本文選題：激光織構(gòu) + 缸孔-活塞環(huán)　； 參考：《江蘇大學(xué)》2016年碩士論文

【摘要】：缸孔-活塞環(huán)摩擦副系統(tǒng)是發(fā)動機中最為關(guān)鍵的摩擦副之一,其摩擦功耗占整個發(fā)動機的50~60%。激光表面微織構(gòu)技術(shù)能夠有效改善缸孔-活塞環(huán)摩擦副的摩擦學(xué)性能,減少摩擦磨損,提高整機燃油效率,實現(xiàn)節(jié)能減排的效果。本文以某型號發(fā)動機為研究對象,建立潤滑理論模型,數(shù)值模擬潤滑性能與織構(gòu)形貌參數(shù)的關(guān)系,為設(shè)計發(fā)動機試驗方案提供理論支撐,系統(tǒng)開展激光微織構(gòu)工藝試驗研究,并進行發(fā)動機的倒拖與臺架對比驗證性能試驗。其主要內(nèi)容如下。首先,考慮時變效應(yīng)及缸內(nèi)氣體壓力變化對活塞環(huán)背壓的影響,建立微凹坑織構(gòu)化缸孔-活塞環(huán)潤滑理論模型。對數(shù)學(xué)方程進行無量綱化處理,利用有限差分法進行參數(shù)離散化,采用多重網(wǎng)格法求解離散后的雷諾方程,得到一個沖程全周期過程中缸孔-活塞環(huán)間的最小油膜厚度、無量綱摩擦力變化曲線,研究發(fā)現(xiàn)微凹坑深度與面積密度對摩擦副潤滑性能影響較大,優(yōu)化微凹坑幾何參數(shù)能夠顯著提高缸孔-活塞環(huán)的潤滑性能。然后,圍繞缸孔激光微織構(gòu)技術(shù),開展了三種系列工藝試驗。其一,為最大程度發(fā)揮缸孔表面織構(gòu)形貌的優(yōu)勢,降低機械珩磨網(wǎng)紋形貌的干擾,減少發(fā)動機機油耗,應(yīng)優(yōu)化缸孔前處理表面粗糙度參數(shù)值,開展缸孔前處理鏡面珩磨工藝試驗研究。以五個缸孔表面關(guān)鍵參數(shù)為衡量指標(Rz"f2μm,Ra"f0.2μm和Rpk"f0.15μm,Rk"f0.4μm,Rvk"f1μm),主要研究珩磨條粒度、珩磨壓力對缸孔表面粗糙度值的影響。珩磨條粒度與珩磨壓力對缸孔表面參數(shù)影響較大,得到優(yōu)化鏡面珩磨加工工藝參數(shù);其二,開展激光微織構(gòu)工藝試驗,揭示了激光工藝參數(shù)對微凹坑形貌的影響規(guī)律。結(jié)果表明,單脈沖能量、脈沖次數(shù)為關(guān)鍵加工參數(shù),不同材料、涂層和波長對微凹坑幾何參數(shù)的影響顯著;其三,為去除激光織構(gòu)產(chǎn)生的熔渣,減少發(fā)動機磨合時間,避免因熔渣剝落造成的磨粒磨損,需對織構(gòu)后的缸孔進行去除熔渣后處理工藝試驗。以缸孔表面Rz為指標參數(shù),采用四因素二水平正交試驗,確定合理的后處理工藝參數(shù)。最后,針對某型四缸汽油機,加工三種不同缸孔織構(gòu)方案樣機,進行裝機后倒拖與臺架試驗�？疾煳伎有蚊矃�(shù)對發(fā)動機動力性能、油耗性能影響。倒拖試驗結(jié)果顯示,當缸孔上止點與中部行程區(qū)域面積密度為10%時,摩擦功耗表現(xiàn)出有益的效果。臺架點火試驗表明,經(jīng)24小時機油耗對比,兩種織構(gòu)方案機油耗低于原機,最大降幅達26.48%;發(fā)動機萬有特性曲線看出,發(fā)動機大部分工況下,三種織構(gòu)發(fā)動機燃油耗低于原機,激光織構(gòu)位置為上止點、行程中部區(qū)域,且微凹坑直徑為70μm、深度為4μm、面積密度為10%時,瞬時工況的燃油耗最大降幅達15%。
[Abstract]:Cylinder hole-piston ring friction pair system is one of the most critical friction pairs in the engine, its friction power consumption accounts for 5060% of the whole engine. Laser surface microtexture technology can effectively improve the tribological performance of cylinder hole piston ring friction pair, reduce friction and wear, improve the fuel efficiency of the whole machine, and achieve the effect of energy saving and emission reduction. In this paper, a theoretical model of lubrication is established for a certain engine, and the relationship between lubrication performance and texture parameters is numerically simulated, which provides theoretical support for the design of engine test scheme. The experimental research on laser microtexture technology is carried out systematically. The performance test of the engine is compared with that of the bench. The main contents are as follows. Firstly, considering the influence of time-varying effect and the change of gas pressure in cylinder on the back pressure of piston ring, a theoretical model of micro-crater textured cylinder orifice and piston ring lubrication is established. The mathematical equation is dimensionless, the finite difference method is used to discretize the parameters, and the multigrid method is used to solve the discrete Reynolds equation. The minimum oil film thickness between the cylinder hole and the piston ring is obtained during the whole cycle of stroke. It is found that the depth and area density of micropits have a great influence on the lubrication performance of friction pairs. Optimizing the geometric parameters of micropits can significantly improve the lubrication performance of cylinder holes and piston rings. Then, three series of process tests were carried out around the cylinder hole laser microtexture technology. First, in order to maximize the advantages of the surface texture of cylinder hole, reduce the interference of mechanical honing mesh morphology and reduce engine oil consumption, the parameters of surface roughness should be optimized. Experimental study on honing process of pre-treatment mirror surface of cylinder hole is carried out. The effects of honing bar particle size and honing pressure on the surface roughness of cylinder bore were studied by using the key parameters of five cylinder holes (RZ "f 2 渭 m Ra" f 0.2 渭 m and Rpk "f 0.15 渭 m Rk" f 0.4 渭 m Rvk "f 1 渭 m),). The honing bar particle size and honing pressure have great influence on the surface parameters of cylinder hole and obtain the optimized processing parameters of mirror honing. Secondly the experiments of laser micro-texture technology are carried out to reveal the influence of laser processing parameters on the morphology of micro-pits. The results show that the single pulse energy and pulse number are the key processing parameters, and different materials, coatings and wavelengths have significant effects on the geometric parameters of the microcrater. Thirdly, in order to remove the slag produced by the laser texture and reduce the engine running-in time, To avoid abrasive wear caused by slag spalling, it is necessary to carry out post-treatment experiments on textured cylinder holes. Taking the cylinder hole surface Rz as the index parameter, four factors and two levels orthogonal test were used to determine the reasonable post-treatment process parameters. Finally, three different cylinder hole texture prototypes are processed for a four-cylinder gasoline engine, and the backward towing and bench test are carried out. The effect of microcrater shape parameters on engine dynamic performance and fuel consumption was investigated. The results of backward drag test show that the friction power consumption shows a beneficial effect when the area density between the upper stop point and the middle stroke area of the cylinder hole is 10. The bench ignition test shows that the fuel consumption of the two texture schemes is lower than that of the original engine after 24 hours' fuel consumption comparison, and the maximum decrease is 26.48. The engine characteristic curve shows that the fuel consumption of the three texture engines is lower than that of the original engine under most of the engine working conditions. When the laser texture is located at the upper stop point, the middle travel area is in the middle region, and the diameter of the microcrater is 70 渭 m, the depth is 4 渭 m, and the area density is 10, the maximum reduction of fuel consumption in the instantaneous working condition is 15%.
【學(xué)位授予單位】：江蘇大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2016
【分類號】：TK406

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