摘要
摩擦是关系到机械设备可靠性、耐久性以及能量利用率的主要因素。有效减小摩擦可使机械设备处于良好的润滑状态，发挥更好的性能，节省能耗，延长检修周期和使用寿命，从而获得更大的经济效益。近年来，表面织构技术已被证明是改善摩擦副摩擦学性能的有效手段。合理的表面织构设计可以使其发挥出更为优越的摩擦学性能。为丰富表面织构设计领域的研究，本文对影响织构化表面润滑减摩性能的表面织构参数、组成表面织构的微凹坑形状、以及微凹坑排布形式等进行了较为系统的研究。
首先，在流体动压润滑条件下，基于Renolds方程建立了表面织构的润滑模型，并以此分析表面织构参数、微凹坑形状、以及微凹坑排布形式等对润滑膜承载力的影响。然后，根据理论分析结果，进行了织构化表面减摩试验的设计及研究。试验中选择面-面接触摩擦副为研究对象，并利用光刻微细电解加工方法加工织构，试验在往复式摩擦磨损试验机上进行。
在对表面织构参数的研究中发现：对于圆柱形微凹坑，深径比和面积率都是影响润滑膜承载力的重要因素。最优微凹坑深径比和最优微凹坑面积率受到最小润滑膜厚度的影响。该结论在试验中得到了较好的验证。在试验所选择的参数中，微凹坑直径为200μm、深度为8~10μm、面积率为10.4%的织构化表面，相比无织构化表面表现出最优减摩效果。
在对微凹坑形状的研究中发现：微凹坑形状也是影响润滑膜承载力的重要因素。在固定的微凹坑面积、深度和面积率下，不同的微凹坑形状产生的润滑膜承载力大小不同。在试验所选择的圆形、正方形和椭圆形微凹坑中，长轴与润滑剂速度方向垂直的椭圆形微凹坑总能使织构化表面表现出最优减摩效果，其次是正方形，再次是圆形。当试验载荷为200N、曲柄转速为200r/min时，上述三种形状的微凹坑织构化表面最大减摩率分别为26.7%、21.8%和18.3%。
在对微凹坑排布形式的研究中发现：改变微凹坑之间的相对位置同样会影响润滑膜承载力。与微凹坑正方形网格分布形式的织构化表面相比，选择合适的微凹坑排布形式可使减摩效果得到进一步提高。在研究范围内，微凹坑横向间距与纵向间距比值为1/3的织构化表面所表现出的进一步减摩效果最为明显。当试验载荷为200N、曲柄转速为400r/min时，减摩率进一步提高了22.14%。
部分织构作为一种微凹坑排布的特殊形式，其润滑减摩性能同时受到微凹坑参数、部分织构位置、以及部分织构率的影响。研究发现：只有当微凹坑面积率大于10%时，部分织构才可能体现出比全织构更好的润滑减摩性能。在所研究的入口边界部分织构、出口边界部分织构、中间部分织构和双边部分织构四种部分织构位置形式中，相比全织构入口边界部分织构表现的进一步减摩效果最为明显。当试验载荷为200N、曲柄转速为400r/min时，最优部分织构率为70%的入口边界部分织构，相比全织构可进一步提高减摩率18.8%。
本文的研究结果，能够为引导表面织构领域的深入研究以及表面织构技术在实际工程中的应用提供参考。
Friction, to a great extent, affects the mechanical reliability, durability and the energy efficiency.Reducing friction in mechanical systems plays a very important role in changing lubrication state,saving energy source, and increasing repair circle and working life, which can also significantlyincrease economic benefit. In recent years, the surface texturing has been proven as a viable means toenhance the tribological performance of friction pairs. The optimum tribological performance can beobtained by choosing suitable textural parameters. In order to enrich the research on design of surfacetexture, the textural parameters, dimple shapes and dimple arrangements were systematically studied.
At first, an analytical model was developed in hydrodynamic lubrication region based onRenolds equation to investigate the effect of surface textural parameters, dimple shapes and dimplearrangements on hydrodynamic pressure generation. Then, the textured surfaces were designedaccording to the analytical results. And the friction tests were carried out using a reciprocating frictiontest rig. The friction pair which the upper specimen face-to-face contacting with the lower specimenwas selected as the research object. The texturing method used in the study was the photoelectrolyticetching.
The results obtained from the research about surface textural parameters showed that both thedimple depth to diameter ratio and the dimple area ratio are the factors affecting hydrodynamicpressure generation. The optimum dimple depth to diameter ratio and the optimum dimple area ratioare affected by minimum film thickness. The test results showed a good correlation with thoseobtained from the analytical model. In the research, the specimen with a dimple diameter of200μm，adimple depth of8~10μm, and a dimple area ratio of10.4%presents optimum friction reductioncompared with untextured specimen.
The results obtained from the research about dimple shapes showed that dimple shapes alsoaffect the hydrodynamic pressure generation. Under the condition of having the same dimple area,same depth, and same area ratio, dimple shapes have an obvious influence on film load carryingcapacity. Among the dimple shapes of circular, square, and elliptical selected in the experimentalstudy, elliptical dimples that the major axis is perpendicular to the flow direction of the lubricantalways showed the best friction reduction compared with untextured specimen. The square dimplesperformed the second best, and the circular dimples showed the worst results. Under the condition oftest load200N and crank rotational speed400r/min, the biggest friction reduction ratio is26.7%for elliptical dimple,21.8%for square dimple, and18.3%for circular dimple.
The results obtained from the research about dimple arrangements showed that changing therelative location between dimples also affects the hydrodynamic pressure generation. Suitable dimplearrangement can improve the friction reduction once again compared with the textured surfaces whichthe dimples were located at the four corners of a square. In the extent of the research, The dimplearrangement which the transverse interval between dimples to longitudinal interval ratio of1/3givesthe best increasing rate of friction reduction22.14%when the test load was200N and the crankrotational speed was400r/min.
As a special form in dimple arrangements, partial surface texture was also studied. The resultsshowed that the tribological performance of partial surface texture is affected by the dimpleparameters, dimples location, and partial texture ratio. Only if the dimple area ratio is bigger than10%,the partial surface texture owns the better friction reduction than full surface texture. Of the inletpartial surface texture, outlet partial surface texture, middle partial surface texture, and the two-sidepartial surface texture, the inlet partial surface texture presents the best friction reduction effect. Underthe optimum partial texture ratio of70%, an increasing rate of friction reduction18.8%can beobtained when test load was200N and crank rotational speed was400r/min.
The results obtained in the research provide a reference for the further research and applicationof surface texture.
引文
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