活塞组多物理场耦合非线性问题及环组机油消耗改进设计研究
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摘要
活塞组部件的设计对内燃机的动力性、经济性以及振动噪声、摩擦损失和排放性能都有着重要的影响。本文针对活塞组多物理场耦合非线性问题进行了深入细致的理论分析和试验研究,并结合企业工程问题,对一台车用柴油机活塞组进行了相应的改进设计和应用试验,达到了预期的研究目标。
论文可以概括为两大部分。第一部分是活塞组机械特性的研究。对活塞温度场、强度和高周疲劳问题进行了系统地研究。确定了活塞热边界的计算方法,通过活塞温度场试验数据对仿真模型进行了校核,建立了活塞三维热机耦合强度分析模型,分析了活塞在不同载荷作用下的应力状况和径向变形情况,对活塞高周疲劳进行了数值预测；对活塞二阶运动及其影响因素进行了系统地研究,研究了活塞对缸套的敲击过程和常用评价指标,分析了活塞组不同设计参数对活塞运动特性的影响；对活塞激励传递途径和发动机结构固有特性进行了系统地研究。创新设计了活塞组受力的传递路径试验,剖析了气体力激励和活塞激励的传递途径,提出了发动机子部件和整机结构固有特性的分析思路,进而分解研究了发动机各主要激励源对整机结构振动和辐射噪声的影响,为发动机低噪声设计提供了重要参考依据。
第二部分是活塞组的密封性能及其相关的机油消耗研究。首先是活塞环组的密封原理和活塞环动力学理论的研究,建立了环组密封特性和环组动力学数值分析模型,得到了环组总窜气量和各环表面的气体流量特性,并利用窜气量试验对分析结果进行了验证；采用称重法进行了机油消耗试验,得到了不同转速和负荷下总机油消耗和窜油量,研究了机油消耗随转速和负荷的变化规律；研究了活塞环组机油消耗的产生机理和相关理论,建立了活塞环组数值仿真分析模型,提出了活塞环组机油消耗计算模型的标定方法,并根据此方法利用试验数据对仿真模型进行了标定,最后通过标定后的模型对各个工况下的机油消耗情况进行了预测和影响因素评估；结合CAE仿真分析结果,对活塞各环岸尺寸和裙部型线进行了调整,并对第一道活塞环进行了改进设计,以改善活塞的二阶运动和降低该机型机油消耗；进行了多台样机的机油消耗对比试验,结果表明,改进后发动机的机油消耗特性明显改善,达到了预期的效果。同时表明,试验结果与CAE预测趋势是一致的。
本文拓展了内燃机活塞组多物理场耦合非线性问题的理论研究,补充和发展了数字化设计在活塞组结构设计中的应用技术,取得了一系列具有工程实用价值的新结论和成果,为活塞组低噪声、低摩擦、低机油消耗设计提供了重要参考依据。
The design of piston group exerts great impact on vibration noise performance, friction loss and emission performance of internal combustion engine. This dissertation focuses on multi-physical nonlinear problems of the piston group experimentally and numerically, improves the design of piston group, and solves practical engineering problems based on a diesel engine.
This dissertation mainly consists of two parts. The first part investigates the mechanical characteristics of piston group. The temperature field, strength and high cycle fatigue problems of the piston are studied systematically. The calculation model for the piston thermal boundary condition is established and calibrated by test data. The3d coupling strength analysis model for piston group is built, analyzing the piston stress and radial deformation condition under various loads and predicting piston high cycle fatigue results. The dynamic simulation model for piston secondary motion is built, analyzing the slap of piston on cylinder liner and its evaluation index, and the influence of piston parameters on its secondary motion characteristics. This dissertation systematically investigates the transmission path of piston excitation and engine structure characteristics and designs innovative experiments to explore the transmission path between piston and gas excitations, to analyze the inherent properties of engine components and the whole engine, and to study the effects of main excitations on the vibration and noise radiation of engine, which provides reference for engine low noise design.
The second part investigates the sealing of piston group and subsequent lubricating oil consumption (LOC). The sealing principle of piston ring pack and the theory of piston ring dynamics are carried out, and the simulation model for ring pack sealing characteristics and ring dynamics is established, analyzing gas flow characteristics of piston ring surfaces and verified by flow-by test. The total LOC and flow-by of engine are obtained through the LOC experiments by weighing method, then the relationship between engine working conditions and LOC is gotten. The generation mechanism of LOC and related theory of ring-pack are expounded, and the LOC predication model for ring-pack is established and calibrated by the test data according to the method proposed in this dissertation. In addition, through the calibrated simulation model, the LOC under different working conditions is predicated and the influence factors of LOC are studied. Combined with simulation results, the size of piston land and skirt profile are modified, and the first ring is modified in order to reduce the engine LOC. The comparison test of many sample engines shows that the LOC of modified engine drops significantly, satisfies the design requirements, and fits the CAE predication very well.
The studies in this dissertation expand the researches on multi-physical nonlinear problems of the piston group of internal combustion engine, improve and enrich the structure design of piston group using the numeral simulation technology, and achieve several innovative models with great engineering application value, which provides important reference for piston ring low noise, low friction and low LOC design.
论文可以概括为两大部分。第一部分是活塞组机械特性的研究。对活塞温度场、强度和高周疲劳问题进行了系统地研究。确定了活塞热边界的计算方法,通过活塞温度场试验数据对仿真模型进行了校核,建立了活塞三维热机耦合强度分析模型,分析了活塞在不同载荷作用下的应力状况和径向变形情况,对活塞高周疲劳进行了数值预测；对活塞二阶运动及其影响因素进行了系统地研究,研究了活塞对缸套的敲击过程和常用评价指标,分析了活塞组不同设计参数对活塞运动特性的影响；对活塞激励传递途径和发动机结构固有特性进行了系统地研究。创新设计了活塞组受力的传递路径试验,剖析了气体力激励和活塞激励的传递途径,提出了发动机子部件和整机结构固有特性的分析思路,进而分解研究了发动机各主要激励源对整机结构振动和辐射噪声的影响,为发动机低噪声设计提供了重要参考依据。
第二部分是活塞组的密封性能及其相关的机油消耗研究。首先是活塞环组的密封原理和活塞环动力学理论的研究,建立了环组密封特性和环组动力学数值分析模型,得到了环组总窜气量和各环表面的气体流量特性,并利用窜气量试验对分析结果进行了验证；采用称重法进行了机油消耗试验,得到了不同转速和负荷下总机油消耗和窜油量,研究了机油消耗随转速和负荷的变化规律；研究了活塞环组机油消耗的产生机理和相关理论,建立了活塞环组数值仿真分析模型,提出了活塞环组机油消耗计算模型的标定方法,并根据此方法利用试验数据对仿真模型进行了标定,最后通过标定后的模型对各个工况下的机油消耗情况进行了预测和影响因素评估；结合CAE仿真分析结果,对活塞各环岸尺寸和裙部型线进行了调整,并对第一道活塞环进行了改进设计,以改善活塞的二阶运动和降低该机型机油消耗；进行了多台样机的机油消耗对比试验,结果表明,改进后发动机的机油消耗特性明显改善,达到了预期的效果。同时表明,试验结果与CAE预测趋势是一致的。
本文拓展了内燃机活塞组多物理场耦合非线性问题的理论研究,补充和发展了数字化设计在活塞组结构设计中的应用技术,取得了一系列具有工程实用价值的新结论和成果,为活塞组低噪声、低摩擦、低机油消耗设计提供了重要参考依据。
The design of piston group exerts great impact on vibration noise performance, friction loss and emission performance of internal combustion engine. This dissertation focuses on multi-physical nonlinear problems of the piston group experimentally and numerically, improves the design of piston group, and solves practical engineering problems based on a diesel engine.
This dissertation mainly consists of two parts. The first part investigates the mechanical characteristics of piston group. The temperature field, strength and high cycle fatigue problems of the piston are studied systematically. The calculation model for the piston thermal boundary condition is established and calibrated by test data. The3d coupling strength analysis model for piston group is built, analyzing the piston stress and radial deformation condition under various loads and predicting piston high cycle fatigue results. The dynamic simulation model for piston secondary motion is built, analyzing the slap of piston on cylinder liner and its evaluation index, and the influence of piston parameters on its secondary motion characteristics. This dissertation systematically investigates the transmission path of piston excitation and engine structure characteristics and designs innovative experiments to explore the transmission path between piston and gas excitations, to analyze the inherent properties of engine components and the whole engine, and to study the effects of main excitations on the vibration and noise radiation of engine, which provides reference for engine low noise design.
The second part investigates the sealing of piston group and subsequent lubricating oil consumption (LOC). The sealing principle of piston ring pack and the theory of piston ring dynamics are carried out, and the simulation model for ring pack sealing characteristics and ring dynamics is established, analyzing gas flow characteristics of piston ring surfaces and verified by flow-by test. The total LOC and flow-by of engine are obtained through the LOC experiments by weighing method, then the relationship between engine working conditions and LOC is gotten. The generation mechanism of LOC and related theory of ring-pack are expounded, and the LOC predication model for ring-pack is established and calibrated by the test data according to the method proposed in this dissertation. In addition, through the calibrated simulation model, the LOC under different working conditions is predicated and the influence factors of LOC are studied. Combined with simulation results, the size of piston land and skirt profile are modified, and the first ring is modified in order to reduce the engine LOC. The comparison test of many sample engines shows that the LOC of modified engine drops significantly, satisfies the design requirements, and fits the CAE predication very well.
The studies in this dissertation expand the researches on multi-physical nonlinear problems of the piston group of internal combustion engine, improve and enrich the structure design of piston group using the numeral simulation technology, and achieve several innovative models with great engineering application value, which provides important reference for piston ring low noise, low friction and low LOC design.
引文
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