汽车轮毂轴承润滑脂研究与试验评价
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摘要
轮毂轴承作为汽车关键零部件，在承受轴向载荷与径向载荷作用的同时还起着精确导向作用，轮毂轴承一般是在高温、重载、高速等苛刻条件下工作，对润滑剂的要求也较高。汽车轮毂轴承润滑脂对轮毂轴承的使用寿命以及汽车的行驶安全起着非常重要的作用，因此对轮毂轴承润滑进行深入研究对于节省能源、提高行车安全、延长轮毂轴承使用寿命具有重要意义。
本文的主要研究工作有以下几个部分：
首先，论文通过理论分析和实验方法，研究了轮毂轴承失效形式和失效机理。通过对1200余套失效轮毂轴承进行统计分析，归纳总结出汽车轮毂轴承典型失效型式。采用红外光谱（FTIR）与MOAII原子发射光谱仪对失效轮毂轴承的润滑脂进行分析，采用扫描电镜（SEM）以及能谱(EDS)分析方法对失效轮毂轴承表面进行分析，研究了轮毂轴承失效机理。通过工况调查与失效机理研究，提出了汽车轮毂轴承润滑脂所需具备的性能参数要求。
其次，本文设计了一套润滑脂生产工艺，该工艺提出了一种润滑脂在高温炼制阶段的保护方法，有效提高了润滑脂的抗氧化能力与高温使用性能，并对润滑脂调和工艺进行改进，提高了润滑脂调和速度。文章根据润滑脂所需的生产工艺要求，研发了一套集皂化工艺、调和工艺、过滤工艺于一体的润滑脂生产设备，设计了双层夹套反应釜及其釜外循环工艺装置，并采用了预测-积分分离算法对反应釜的温度进行控制。
再次，本文根据汽车轮毂轴承对润滑脂的性能参数要求，对润滑脂的生产材料进行了分析选择，经过初次筛选，确定了四种轮毂轴承润滑脂配方，采用新设计的生产工艺与设备制备了轮毂轴承润滑脂，并对其进行了相关试验研究。对润滑脂理化指标进行了检测，结果表明，所研制的润滑脂能满足轮毂轴承对润滑脂性能参数的要求；采用FTIR技术研究了轮毂轴承润滑脂稠化剂结构，并给出了其二维与三维分子模型；采用差热分析法（TG-DSC）研究了润滑脂的高温性能，结果表明，所配润滑脂在350℃高温下热失重较小，具有较好的抗蒸发、抗氧化性能。
另外，为了进一步提高轮毂轴承润滑脂性能，本文选择性的在上述四种润滑脂基础上加入了三种不同粒径的二硫化钨固体添加剂以配制新脂。先采用扫描电镜（SEM）、能谱（EDS）、XRD、激光粒度仪、差热分析仪（TG-DSC）等方法对二硫化钨固体添加剂的微观形貌、组成、粒径以及高温性能进行了分析，结果表明，层状二硫化钨粉末具备良好的高温性能。实验将三种粒径的二硫化钨以不同的质量分数加入到轮毂轴承润滑脂中，研究对轮毂轴承润滑脂的性能改善。通过对润滑脂滴点、极压性能、抗磨性能的检测，结果表明，纳米级固体添加剂能较大幅度改善润滑脂的极压与抗磨性能，对润滑脂滴点影响较小。通过四球长磨试验研究结果表明，固体添加剂的加入，能显著降低润滑脂的摩擦系数与磨斑直径。文章给出了纳米材料在润滑脂中的流动模型，研究了润滑脂的抗磨减摩机理。采用FTIR与TG-DSC研究了纳米材料对轮毂轴承润滑脂稠化剂结构以及高温性能的影响，结果表明，纳米材料的加入对润滑脂稠化剂结构以及高温性能无显著影响。
最后，本文从研制的润滑脂中选择了综合性能较好的四种轮毂轴承润滑脂(M-15、P-15、H-15、L-15)与壳牌轮毂轴承润滑脂、克努伯轮毂轴承润滑脂以及国内汽车通用锂基润滑脂进行台架试验评价，结果表明，所研制的M-15与P-15轮毂轴承润滑脂的性能优于国内同类产品，并且达到或接近了国际先进产品水平。
As the key parts of automotive, the wheel hub bearing plays a role of bearing the axialload and radial load, also guiding the direction precisely at the same time. Wheel hubbearing usually working in harsh condition, such as high temperature, heavy load and highspeed and so on, so it demands on the properties of lubricant is very high. The bearing lifeand driving safety depends on the grease of wheel hub bearing seriously. Therefore, carryout an in-depth research on the wheel hub bearing lubrication, has an important significancefor save energy, increase driving safety and bearing life.
The main research works of this paper are the following several parts:
Firstly, investigate the failure models and mechanisms of wheel hub bearings bytheoretical and experimental methods.1200sets of failure wheel hub bearing are counted,and summarized the typical failure model of wheel hub bearing. The grease of failure wheelhub bearing are analyzed by FITR and MOA II, and the surface of failure wheel hubbearings are analyzed by SEM and EDS, in order to research for the failure mechanism ofwheel hub bearings. Index that the performance parameters for grease of wheel hub bearingby working condition investigation and failure mechanism research.
Secondly, a set of technology route for grease production is designed, which is aprotection method for grease in refining state of high temperature condition, enhancing theperformance of ant-oxidation and high temperature service for grease effectively, andenhancing the velocity of blending process by improve the blending technology. Accordingto the production process in this paper, a set of saponification, blending and filter process ofproduction equipment for grease is designed, and double jacketed reactor and the externalcirculation process piping are designed too, in addition, the prediction and integralseparation algorithm is used to control the temperature of reactor.
Thirdly, according to the demands of performance parameters for grease of wheel hubbearings, production materials of grease is analyzed and selected, after an initial screening,four types of grease formula are manufactured. The new designed production process andequipment are used to research the grease of wheel hub bearing by experimental method,the Physical and chemical indicators are tested, the results show that the indicators of greasesatisfy the demand of wheel hub bearing lubrication. The structures of thickener of grease are researched by FTIR technology, and carry out the molecular models in two-dimensionaland three-dimensional space. The high temperature performance of grease is analyzed byTG-DSC, the results show that the thermal weight loss of grease under350°C is low, andhas a nice performance of anti-evaporation and anti-oxidation.
Besides, in order to improve the performance of grease fatherly, three kinds of size fortungsten disulfide additive are selected to add in the grease, and prepare four types of newgrease. The micro morphology, composition, particle size and high temperature stability oftungsten disulfide additive are analyzed by SEM, EDS, XRD, laser particle size analyzer,TG-DSC technology and so on, the results show that layered tungsten disulfide powder witha good high temperature performance. The different size of tungsten disulfide powder addedto the grease according to the concentration of1%to5%respectively, and the droppingpoint, EP and anti-wear properties are tested. The results show that The EP and anti-wearproperties of grease are improved noticeable by mixed with solid additive of micro scale,but the effect on the dropping point slightly. Through the experiment results of four balltester rig, indicate that the friction coefficient and diameter of scar diameter are decreasednoticeable by add the solid additive into the grease. The flow model of the nano materialstreaming in the grease is carried out in this paper, and the mechanism of anti-wear andfriction reduction for grease is analyzed too. The effect of nano material on the thickenerstructure and high temperature performance are analyze by FTIR and TG-DSC technology,the results show that add the nano material into the grease has a tiny influence on thethickener structure and high temperature performance.
Finally, comparison the four kinds of new grease (M-15, P-15, H-15, L-15) with theShell and Krupp wheel hub bearing grease, and general lithium grease for domestic motorsby test rig experiments, the results show that the performance of M-15and P-15wheelbearing grease has reached or better than the similar domestic products, and reached ornearly to the international advanced level.
本文的主要研究工作有以下几个部分：
首先，论文通过理论分析和实验方法，研究了轮毂轴承失效形式和失效机理。通过对1200余套失效轮毂轴承进行统计分析，归纳总结出汽车轮毂轴承典型失效型式。采用红外光谱（FTIR）与MOAII原子发射光谱仪对失效轮毂轴承的润滑脂进行分析，采用扫描电镜（SEM）以及能谱(EDS)分析方法对失效轮毂轴承表面进行分析，研究了轮毂轴承失效机理。通过工况调查与失效机理研究，提出了汽车轮毂轴承润滑脂所需具备的性能参数要求。
其次，本文设计了一套润滑脂生产工艺，该工艺提出了一种润滑脂在高温炼制阶段的保护方法，有效提高了润滑脂的抗氧化能力与高温使用性能，并对润滑脂调和工艺进行改进，提高了润滑脂调和速度。文章根据润滑脂所需的生产工艺要求，研发了一套集皂化工艺、调和工艺、过滤工艺于一体的润滑脂生产设备，设计了双层夹套反应釜及其釜外循环工艺装置，并采用了预测-积分分离算法对反应釜的温度进行控制。
再次，本文根据汽车轮毂轴承对润滑脂的性能参数要求，对润滑脂的生产材料进行了分析选择，经过初次筛选，确定了四种轮毂轴承润滑脂配方，采用新设计的生产工艺与设备制备了轮毂轴承润滑脂，并对其进行了相关试验研究。对润滑脂理化指标进行了检测，结果表明，所研制的润滑脂能满足轮毂轴承对润滑脂性能参数的要求；采用FTIR技术研究了轮毂轴承润滑脂稠化剂结构，并给出了其二维与三维分子模型；采用差热分析法（TG-DSC）研究了润滑脂的高温性能，结果表明，所配润滑脂在350℃高温下热失重较小，具有较好的抗蒸发、抗氧化性能。
另外，为了进一步提高轮毂轴承润滑脂性能，本文选择性的在上述四种润滑脂基础上加入了三种不同粒径的二硫化钨固体添加剂以配制新脂。先采用扫描电镜（SEM）、能谱（EDS）、XRD、激光粒度仪、差热分析仪（TG-DSC）等方法对二硫化钨固体添加剂的微观形貌、组成、粒径以及高温性能进行了分析，结果表明，层状二硫化钨粉末具备良好的高温性能。实验将三种粒径的二硫化钨以不同的质量分数加入到轮毂轴承润滑脂中，研究对轮毂轴承润滑脂的性能改善。通过对润滑脂滴点、极压性能、抗磨性能的检测，结果表明，纳米级固体添加剂能较大幅度改善润滑脂的极压与抗磨性能，对润滑脂滴点影响较小。通过四球长磨试验研究结果表明，固体添加剂的加入，能显著降低润滑脂的摩擦系数与磨斑直径。文章给出了纳米材料在润滑脂中的流动模型，研究了润滑脂的抗磨减摩机理。采用FTIR与TG-DSC研究了纳米材料对轮毂轴承润滑脂稠化剂结构以及高温性能的影响，结果表明，纳米材料的加入对润滑脂稠化剂结构以及高温性能无显著影响。
最后，本文从研制的润滑脂中选择了综合性能较好的四种轮毂轴承润滑脂(M-15、P-15、H-15、L-15)与壳牌轮毂轴承润滑脂、克努伯轮毂轴承润滑脂以及国内汽车通用锂基润滑脂进行台架试验评价，结果表明，所研制的M-15与P-15轮毂轴承润滑脂的性能优于国内同类产品，并且达到或接近了国际先进产品水平。
As the key parts of automotive, the wheel hub bearing plays a role of bearing the axialload and radial load, also guiding the direction precisely at the same time. Wheel hubbearing usually working in harsh condition, such as high temperature, heavy load and highspeed and so on, so it demands on the properties of lubricant is very high. The bearing lifeand driving safety depends on the grease of wheel hub bearing seriously. Therefore, carryout an in-depth research on the wheel hub bearing lubrication, has an important significancefor save energy, increase driving safety and bearing life.
The main research works of this paper are the following several parts:
Firstly, investigate the failure models and mechanisms of wheel hub bearings bytheoretical and experimental methods.1200sets of failure wheel hub bearing are counted,and summarized the typical failure model of wheel hub bearing. The grease of failure wheelhub bearing are analyzed by FITR and MOA II, and the surface of failure wheel hubbearings are analyzed by SEM and EDS, in order to research for the failure mechanism ofwheel hub bearings. Index that the performance parameters for grease of wheel hub bearingby working condition investigation and failure mechanism research.
Secondly, a set of technology route for grease production is designed, which is aprotection method for grease in refining state of high temperature condition, enhancing theperformance of ant-oxidation and high temperature service for grease effectively, andenhancing the velocity of blending process by improve the blending technology. Accordingto the production process in this paper, a set of saponification, blending and filter process ofproduction equipment for grease is designed, and double jacketed reactor and the externalcirculation process piping are designed too, in addition, the prediction and integralseparation algorithm is used to control the temperature of reactor.
Thirdly, according to the demands of performance parameters for grease of wheel hubbearings, production materials of grease is analyzed and selected, after an initial screening,four types of grease formula are manufactured. The new designed production process andequipment are used to research the grease of wheel hub bearing by experimental method,the Physical and chemical indicators are tested, the results show that the indicators of greasesatisfy the demand of wheel hub bearing lubrication. The structures of thickener of grease are researched by FTIR technology, and carry out the molecular models in two-dimensionaland three-dimensional space. The high temperature performance of grease is analyzed byTG-DSC, the results show that the thermal weight loss of grease under350°C is low, andhas a nice performance of anti-evaporation and anti-oxidation.
Besides, in order to improve the performance of grease fatherly, three kinds of size fortungsten disulfide additive are selected to add in the grease, and prepare four types of newgrease. The micro morphology, composition, particle size and high temperature stability oftungsten disulfide additive are analyzed by SEM, EDS, XRD, laser particle size analyzer,TG-DSC technology and so on, the results show that layered tungsten disulfide powder witha good high temperature performance. The different size of tungsten disulfide powder addedto the grease according to the concentration of1%to5%respectively, and the droppingpoint, EP and anti-wear properties are tested. The results show that The EP and anti-wearproperties of grease are improved noticeable by mixed with solid additive of micro scale,but the effect on the dropping point slightly. Through the experiment results of four balltester rig, indicate that the friction coefficient and diameter of scar diameter are decreasednoticeable by add the solid additive into the grease. The flow model of the nano materialstreaming in the grease is carried out in this paper, and the mechanism of anti-wear andfriction reduction for grease is analyzed too. The effect of nano material on the thickenerstructure and high temperature performance are analyze by FTIR and TG-DSC technology,the results show that add the nano material into the grease has a tiny influence on thethickener structure and high temperature performance.
Finally, comparison the four kinds of new grease (M-15, P-15, H-15, L-15) with theShell and Krupp wheel hub bearing grease, and general lithium grease for domestic motorsby test rig experiments, the results show that the performance of M-15and P-15wheelbearing grease has reached or better than the similar domestic products, and reached ornearly to the international advanced level.
引文
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