重型静压推力轴承综合物理场研究
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摘要
重型静压推力轴承是重型数控装备的关键部件,其性能优劣直接影响设备的加工质量和运行效率。由于国内大型零件机械加工精度达不到要求,使得静压轴承工作时摩擦副间的间隙不均匀,在高速重载的工况下,轴承本体及油膜的温度随工作台转速的升高而升高,使承载油膜变薄,进而产生静压轴承变形导致润滑失效,使油垫的实际结构偏离理论设计模型,限制了转速。因此,进行重型静压推力轴承间隙油膜流场、压力场、温度场以及静压轴承的变形场(综合物理场)的研究是解决问题的关键。
本文在总结了国内外对静压推力轴承结构优化、性能计算、刚度特性、阻尼特性和实验装置研究的基础上,以多油垫圆导轨重型静压推力轴承为研究对象,对变粘度条件下的重型静压推力轴承综合物理场进行了系统的理论研究,主要包括以下几个方面：
首先,在对两平行平板和环形油垫的润滑机理研究基础上,得到了简化后的静压推力轴承模型,以单个油垫为研究对象,利用计算流体力学、润滑理论、摩擦学理论,建立了间隙油膜的粘温方程,并采用B-Spline曲线拟合出粘温曲线,在此基础上建立变粘度下重型静压推力轴承单个油垫上油膜相应的数学模型,包括流量方程、承载能力方程、油膜刚度方程、摩擦力方程、摩擦功率方程及温升方程。
其次,基于有限体积法,针对实际物理模型(由工厂提供数据建立的模型),在等粘度和变粘度条件下,分别对静压轴承间隙油膜的压力场、速度场和温度场进行三维场特征分析,得到粘度对静压推力轴承性能的影响规律。
再次,在变粘度条件下又模拟了不同转速及腔深条件下油膜的压力场、动压及温度场分布情况,揭示了转速及油腔深度对油膜压力场、动压及温度场的影响规律。同时在不同膜厚下数值模拟了油膜的温度分布情况,探讨了膜厚对油膜温度场的影响情况。
另外,建立了重型静压推力轴承旋转工作台和多垫圆导轨底座的有限元模型,利用对油膜温度场计算得到的数值模拟结果作为体载荷施加给工作台及底座得到静压轴承热变形。考虑旋转工作台的自重及承载,把对油膜压力场计算得到的数值模拟结果耦合到与油膜接触的上、下环面上得到力变形。最终把力变形场与热变形场叠加后得到静压推力轴承的总变形结果。
最后,为了验证本文所建数学模型及数值模拟结果的正确性,在双柱立式车床DVT1000×50/150Q-NC上,对不同工况下静压推力轴承的油膜压力、油膜厚度进行实际测量。结果表明：试验测得的油膜压力值与数值模拟结果及理论计算结果比较吻合,说明了对静压推力轴承压力场数值模拟结果的可信性及理论数学模型建立的正确性；通过油膜厚度试验得到了工作台、底座与油膜接触的上、下面的变形情况,变形后的油膜在径向上由内侧到外侧呈喇叭形状,这与通过有限元方法计算变形场得到的结论是一致的。
通过对重型静压推力轴承综合物理场的研究,揭示了多油垫静压轴承间隙流体的流动规律,探明了此类静压推力轴承的失效机理,为工程实际中静压推力轴承设计、仿真分析及性能研究提供了理论依据。
The heavy hydrostatic thrust bearing is the key component of the heavy numerical control equipment; the machining quality and the operating efficiency are directly influenced by its performance. The gaps between friction pairs are uneven because of the low machining precision of the large-scale components in domestic. Under working situations of high speed and heavy load, the bearing body and the temperature of the lubricant film rise alonge with the speed of the worktable increasing, that causes the load bearing lubricant film to thin, as a result, the lubrication is failed due to the deformation of the hydrostatic bearing, then, the actual structure of the oil pad is deviated from theoretical designing model, the spindle speed is also limited. Consequently, the studying on the flow field, the pressure field, the temperature field and the deformation field of heavy hydrostatic bearing is the key to solveing all those problems.
This thesis based on the summary of studying on the structure optimization, performance calculation, rigidity property, damping property and experimental apparatus of the hydrostatic thrust bearing, takes the hydrostatic thrust bearing with the multi-oil pad circular guideway as the research object, to carry on the theory research to the integrated physical fields of the heavy hydrostatic thrust bearing with variable viscosity, The followings are mainly included:
First of all, the thesis based on the lubrication mechanism research of two parallel plates and circular oil pad obtains the simplified model of the hydrostatic thrust bearing, then, the viscosity-temperature equation of the gap film is set up, and the viscosity-temperature curve is fitted by B-Spline curve. Further, the mathematical model of the single oil pad is established, that includs the flow equation, the carrying equation, the oil film rigidity equation, the friction equation, the friction power equation and the temperature rise equation.
Secondly, aiming at the actual physical model (set up by data of factory offered), the pressure field, the flow field and the temperature field of heavy hydrostatic bearing based on the FVM(finite volume method) are respectively carried on the analysis of three-dimensional characteristics in constant and variable viscosity condition, then the Influence Law of the viscosity to the hydrostatic thrust bearing is found.
Thirdly, the pressure field, the dynamic pressure and the temperature field of lubricant film in different rotating velocity and cavity depth are respectively simulated under considering the variable viscosity condition. Influence laws of rotating velocity and cavity depth to the pressure field, the dynamic pressure and the temperature field of oil film are also found. At the same time, temperature distributions of oil film in different film thickness are simulated, and influence of film thickness on the temperature field also is formulated.
Furthermore, the finite element models of rotating worktable and multiple oil pad circular guideway of heavy hydrostatic thrust bearing are established. Numerical simulation results of oil film temperature field are treated as a body load applied to the worktable to calculate thermal deformation. Considering the weight of rotating worktable and load on it, numerical simulation results of lubricant film pressure field are coupled to upper and lower ring surface and base contacting with lubricant film to calculate force deformation. Finally thermal deformation field and force deformation field are superposed to obtain the total deformation of hydrostatic thrust bearing.
At last, in order to validate the mathematical model and the numerical simulation results, practical measures of lubricant film pressure and thickness of hydrostatic thrust bearing are performed on the double column vertical lathe—DVT1000×50/150Q-NC in different working conditions. The results demonstrate that the theoretical results of lubricant film pressure are consistent with the measurement results and numerical simulation results. It shows that the results of numerical simulation of hydrostatic thrust bearing pressure field and the established mathematical theory model are creditable; and the upper and lower ring surface deformation of worktable and base contacting with oil film through lubricant film thickness tests is obtained, the shape of lubricant film deformation from inside to outside in radial is a bugle, that accords with deformation field calculated in the finite element method.
With the research on integrated physical field of heavy hydrostatic thrust bearing, this thesis reveals the flow law of gap fluid of hydrostatic bearing with multiple oil pad and the failure mechanism of hydrostatic thrust bearing. It provides theoretical basis for design, simulation analysis and performance research of hydrostatic thrust bearing in practical projects.
本文在总结了国内外对静压推力轴承结构优化、性能计算、刚度特性、阻尼特性和实验装置研究的基础上,以多油垫圆导轨重型静压推力轴承为研究对象,对变粘度条件下的重型静压推力轴承综合物理场进行了系统的理论研究,主要包括以下几个方面：
首先,在对两平行平板和环形油垫的润滑机理研究基础上,得到了简化后的静压推力轴承模型,以单个油垫为研究对象,利用计算流体力学、润滑理论、摩擦学理论,建立了间隙油膜的粘温方程,并采用B-Spline曲线拟合出粘温曲线,在此基础上建立变粘度下重型静压推力轴承单个油垫上油膜相应的数学模型,包括流量方程、承载能力方程、油膜刚度方程、摩擦力方程、摩擦功率方程及温升方程。
其次,基于有限体积法,针对实际物理模型(由工厂提供数据建立的模型),在等粘度和变粘度条件下,分别对静压轴承间隙油膜的压力场、速度场和温度场进行三维场特征分析,得到粘度对静压推力轴承性能的影响规律。
再次,在变粘度条件下又模拟了不同转速及腔深条件下油膜的压力场、动压及温度场分布情况,揭示了转速及油腔深度对油膜压力场、动压及温度场的影响规律。同时在不同膜厚下数值模拟了油膜的温度分布情况,探讨了膜厚对油膜温度场的影响情况。
另外,建立了重型静压推力轴承旋转工作台和多垫圆导轨底座的有限元模型,利用对油膜温度场计算得到的数值模拟结果作为体载荷施加给工作台及底座得到静压轴承热变形。考虑旋转工作台的自重及承载,把对油膜压力场计算得到的数值模拟结果耦合到与油膜接触的上、下环面上得到力变形。最终把力变形场与热变形场叠加后得到静压推力轴承的总变形结果。
最后,为了验证本文所建数学模型及数值模拟结果的正确性,在双柱立式车床DVT1000×50/150Q-NC上,对不同工况下静压推力轴承的油膜压力、油膜厚度进行实际测量。结果表明：试验测得的油膜压力值与数值模拟结果及理论计算结果比较吻合,说明了对静压推力轴承压力场数值模拟结果的可信性及理论数学模型建立的正确性；通过油膜厚度试验得到了工作台、底座与油膜接触的上、下面的变形情况,变形后的油膜在径向上由内侧到外侧呈喇叭形状,这与通过有限元方法计算变形场得到的结论是一致的。
通过对重型静压推力轴承综合物理场的研究,揭示了多油垫静压轴承间隙流体的流动规律,探明了此类静压推力轴承的失效机理,为工程实际中静压推力轴承设计、仿真分析及性能研究提供了理论依据。
The heavy hydrostatic thrust bearing is the key component of the heavy numerical control equipment; the machining quality and the operating efficiency are directly influenced by its performance. The gaps between friction pairs are uneven because of the low machining precision of the large-scale components in domestic. Under working situations of high speed and heavy load, the bearing body and the temperature of the lubricant film rise alonge with the speed of the worktable increasing, that causes the load bearing lubricant film to thin, as a result, the lubrication is failed due to the deformation of the hydrostatic bearing, then, the actual structure of the oil pad is deviated from theoretical designing model, the spindle speed is also limited. Consequently, the studying on the flow field, the pressure field, the temperature field and the deformation field of heavy hydrostatic bearing is the key to solveing all those problems.
This thesis based on the summary of studying on the structure optimization, performance calculation, rigidity property, damping property and experimental apparatus of the hydrostatic thrust bearing, takes the hydrostatic thrust bearing with the multi-oil pad circular guideway as the research object, to carry on the theory research to the integrated physical fields of the heavy hydrostatic thrust bearing with variable viscosity, The followings are mainly included:
First of all, the thesis based on the lubrication mechanism research of two parallel plates and circular oil pad obtains the simplified model of the hydrostatic thrust bearing, then, the viscosity-temperature equation of the gap film is set up, and the viscosity-temperature curve is fitted by B-Spline curve. Further, the mathematical model of the single oil pad is established, that includs the flow equation, the carrying equation, the oil film rigidity equation, the friction equation, the friction power equation and the temperature rise equation.
Secondly, aiming at the actual physical model (set up by data of factory offered), the pressure field, the flow field and the temperature field of heavy hydrostatic bearing based on the FVM(finite volume method) are respectively carried on the analysis of three-dimensional characteristics in constant and variable viscosity condition, then the Influence Law of the viscosity to the hydrostatic thrust bearing is found.
Thirdly, the pressure field, the dynamic pressure and the temperature field of lubricant film in different rotating velocity and cavity depth are respectively simulated under considering the variable viscosity condition. Influence laws of rotating velocity and cavity depth to the pressure field, the dynamic pressure and the temperature field of oil film are also found. At the same time, temperature distributions of oil film in different film thickness are simulated, and influence of film thickness on the temperature field also is formulated.
Furthermore, the finite element models of rotating worktable and multiple oil pad circular guideway of heavy hydrostatic thrust bearing are established. Numerical simulation results of oil film temperature field are treated as a body load applied to the worktable to calculate thermal deformation. Considering the weight of rotating worktable and load on it, numerical simulation results of lubricant film pressure field are coupled to upper and lower ring surface and base contacting with lubricant film to calculate force deformation. Finally thermal deformation field and force deformation field are superposed to obtain the total deformation of hydrostatic thrust bearing.
At last, in order to validate the mathematical model and the numerical simulation results, practical measures of lubricant film pressure and thickness of hydrostatic thrust bearing are performed on the double column vertical lathe—DVT1000×50/150Q-NC in different working conditions. The results demonstrate that the theoretical results of lubricant film pressure are consistent with the measurement results and numerical simulation results. It shows that the results of numerical simulation of hydrostatic thrust bearing pressure field and the established mathematical theory model are creditable; and the upper and lower ring surface deformation of worktable and base contacting with oil film through lubricant film thickness tests is obtained, the shape of lubricant film deformation from inside to outside in radial is a bugle, that accords with deformation field calculated in the finite element method.
With the research on integrated physical field of heavy hydrostatic thrust bearing, this thesis reveals the flow law of gap fluid of hydrostatic bearing with multiple oil pad and the failure mechanism of hydrostatic thrust bearing. It provides theoretical basis for design, simulation analysis and performance research of hydrostatic thrust bearing in practical projects.
引文
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