發(fā)布時(shí)間：2017-12-28 10:10

  本文關(guān)鍵詞：軸向柱塞泵摩擦副功率損失分析與表面形貌設(shè)計(jì)研究　出處：《浙江大學(xué)》2017年博士論文　論文類型：學(xué)位論文

  更多相關(guān)文章： 軸向柱塞泵 摩擦損失 泄漏容積損失 壓縮容積損失 表面形貌 固液耦合柱 塞副測試臺 減摩抗磨

【摘要】：節(jié)能和高效是當(dāng)今液壓傳動(dòng)技術(shù)研究的一個(gè)重點(diǎn)和難點(diǎn),變排量泵控系統(tǒng)取代閥控系統(tǒng),可以顯著提高液壓傳動(dòng)系統(tǒng)能量的利用率,有助于降低系統(tǒng)裝機(jī)功率和發(fā)熱量,提高系統(tǒng)可靠性和工作壽命,為主機(jī)裝備的最終用戶帶來可觀的經(jīng)濟(jì)效益,因此,液壓傳動(dòng)系統(tǒng)直接泵控、無閥化是其未來發(fā)展趨勢。在泵控系統(tǒng)中,作為動(dòng)力源的軸向柱塞泵,其全工況效率性能在整機(jī)液壓傳動(dòng)系統(tǒng)效率性能中的影響已日漸凸顯,本學(xué)位論文基于這一背景,對全工況下軸向柱塞泵效率與能耗變化、分布特征,及能耗產(chǎn)生機(jī)理與摩擦副節(jié)能高效設(shè)計(jì)技術(shù)展開研究,目的在于為節(jié)能高效、高可靠性軸向柱塞泵摩擦副的設(shè)計(jì)奠定理論基礎(chǔ),提供設(shè)計(jì)方法,提高軸向柱塞泵綜合性能,選題具有廣泛的工程應(yīng)用背景和重要的學(xué)術(shù)研究價(jià)值。本學(xué)位論文首先基于數(shù)學(xué)理論分析、動(dòng)態(tài)仿真建模和試驗(yàn)測試相結(jié)合的方法,對軸向柱塞泵在不同壓力、轉(zhuǎn)速和排量等級工況下的效率,以及軸向柱塞泵內(nèi)部分布于各摩擦副處的摩擦損失、容積損失等能耗變化、分布特征與產(chǎn)生機(jī)理進(jìn)行了研究,發(fā)現(xiàn)軸向柱塞泵總效率隨著排量的減小而快速降低,在低壓工況時(shí)泵也處于低效區(qū),且在低效區(qū)時(shí)泵總效率的降低在68～97%的程度上是由摩擦副處摩擦損失引起的,其中柱塞副及滑靴副處的摩擦損失是軸向柱塞泵主要的兩個(gè)功率損失源;為此,論文接著進(jìn)一步地以柱塞副為研究對象,提出了柱塞副油膜與摩擦界面結(jié)構(gòu)體間固液耦合作用變形矩陣法求解方法,該方法基于有限容積法(FVM)解油膜流體潤滑方程,通過提出的基于有限元(FEM)軟件的摩擦界面計(jì)算節(jié)點(diǎn)規(guī)則化設(shè)置及變形矩陣精準(zhǔn)計(jì)算方法,獲得與油膜流體求解域計(jì)算節(jié)點(diǎn)一一對應(yīng)的系列變形矩陣,基于變形矩陣對彈性變形方程進(jìn)行離散化,通過將變形矩陣融入于油膜流體計(jì)算程序內(nèi)部,實(shí)現(xiàn)油膜流體域與摩擦偶件固體域融于一體的、單一計(jì)算領(lǐng)域環(huán)境下的高效雙向固液耦合計(jì)算,在此基礎(chǔ)上,進(jìn)一步建立起了柱塞副油膜流體動(dòng)力潤滑計(jì)算模型,以及油膜與摩擦界面結(jié)構(gòu)體之間的耦合作用彈性流體動(dòng)力潤滑計(jì)算模型,并分析了柱塞副油膜的固液耦合作用現(xiàn)象及其潤滑承載機(jī)理;另一方面,為在實(shí)踐中考察柱塞副的潤滑承載性能,以中、大排量等級及高速高壓為設(shè)計(jì)參數(shù),研制了基于斜盤旋轉(zhuǎn)驅(qū)動(dòng)的柱塞副三軸力解耦與同步測試裝置,實(shí)現(xiàn)對柱塞副中徑向方向的油膜負(fù)載力、以及相對較小的軸向摩擦力的既解耦獨(dú)立又實(shí)時(shí)同步的檢測,基于柱塞副三軸力測試裝置,測試分析了不同轉(zhuǎn)速及壓力工況下柱塞副的摩擦學(xué)性能,并對建立的柱塞副油膜潤滑模型等理論模型進(jìn)行了實(shí)驗(yàn)驗(yàn)證;論文最后,基于建立的柱塞副油膜潤滑模型,提出了柱塞副表面形貌摩擦學(xué)設(shè)計(jì)與分析方法,通過理論與實(shí)驗(yàn)測試分析了不同表面形貌結(jié)構(gòu)的摩擦界面對柱塞副減摩性能的影響,得到了一種新型的順錐形柱塞孔表面形貌結(jié)構(gòu),對比于傳統(tǒng)的柱形結(jié)構(gòu)柱塞副,新型的順錐形結(jié)構(gòu)的柱塞副在全工況范圍內(nèi)具有更小的泄漏損失,更好的減摩抗磨性能,在工藝性方面也不難于實(shí)現(xiàn)加工制造,其中的順錐形柱塞孔結(jié)構(gòu)的S20型缸體試件對應(yīng)的柱塞副,與傳統(tǒng)的柱形柱塞孔結(jié)構(gòu)的Z30型缸體試件對應(yīng)的柱塞副相對比,在不同試驗(yàn)工況下其減摩率最高達(dá)到-40.1%,最低時(shí)也達(dá)到了-22.1%,綜合最優(yōu)的順錐形柱塞孔表面形貌幾何結(jié)構(gòu)為:柱塞孔中錐形區(qū)域高度差為柱形區(qū)域柱塞與柱塞孔間隙大小的46.67%,錐形區(qū)域軸向分布長度為柱塞與柱塞孔最大接觸長度的49.44%。論文主要結(jié)構(gòu)如下:第一章,指出了論文研究的背景和意義,對國內(nèi)外主要的軸向柱塞泵科研院所和企業(yè)相關(guān)研究情況進(jìn)行調(diào)研,綜述了軸向柱塞泵摩擦副功率損失分析及表面形貌摩擦學(xué)設(shè)計(jì)相關(guān)技術(shù)的研究現(xiàn)狀和發(fā)展趨勢,在此基礎(chǔ)上確定了本學(xué)位論文的研究內(nèi)容和技術(shù)難點(diǎn)。第二章,軸向柱塞泵全工況下效率及能耗變化與分布特征分析。采用數(shù)學(xué)理論分析、動(dòng)態(tài)仿真建模和試驗(yàn)測試相結(jié)合的方法,對軸向柱塞泵在不同壓力、轉(zhuǎn)速及排量等級下的效率,以及各摩擦副處的摩擦損失、容積損失等能耗變化、分布特征與產(chǎn)生機(jī)理進(jìn)行研究。第三章,分析柱塞副間隙內(nèi)油膜與摩擦界面結(jié)構(gòu)體間的固液耦合作用現(xiàn)象及其潤滑承載機(jī)理,建立油膜潤滑計(jì)算模型,為節(jié)能高效、高可靠性柱塞副結(jié)構(gòu)的設(shè)計(jì)奠定理論研究基礎(chǔ)。第四章,柱塞副力學(xué)特性測試方法研究與試驗(yàn)分析。研制中、大排量等級高壓高速柱塞副三軸力解耦與同步測試裝置,實(shí)現(xiàn)對柱塞副中徑向方向的油膜負(fù)載力及軸向摩擦力的同步檢測,測試分析不同工況下柱塞副的摩擦學(xué)性能,并對建立的柱塞滑靴組件動(dòng)力學(xué)數(shù)學(xué)模型,柱塞副油膜潤滑模型以及試驗(yàn)臺主體機(jī)構(gòu)動(dòng)力學(xué)仿真模型進(jìn)行實(shí)驗(yàn)驗(yàn)證。第五章,柱塞副表面形貌摩擦學(xué)設(shè)計(jì)與性能強(qiáng)化。分析柱塞副摩擦界面微觀形貌幾何結(jié)構(gòu)的建模方法,提出柱塞副表面形貌摩擦學(xué)設(shè)計(jì)與分析方法,通過理論及實(shí)驗(yàn)研究不同表面形貌結(jié)構(gòu)對柱塞副減摩抗磨性能的影響,設(shè)計(jì)較易于加工制造的、具有更小容積損失及更好的減摩抗磨性能的表面形貌結(jié)構(gòu),并驗(yàn)證提出的柱塞副表面形貌摩擦學(xué)設(shè)計(jì)與分析方法的正確性。第六章,對論文的研究結(jié)論進(jìn)行總結(jié),在此基礎(chǔ)上提出本博士學(xué)位論文的創(chuàng)新點(diǎn),并展望該研究課題的后續(xù)研究方向。
[Abstract]:Energy saving and efficiency is a key and difficult point in the research of hydraulic transmission technology, variable displacement pump control system to replace the valve control system, can significantly improve the utilization rate of energy hydraulic transmission system, helps to reduce system installed power and heat, improve system reliability and working life, for the end user equipment to bring the host considerable economic benefits, therefore, direct pump hydraulic system control valve, is the future development trend. In the pump control system, as the axial piston pump power source, affects the performance of the whole machine performance efficiency in power efficiency in the hydraulic transmission system has become increasingly prominent. This thesis is based on this background, changes in all conditions of axial piston pump efficiency and energy distribution, and energy consumption have studied the mechanism and technology of friction Deputy energy efficient design, the purpose is to establish the theoretical basis for high efficiency, high reliability of friction pair in axial piston pump design, design methods, improve the comprehensive performance of axial piston pump, the topic has extensive engineering application background and important academic value. In this paper, based on the method of mathematical analysis, dynamic simulation modeling and test combining the efficiency of axial piston pump under different pressure, speed and displacement level condition, and the friction loss, axial piston pump internal friction pair is distributed to the volume loss of energy consumption changes, distribution characteristics and the formation mechanism of study found that the total efficiency of axial piston pump and the rapid decrease with the displacement decreases, in the condition of low pressure when the pump is in the inefficient zone, and reduce the total efficiency of 68 in the area of inefficient pump ~ 97% degree is caused by friction or friction loss, the piston pair and the slipper pair of the axial piston friction loss two pump power loss of the main source; therefore, the paper then further to the piston as the research object, put forward the solid-liquid coupling piston oil film and friction interface structure between Solving the deformation matrix method, the method based on the finite volume method (FVM) solution of oil film lubrication equation, through the proposed based on finite element (FEM) friction interface software computing node rule setting and matrix deformation precision calculation method, and obtain the oil film fluid solution domain computing nodes corresponding to the series of deformation matrix. The transformation matrix is used to discretize the elastic deformation equation based on the deformation matrix into the oil film flow calculation program, to achieve efficient bidirectional solid-liquid coupling oil film and friction coupling of single fluid domain calculation of solid domain into one field, computing environment, on this basis, further establish a plunger oil film the hydrodynamic lubrication calculation model, as well as between the oil film and friction interface structure coupling elastic hydrodynamic lubrication calculation model, and analyzes the effect of solid-liquid coupling piston pair of oil film The phenomenon and mechanism of bearing lubrication; on the other hand, in practice for investigation of lubrication piston bearing performance in large displacement and high voltage level as design parameters, developed plunger pair three axis force decoupling of rotation of the swash plate drive and synchronous test device based on the oil film on the piston side in the radial direction the load, as well as the decoupling independent relatively small axial friction and synchronous detection, plunger pair three axis force testing device based on test and analysis of tribological performance of piston pairs at different speed and pressure conditions, and the establishment of the plunger oil film lubrication model and the theoretical model is verified by experiment; thesis finally, the plunger oil film lubrication model based on the proposed design and analysis method of plunger pair surface tribology, through theoretical and experimental test analysis of friction interface of different surface structure Effect of piston friction reducing performance, a cis tapered plunger hole surface microstructure model is obtained. The columnar structure of plunger pair compared to the traditional model, the structure of the CIS tapered piston pair in the whole operating range with smaller leakage loss, friction reduction and antiwear properties better, in the process of it not difficult to achieve manufacturing, the CIS S20 type cylinder conical column jack structure specimens corresponding to the plunger vice, the specimen corresponding to the plunger pair compared with Z30 type of cylinder cylinder plunger hole structure of the traditional in different test condition the friction ratio reached -40.1%, the lowest also reached -22.1% comprehensive, optimal CIS tapered plunger hole surface morphology of geometric structure: the piston hole cone height difference cylindrical region of the plunger and the plunger hole clearance 46.67% cone axial distribution of length of maximum contact plunger and the plunger hole 49.44% of the length. The main contents are as follows: the first chapter points out the background and significance of the research of the main axial piston pump research institute and the relevant research on the situation of enterprises to conduct research, summarized the axial piston pump friction pair research status and development trend analysis of power loss of surface topography and tribological design of related technology, on the basis of the research content and the technical difficulties of this thesis were determined. In the second chapter, the changes and distribution characteristics of the efficiency and energy consumption of the axial piston pump are analyzed in all conditions. By using the method of mathematical analysis, dynamic simulation modeling and test combining the efficiency of axial piston pump under different pressure, speed and displacement level, and friction loss, the friction pair volume loss energy change, distribution characteristics and mechanism research. The third chapter analyzes the solid liquid coupling phenomenon and the lubrication bearing mechanism between the oil film and the frictional interface structure, and establishes the oil film lubrication calculation model, so as to lay a theoretical foundation for the design of the sub structure of energy saving, high efficiency and high reliability. The fourth chapter is the research and test analysis of the test method of the mechanical characteristics of the plunger. Three axial force decoupling and synchronization of high pressure and high speed plunger pair in medium and large displacement
【學(xué)位授予單位】：浙江大學(xué)
【學(xué)位級別】：博士
【學(xué)位授予年份】：2017
【分類號】：TH137.51
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本文編號：1345578