汽车水泵轴承动力学性能、热学性能与疲劳寿命计算方法研究
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摘要
水泵轴连轴承具有结构紧凑、安装方便等优点,广泛用于汽车、纺织机械、工程机械等内燃机的冷却水泵中。随着现代内燃机的发展,对水泵轴承的工作性能,如运转速度、运行精度、耐热性和使用寿命等提出了更高的要求。如何准确高效地评估水泵轴承在具体应用中的各种性能指标从而实现水泵轴承的设计优化,一直以来都是工程领域的研究热点和难题。本文以WR型汽车水泵轴承为研究对象,从水泵轴承的受力和运动特性、轴承-转子系统动力学特性、热学特性和疲劳寿命等几个方面展开了较为系统深入的研究,主要研究内容和取得的成果包括：
(1)在综合考虑转轴挠曲变形、润滑剂流体动压效应、滚动体离心力和轴承游隙等因素影响的基础上,建立了柔性-动压条件下的汽车水泵轴连轴承内部载荷分布和变形计算模型,能够实现对水泵轴承两滚动体列的受载、内部载荷分布及位移的准确高效计算。根据该模型系统研究了转轴挠曲变形、润滑剂动压效应、轴承转速与载荷大小对水泵轴承两滚动体列载荷分布和位移的影响规律。
(2)考虑流体润滑膜和转轴偏斜的影响,构建了汽车水泵轴承两滚动体列各方向刚度和油膜阻尼系数的理论计算方法,实现了对不同转速下轴承刚度和阻尼较为准确的计算。计入轴上零部件的转动惯量与陀螺效应、油膜作用下的轴承刚度与阻尼,建立了非对称水泵轴承转子系统改进型传递矩阵分析模型,并利用该模型对水泵轴承-转子系统的不平衡响应和VC振动响应进行了分析计算,得到了不同转速下水泵轴承的振动响应振幅曲线以及两滚动体列的频谱与轴心轨迹图。研究了带轮不平衡量与风扇不平衡量大小和空间方位关系对水泵轴承转子系统振动特性的影响规律,得到了使转子系统各轴向位置不平衡响应振幅最小时的带轮与风扇不平衡量方位差及其大小的比例关系。
(3)建立了水泵轴承拟动力学发热分析模型,考虑了润滑剂流体动压效应、转轴挠曲变形以及滚动体离心力对轴承内部载荷分布的影响以及润滑乏油和接触椭圆截断对滚动体-滚道接触流动动压滚动摩擦力的影响。利用该发热计算模型对水泵轴承的发热特性进行了实例计算研究,得到了水泵轴承各滚动体-滚道间的滑动摩擦切应力分布、滚动体-保持架兜孔作用力、轴承两滚动体列的发热率周向分布以及轴承总发热随载荷和转速的变化曲线。
(4)设计和搭建了一台水泵轴承温升试验装置,测试了水泵轴承在不同工况下两滚动体列的外圈温升曲线,并针对该试验装置,利用热网格法建立了瞬态热分析模型,对各种试验工况下水泵轴承的瞬态温度场进行了理论计算。理论计算得到的轴承外圈温升曲线与试验测得温升曲线具有较好的一致性,从而验证了所构建的水泵轴承发热计算模型的正确性。
(5)基于ISO标准推荐的寿命系统法,综合考虑转轴挠曲变形与润滑剂流体动压效应引起的轴承非标准载荷分布以及轴承-转子系统的振动的影响,对水泵轴承各组件的疲劳寿命进行了实例计算研究,得到了转轴挠曲变形、润滑剂流体动压效应、轴承转速、风扇与带轮不平衡量等因素引起的轴承-转子系统振动对水泵轴承的疲劳寿命的影响规律。
本文的研究成果能够为准确评估水泵轴连轴承的工作性能进而实现优化的轴承设计和合理的工况匹配提供理论支撑。
The coaxial water pump bearing is widely used in the water cooling systems of the combustion engines of automobiles, textile machines and construction machines due to its compact structure, easy installation and so on. More excellent operating performances of this bearing such as higher running accuracy, better heat resistance and longer fatigue life are required to satisfy the development of modern combustion engines. However, how to accurately evaluate these operating perpormances in the specific bearing applications and eventually optimize the bearing design is a difficult problem puzzling bearing engineers and so it is always a research hotspot in the rolling bearing industry. In this dissertation, the automobile water pump bearing is taken as the research object. The loads and motions of bearing components, the dynamic and theromal performances of the bearing-rotor system, and the bearing fatigue life are investigated in detail. The research contents and achievements of this dissertation include following aspects:
(1) A new calculation model based on flexible-hydrodynamic condition is established to accurately and rapidly calculate the loadings, internal load distributions and displacements of the automobile water pump bearing, in which the deflection of bearing spindle, the hydrodynamic effects at raceway-rolling element contacts, the centrifugal forces of rolling elements and the alterable clearances of bearing are all considered. Making use of this model, the influence rules of the deflection of the bearing spindle, the hydrodynamic effect, the bearing rotational speed and the load carried by the bearing on the bearing internal load distributions and displacements are specifically studied.
(2) Taking the influences of the spindle deflection and lubrication film into consideration, the theoretical calculation methods of the bearing stiffnesses and dampings along various directions are derived for water pump bearings running under different speeds and loads. A modified transfer matix method is developed to analyze the vibration characteristics of the asymmetric rotor-water pump bearing system, considering the rotary inertias and gyroscopic moments of all components within the rotor system and the bearing stiffnesses and dampings related to the bearing speed and load. With this modified method, the vibrations of the rotor-water pump bearing system due to the mass unbalances of system components and the varying compliance (VC) of the bearing are calculated and analyzed. The response amplitudes under different bearing rotational speeds, the frequency spectra and axis orbits of two rolling element rows of the bearing are obtained. The influences of the cooling fan and driving pulley unbalanes including their magnitudes and azimuths on the vibration of the rotor-water pump bearing system are also investigated and the optimum azimuth differences and magnitude ratios between the fan and pulley unbalances are obtained to minimize the vibration responses at individual axial positons along the rotor.
(3) An improved quasi-dynamic model used to calculate the heat generations of the water pump bearing is proposed. In this model, the influence of the spindle deflection, the lubricant hydrodynamic effect and rolling element centrifugal forces on the bearing internal load distribution and the influence of contact ellipse truncation and lubrication starvation on the hydrodynamic rolling force at each rolling element-raceway contact are all considered.The analysis of water pump bearing heat generation performance are conducted by an example calculation. The sliding frictional shear stress distributions over the rolling element-raceway contacts, cage pocket-rolling elment normal contact loads and heat generation rates at all rolling elment azimuth angles, and the relationship curves of the bearing total heat generation rate versus the bearing speed and load are obtained.
(4) An experimental apparatus is designed and built to test the temperature rises of the water pump bearing under different operating conditions. According to the heat generation rates calculated with the improved quasi-dynamic model, transient thermal analysis for this apparatus is performed using a network approach. The temperature rises of the bearing outer ring got from the thermal analysis agree well with those measured from the experimental apparatus and so the heat generation calculation model developed for the water pump bearing is validated.
(5) The individual fatigue lives of the bearing components and then the total fatigue live of the bearing are predicted based on the systems approach of bearing fatigue life calculation proposed by the ISO standard and further considering the nonstandard internal load distributions of the bearing and the vibrations of the rotor-bearing system. The influence rules of the spindle deflection, the hydrodynamic effects, the bearing rotational speed and the rotor-bearing system vibrations on the fatigue life of the water pump bearing are obtained.
The researches and achievements obtained in this dissertation can provide theoretical foundations for evaluating the operation performances of the water pump bearing accurately and further for optimizing the bearing design and matching the practical operating conditions reasonably for the bearing.
(1)在综合考虑转轴挠曲变形、润滑剂流体动压效应、滚动体离心力和轴承游隙等因素影响的基础上,建立了柔性-动压条件下的汽车水泵轴连轴承内部载荷分布和变形计算模型,能够实现对水泵轴承两滚动体列的受载、内部载荷分布及位移的准确高效计算。根据该模型系统研究了转轴挠曲变形、润滑剂动压效应、轴承转速与载荷大小对水泵轴承两滚动体列载荷分布和位移的影响规律。
(2)考虑流体润滑膜和转轴偏斜的影响,构建了汽车水泵轴承两滚动体列各方向刚度和油膜阻尼系数的理论计算方法,实现了对不同转速下轴承刚度和阻尼较为准确的计算。计入轴上零部件的转动惯量与陀螺效应、油膜作用下的轴承刚度与阻尼,建立了非对称水泵轴承转子系统改进型传递矩阵分析模型,并利用该模型对水泵轴承-转子系统的不平衡响应和VC振动响应进行了分析计算,得到了不同转速下水泵轴承的振动响应振幅曲线以及两滚动体列的频谱与轴心轨迹图。研究了带轮不平衡量与风扇不平衡量大小和空间方位关系对水泵轴承转子系统振动特性的影响规律,得到了使转子系统各轴向位置不平衡响应振幅最小时的带轮与风扇不平衡量方位差及其大小的比例关系。
(3)建立了水泵轴承拟动力学发热分析模型,考虑了润滑剂流体动压效应、转轴挠曲变形以及滚动体离心力对轴承内部载荷分布的影响以及润滑乏油和接触椭圆截断对滚动体-滚道接触流动动压滚动摩擦力的影响。利用该发热计算模型对水泵轴承的发热特性进行了实例计算研究,得到了水泵轴承各滚动体-滚道间的滑动摩擦切应力分布、滚动体-保持架兜孔作用力、轴承两滚动体列的发热率周向分布以及轴承总发热随载荷和转速的变化曲线。
(4)设计和搭建了一台水泵轴承温升试验装置,测试了水泵轴承在不同工况下两滚动体列的外圈温升曲线,并针对该试验装置,利用热网格法建立了瞬态热分析模型,对各种试验工况下水泵轴承的瞬态温度场进行了理论计算。理论计算得到的轴承外圈温升曲线与试验测得温升曲线具有较好的一致性,从而验证了所构建的水泵轴承发热计算模型的正确性。
(5)基于ISO标准推荐的寿命系统法,综合考虑转轴挠曲变形与润滑剂流体动压效应引起的轴承非标准载荷分布以及轴承-转子系统的振动的影响,对水泵轴承各组件的疲劳寿命进行了实例计算研究,得到了转轴挠曲变形、润滑剂流体动压效应、轴承转速、风扇与带轮不平衡量等因素引起的轴承-转子系统振动对水泵轴承的疲劳寿命的影响规律。
本文的研究成果能够为准确评估水泵轴连轴承的工作性能进而实现优化的轴承设计和合理的工况匹配提供理论支撑。
The coaxial water pump bearing is widely used in the water cooling systems of the combustion engines of automobiles, textile machines and construction machines due to its compact structure, easy installation and so on. More excellent operating performances of this bearing such as higher running accuracy, better heat resistance and longer fatigue life are required to satisfy the development of modern combustion engines. However, how to accurately evaluate these operating perpormances in the specific bearing applications and eventually optimize the bearing design is a difficult problem puzzling bearing engineers and so it is always a research hotspot in the rolling bearing industry. In this dissertation, the automobile water pump bearing is taken as the research object. The loads and motions of bearing components, the dynamic and theromal performances of the bearing-rotor system, and the bearing fatigue life are investigated in detail. The research contents and achievements of this dissertation include following aspects:
(1) A new calculation model based on flexible-hydrodynamic condition is established to accurately and rapidly calculate the loadings, internal load distributions and displacements of the automobile water pump bearing, in which the deflection of bearing spindle, the hydrodynamic effects at raceway-rolling element contacts, the centrifugal forces of rolling elements and the alterable clearances of bearing are all considered. Making use of this model, the influence rules of the deflection of the bearing spindle, the hydrodynamic effect, the bearing rotational speed and the load carried by the bearing on the bearing internal load distributions and displacements are specifically studied.
(2) Taking the influences of the spindle deflection and lubrication film into consideration, the theoretical calculation methods of the bearing stiffnesses and dampings along various directions are derived for water pump bearings running under different speeds and loads. A modified transfer matix method is developed to analyze the vibration characteristics of the asymmetric rotor-water pump bearing system, considering the rotary inertias and gyroscopic moments of all components within the rotor system and the bearing stiffnesses and dampings related to the bearing speed and load. With this modified method, the vibrations of the rotor-water pump bearing system due to the mass unbalances of system components and the varying compliance (VC) of the bearing are calculated and analyzed. The response amplitudes under different bearing rotational speeds, the frequency spectra and axis orbits of two rolling element rows of the bearing are obtained. The influences of the cooling fan and driving pulley unbalanes including their magnitudes and azimuths on the vibration of the rotor-water pump bearing system are also investigated and the optimum azimuth differences and magnitude ratios between the fan and pulley unbalances are obtained to minimize the vibration responses at individual axial positons along the rotor.
(3) An improved quasi-dynamic model used to calculate the heat generations of the water pump bearing is proposed. In this model, the influence of the spindle deflection, the lubricant hydrodynamic effect and rolling element centrifugal forces on the bearing internal load distribution and the influence of contact ellipse truncation and lubrication starvation on the hydrodynamic rolling force at each rolling element-raceway contact are all considered.The analysis of water pump bearing heat generation performance are conducted by an example calculation. The sliding frictional shear stress distributions over the rolling element-raceway contacts, cage pocket-rolling elment normal contact loads and heat generation rates at all rolling elment azimuth angles, and the relationship curves of the bearing total heat generation rate versus the bearing speed and load are obtained.
(4) An experimental apparatus is designed and built to test the temperature rises of the water pump bearing under different operating conditions. According to the heat generation rates calculated with the improved quasi-dynamic model, transient thermal analysis for this apparatus is performed using a network approach. The temperature rises of the bearing outer ring got from the thermal analysis agree well with those measured from the experimental apparatus and so the heat generation calculation model developed for the water pump bearing is validated.
(5) The individual fatigue lives of the bearing components and then the total fatigue live of the bearing are predicted based on the systems approach of bearing fatigue life calculation proposed by the ISO standard and further considering the nonstandard internal load distributions of the bearing and the vibrations of the rotor-bearing system. The influence rules of the spindle deflection, the hydrodynamic effects, the bearing rotational speed and the rotor-bearing system vibrations on the fatigue life of the water pump bearing are obtained.
The researches and achievements obtained in this dissertation can provide theoretical foundations for evaluating the operation performances of the water pump bearing accurately and further for optimizing the bearing design and matching the practical operating conditions reasonably for the bearing.
引文
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