织构化配流副摩擦润滑特性的理论与试验研究
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摘要
配流副是轴向柱塞泵的关键零部件，同时也是其它采用端面配流方式的液压动力元件和执行元件普遍采用的配流方式，如叶片泵、轴向柱塞马达等。随着液压传动技术向着高速、高压方向发展，对配流副的工作性能和使用寿命提出了更高的要求。而表面织构技术因其能提高摩擦副间油膜支撑力、降低摩擦磨损、改善润滑性能而成为摩擦学的一大研究热点，表面织构在机械密封、发动机活塞环、计算机硬盘等上的研究成果和成功应用为改善配流副的摩擦润滑性能提供了一种新的思路。为提高织构化配流副的摩擦学性能，并对配流副织构化参数的设计提供指导，本文从理论和试验两个方面对织构化配流副的摩擦润滑特性进行了系统的研究。
在理论方面：建立了针对配流副结构特点和实际工况的润滑模型，分析了织构化参数，即微凹坑深度、直径及面积率对配流副间油膜支撑力的影响，为减摩和降低磨损提供依据。建立了考虑气穴影响的织构化配流副泄漏模型，寻求一种织构化配流副泄漏量的计算方法，同时也可供机械密封泄漏量的计算提供参考。建立了织构化配流副的动态模型，利用Matlab/Simulink进行了动态仿真，分析了织构化配流副间油膜厚度的变化规律。
在试验方面：依据轴向柱塞泵配流副的工作原理，研制了一台织构化配流副摩擦磨损试验机。针对配流盘相对复杂的结构，对采用光刻电解技术加工微凹坑阵列的工艺和步骤进行了探索，并成功加工出质量较高的微凹坑阵列。依据理论分析的相关结论和实际情况，选择合适的配流副工况和织构化参数进行织构化配流副的试验研究。
通过理论分析和试验研究，得出了如下结论。
织构化配流副间油膜特性方面：织构化配流副能够提高摩擦副间的支撑力；最优面积率与微凹坑深度和油膜厚度的比值有关；较大微凹坑直径能提供较大的支撑力；在油膜厚度与微凹坑深度相等时有最大的支撑力，支撑力随油膜厚度减小而呈现出非线性增大的趋势。
低压区织构化配流副的摩擦学研究方面：最优面积率受到多因素的影响，在相同条件下，面积率为10%和15%表现出最好的摩擦学性能。微凹坑直径为100μm时的摩擦学性能优于其它微凹坑直径，最大减摩率为37.35%。微凹坑深度为10μm时摩擦学性能较好，最大减摩率为27.98%。
全织构化配流副的摩擦学研究方面：面积率为10%和15%时的摩擦学性能接近，微凹坑直径为200μm时，摩擦学性能较好。其减磨机理由织构的三个基本作用决定即容纳固体颗粒、产生动压效应和二次润滑。
在织构化配流副泄漏量方面：微凹坑深度和面积率对泄漏量有较大影响，随着微凹坑深度的增加，泄漏量随之减小。在相同面积率和微凹坑深度时，泄漏量随微凹坑直径增大而增大。
在织构化配流副的动态特性方面：织构化配流副能改善配流副的动态特性，与织构化导致油膜刚度的提高密切相关。在较小稳态油膜厚度时，织构化配流副在避免干摩擦上有较明显的优势。
本文的研究结果表明织构化配流副能改善轴向柱塞泵的摩擦润滑性能，也可供存在轴向不平衡力的液压零部件如齿轮泵轴套/壳体、配流轴的设计提供参考。
The port plate pair is one of the key components, and it is employed by the hydraulic powercomponent and the hydraulic actuator which adopt the way of end plane flow distribution, such asaxial piston motor, vane pump and other products. Along with the hydraulic drive system developingto high speed, high pressure, working performance and service life of the port plate pair is put forwardhigher request. Surface texture technology becomes worldwide research focus on tribology because ofits performance of increase loading capacity, decrease friction coefficient, reduce wear and improvelubricating property, its successful application of the mechanical seal, the engine piston ring, thecomputer hard drive, etc. provides a new thought for improve tribological performance of the portplate pair. The tribological performance of the textured port plate pair is studied in both theory andexperiment in this paper, and it can offer guidance for the design of the textured port plate pair.
In theory: The textured port plate pair’s lubrication model based on its construction features and theactual working condition is established, the textured parameters such as the micro-pit’s depth, themicro-pit’s diameter, the area ratio on the oil load capacity is analyzed, it can provide a basis fordecreasing friction coefficient and reducing wear. On account of cavitation, the textured port platepair’s leakage model is established, a new computing way to the textured port plate pair’s leakage isfound, and it can provide reference for mechanical seal. the textured port plate pair’s dynamic modelis established and dynamic simulation is performed based on the software of Matlab/Simulink, thechange of the oil film thickness is analyzed by the theory.
In experiment: Based on the working principle of the axial piston pump, a textured port plate pair’swear tester is developed. For the complex structure of the port plate, Micro-pits manufacture processand procedure by the use of photolithography combined with electrolytic etching process is found.The suitable working condition and the textured parameters is selected by the conclusions fromtheoretical analysis and physical condition, and the experiment can be carried out.
From theoretical analysis and experimental study, the conclusions are be show as follow:
On the aspect of the textured port plate pair’s oil film characteristics: The textured port plated pairhas a higher oil loading capacity, the optimal area ratio is related to the ratio of the micro-pit depth tothe oil film thickness, the larger micro-pit can produce the larger oil loading capacity, it has the largestoil loading capacity when the oil film thickness is equal to the micro-pit depth, with the oil filmthickness reducing, the oil film stiffness has a sharply increase.
On the aspect of the tribological performance of the textured port plate pair in low pressure area: the optimal area ratio can be effected by multiple factors, in the same environment the area ratiowhose value is10%and15%has a better tribology performance. The value of micro-pit diameter is100μm, the better tribological performance can be got, the largest value of reducing the wear and tearis37.35%. the value of the micro-pit depth is10μm, the largest value of reducing friction is27.98%.
On the aspect of the all textured port plate pair’s tribological performance: when the value of thearea ratio is10%or15%, the all textured port plate pair has a similar tribological performance, whenthe value of the micro-pit is200μm, the all textured port plate pair has a better tribologicalperformance, its anti-friction mechanism can be decided by the surface texture’s three basic role ofcontaining solid particles, dynamical effect and second lubrication.
On the aspect of the all textured port plate pair’s leakage: The micro-pit depth and the area ratiohave large effect on the all textured port plate pair’s leakage, with an increasing the micro-pit depth,the leakage will reduce. Under the same area ratio and micro-pit depth, with an increasing themicro-pit diameter, the leakage will increase.
On the aspect of the all textured port plate pair’s dynamic characteristics: In contrast to theuntextured port plate pair, the all textured port plate pair have better dynamic characteristic, itsdynamic characteristic is closely related to the oil film stiffness, when the less oil film thickness, theall textured port plate pair have an obvious advantage to prevent dry friction.
The research findings in this paper show that the textured port plate can improve the performanceof the friction and lubrication, it can refer for hydraulic components such as gear pump’sbushing/shell, the flow divider pintle which withstand unbalanced axial hydraulic pressure.
在理论方面：建立了针对配流副结构特点和实际工况的润滑模型，分析了织构化参数，即微凹坑深度、直径及面积率对配流副间油膜支撑力的影响，为减摩和降低磨损提供依据。建立了考虑气穴影响的织构化配流副泄漏模型，寻求一种织构化配流副泄漏量的计算方法，同时也可供机械密封泄漏量的计算提供参考。建立了织构化配流副的动态模型，利用Matlab/Simulink进行了动态仿真，分析了织构化配流副间油膜厚度的变化规律。
在试验方面：依据轴向柱塞泵配流副的工作原理，研制了一台织构化配流副摩擦磨损试验机。针对配流盘相对复杂的结构，对采用光刻电解技术加工微凹坑阵列的工艺和步骤进行了探索，并成功加工出质量较高的微凹坑阵列。依据理论分析的相关结论和实际情况，选择合适的配流副工况和织构化参数进行织构化配流副的试验研究。
通过理论分析和试验研究，得出了如下结论。
织构化配流副间油膜特性方面：织构化配流副能够提高摩擦副间的支撑力；最优面积率与微凹坑深度和油膜厚度的比值有关；较大微凹坑直径能提供较大的支撑力；在油膜厚度与微凹坑深度相等时有最大的支撑力，支撑力随油膜厚度减小而呈现出非线性增大的趋势。
低压区织构化配流副的摩擦学研究方面：最优面积率受到多因素的影响，在相同条件下，面积率为10%和15%表现出最好的摩擦学性能。微凹坑直径为100μm时的摩擦学性能优于其它微凹坑直径，最大减摩率为37.35%。微凹坑深度为10μm时摩擦学性能较好，最大减摩率为27.98%。
全织构化配流副的摩擦学研究方面：面积率为10%和15%时的摩擦学性能接近，微凹坑直径为200μm时，摩擦学性能较好。其减磨机理由织构的三个基本作用决定即容纳固体颗粒、产生动压效应和二次润滑。
在织构化配流副泄漏量方面：微凹坑深度和面积率对泄漏量有较大影响，随着微凹坑深度的增加，泄漏量随之减小。在相同面积率和微凹坑深度时，泄漏量随微凹坑直径增大而增大。
在织构化配流副的动态特性方面：织构化配流副能改善配流副的动态特性，与织构化导致油膜刚度的提高密切相关。在较小稳态油膜厚度时，织构化配流副在避免干摩擦上有较明显的优势。
本文的研究结果表明织构化配流副能改善轴向柱塞泵的摩擦润滑性能，也可供存在轴向不平衡力的液压零部件如齿轮泵轴套/壳体、配流轴的设计提供参考。
The port plate pair is one of the key components, and it is employed by the hydraulic powercomponent and the hydraulic actuator which adopt the way of end plane flow distribution, such asaxial piston motor, vane pump and other products. Along with the hydraulic drive system developingto high speed, high pressure, working performance and service life of the port plate pair is put forwardhigher request. Surface texture technology becomes worldwide research focus on tribology because ofits performance of increase loading capacity, decrease friction coefficient, reduce wear and improvelubricating property, its successful application of the mechanical seal, the engine piston ring, thecomputer hard drive, etc. provides a new thought for improve tribological performance of the portplate pair. The tribological performance of the textured port plate pair is studied in both theory andexperiment in this paper, and it can offer guidance for the design of the textured port plate pair.
In theory: The textured port plate pair’s lubrication model based on its construction features and theactual working condition is established, the textured parameters such as the micro-pit’s depth, themicro-pit’s diameter, the area ratio on the oil load capacity is analyzed, it can provide a basis fordecreasing friction coefficient and reducing wear. On account of cavitation, the textured port platepair’s leakage model is established, a new computing way to the textured port plate pair’s leakage isfound, and it can provide reference for mechanical seal. the textured port plate pair’s dynamic modelis established and dynamic simulation is performed based on the software of Matlab/Simulink, thechange of the oil film thickness is analyzed by the theory.
In experiment: Based on the working principle of the axial piston pump, a textured port plate pair’swear tester is developed. For the complex structure of the port plate, Micro-pits manufacture processand procedure by the use of photolithography combined with electrolytic etching process is found.The suitable working condition and the textured parameters is selected by the conclusions fromtheoretical analysis and physical condition, and the experiment can be carried out.
From theoretical analysis and experimental study, the conclusions are be show as follow:
On the aspect of the textured port plate pair’s oil film characteristics: The textured port plated pairhas a higher oil loading capacity, the optimal area ratio is related to the ratio of the micro-pit depth tothe oil film thickness, the larger micro-pit can produce the larger oil loading capacity, it has the largestoil loading capacity when the oil film thickness is equal to the micro-pit depth, with the oil filmthickness reducing, the oil film stiffness has a sharply increase.
On the aspect of the tribological performance of the textured port plate pair in low pressure area: the optimal area ratio can be effected by multiple factors, in the same environment the area ratiowhose value is10%and15%has a better tribology performance. The value of micro-pit diameter is100μm, the better tribological performance can be got, the largest value of reducing the wear and tearis37.35%. the value of the micro-pit depth is10μm, the largest value of reducing friction is27.98%.
On the aspect of the all textured port plate pair’s tribological performance: when the value of thearea ratio is10%or15%, the all textured port plate pair has a similar tribological performance, whenthe value of the micro-pit is200μm, the all textured port plate pair has a better tribologicalperformance, its anti-friction mechanism can be decided by the surface texture’s three basic role ofcontaining solid particles, dynamical effect and second lubrication.
On the aspect of the all textured port plate pair’s leakage: The micro-pit depth and the area ratiohave large effect on the all textured port plate pair’s leakage, with an increasing the micro-pit depth,the leakage will reduce. Under the same area ratio and micro-pit depth, with an increasing themicro-pit diameter, the leakage will increase.
On the aspect of the all textured port plate pair’s dynamic characteristics: In contrast to theuntextured port plate pair, the all textured port plate pair have better dynamic characteristic, itsdynamic characteristic is closely related to the oil film stiffness, when the less oil film thickness, theall textured port plate pair have an obvious advantage to prevent dry friction.
The research findings in this paper show that the textured port plate can improve the performanceof the friction and lubrication, it can refer for hydraulic components such as gear pump’sbushing/shell, the flow divider pintle which withstand unbalanced axial hydraulic pressure.
引文
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