
4、详细推导了润滑脂存在固体颗粒时的线接触和点接触脂润滑Reynolds方程。利用试验方法和统计学理论分析了轮毂轴承润滑脂中杂质颗粒的来源以及颗粒数量与颗粒粒径的关系，并在此基础上分析了固体颗粒中心位置、速度和尺寸对线接触脂润滑弹流润滑油膜的影响以及固体颗粒速度和尺寸对点接触脂润滑弹流润滑油膜的影响。
5、分析了不同物理属性、不同粒径和质量分数的微纳米颗粒对润滑脂润滑性能的影响。为避免润滑脂添加剂对试验结果的影响，自制了一种不含添加剂的复合锂基润滑脂作为基础脂，给出了基础脂的配方和制备工艺流程。并在基础脂中加入不同粒径、质量分数的硬质脆性颗粒SiO2和软质塑性颗粒Cu作为试验样品，利用四球摩擦磨损试验机测试了润滑脂样品的摩擦系数和试验温度随时间变化的关系。
With the development of industrial, harsh conditions are widely exists in machinecomponents, for example: high temperature，over loading and high speed shearing,therebythe demands on lubricant properties and relative theory research increasingly high. After alarge number of scholars efforts, the lubrication theory and measuring apparatus for slidersurface contact, line contact and point contact problems of liquid lubrication had beenresolved well; furthermore, comprehensive investigation on the lubrication mechanism fromthe macro and micro sides respectively, all these works made a positive influence on theapplication of liquid lubricant. As a main part of automotive, wheel hub bearings usuallyadopt grease for the lubricant, due to the special structure and property, the distinguishes ofapplication and theory study for grease are noticeable which compared to liquid lubricant. Atpresent, the study of grease puts particular emphasis on application sides, such asdevelopment of high-performance grease and relatively additive, the methods ordinarilyaccording to the experience and lots of experiment investigations. Consequently, discussingthe lubrication mechanism and perfect the lubrication theory of grease, and applying thetheory study conclusions to practices, there are a lot of problems still need to be resovled.
Firstly, a generalized form of Reynolds equation for grease lubrication is derived, andaims at the lubrication failure which discovered in the statistical analysis of the failured wheelhub bearings, the effects of lubrication factor on bearing life and capability are analyzed. Then,the final expression forms of lubrication failure for wheel hub bearing are summarized:defects on race-way and solid particles in grease. Finally, the influences of defect and solidparticles on grease EHL are discussed by theory and experimental method. Consequently, thispaper may perfect the study of grease EHL theory, and guide the analysis of bearing failureand application of grease additive. The research works of this paper mainly consist offollowing parts:
1、A generalized form of Reynolds equation for grease lubrication is derived, andaccording to the different grease lubrication problems, put out the correspongding greaselubrication equation.
2、The failure wheel hub bearings are counted, the effects of lubrication on bearing lifeand several failure modes which caused by the undesirable lubrication are analyzed. Used thegrease EHL analysis the phenomenon that for the outer ring fixed, inner ring rotating with theshaft ball bearing type, the inner ring race-way compared with the outer ring race-way ismore likely to appearance wear and fatigue failure.
3、The effect of surface defects on film pressure and thickness of grease EHL areanalyzed, and the correctness of numerical calculation is proved by experimental methods.Theeffect of dents and bumps in the race-way surface on the distribution of film pressure andthickness for line contact and point contact grease EHL are analyzed by numerical calculationmethod, include the size and location of the dents and bumps.Furthermore, through the SEMand EDS analyzing for the edge and core of surface dent and bump to proving the correctnessof numerical calculation.
4、The Reynolds equation of line contact and point contact grease EHL for exist a solidparticle in grease is detailed derived. The source of solid particles in wheel hub bearing grease,and the relationship between the particle number and diameter are analyzed by experimentalmethod and statistical theory. The effect of center location, velocity and size of solid particleon line contact grease EHL, and the velocity and size of solid particle on point contact greaseEHL are analyzed.
5、The influence of different physical property, diameter and massfraction of submicroparticle on lubricating property of grease are analyzed. In order to prevent the influence ofgrease additive on the experiment results, self-made a lithium complex grease withoutadditive, and offer the formula and preparation process. The test samples are the grease whichmixed by brittle particle SiO2and ductile particle Cu with different diameter and massfraction,and the friction coefficient and the relationship between the test temperature and times ofsamples are tested by used four-ball tester.
引文
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