Optimization of tribological systems by aimed anticipation of the running-in by final machining on the example of journal bearings

以轴颈轴承为例，通过最终加工的磨合目标优化摩擦学系统

• 批准号: 200420171
• 负责人: Professor Dr.-Ing. Albert Albers
• 金额: --
• 依托单位: Fraunhofer-Institut für Werkstoffmechanik (IWM)
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 财政年份: 2011
• 资助国家: 德国
• 起止时间: 2010-12-31 至 2017-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/200420171?language=en
• 关键词: Optimization; tribological; systems; aimed; anticipation

Aim of the research project is the development of a final machining process for journal bearings and its optimization by analyzing the resulting work piece subsurface layer, topography and the running-in behavior. The cutting process is investigated on the example of shaft journals (42CrMo4). Besides the finishing of journal bearing made of bronze, also high-strength materials made of steel (100Cr6, 42CrMo4) and aluminum housing material are examined on the bore-side. Hereby, the cutting process enables the aimed generation of nanocrystalline subsurface layers, which lead to a defined, short running-in behavior in the following operation. This leads to the formation of the third body with low friction and wear rates.In the second funding period a deeper understanding of the surface layer states within the nanocrystalline material is generated, thus leading to a further improvement of the tribosystem. Furthermore, the transfer of the research work onto an internal cutting process is being analyzed. Hereby, the geometries as well as the subsurface layer states of the journal shafts and bearings can be tribologically optimized. Furthermore, a practical tool for an efficient process management for the final machining is being created and the simulation models at different scales are integrated. The knowledge resulting from manufacturing and design of the bearings is finally validated in the tribological test rig.To assess the results given by simulation, experimental work on a test bench with journal bearings is necessary. Study of the tribological behavior has especially got to take place during the running-in of the bearings and in the regime of mixed lubrication. Another aspect of experimental work is the development of the turning process, which has to yield a reproducible formation of a nanocrystalline subsurface layer and an optimized topography. The adaption of process parameters to the internal cutting process is examined by tribological experiments to further improve tribological behavior.In addition to the experiments simulation is used to engage process understanding during tribological contact. The friction process is therefore examined on different length scales. Simulation of the final machining by WBK yields information on initial properties of the two bodies in contact. Those results as well as the results of the simulation by IAM-ZBS define the values used by the finite element simulation that shows the topography development during the operation of the journal bearing and its influence on the friction.

该研究项目的目的是通过分析工件的次表面层、形貌和磨合行为，开发轴颈轴承的最终加工工艺并进行优化。以轴颈（42 CrMo 4）为例，对切削工艺进行了研究。除了对青铜制成的滑动轴承进行精加工外，还对由钢（100Cr 6，42 CrMo 4）和铝外壳材料制成的高强度材料进行了孔侧检查。因此，切削过程能够有目的地生成纳米晶表面下层，这导致在随后的操作中的限定的短磨合行为。这导致形成具有低摩擦和磨损率的第三体。在第二个资助期内，对纳米晶材料内的表面层状态有了更深入的了解，从而进一步改善了摩擦系统。此外，转移的研究工作到一个内部的切削过程正在进行分析。因此，轴颈轴和轴承的几何形状以及表面下层状态可以在摩擦学上优化。此外，正在创建一个实用的工具，用于最终加工的有效过程管理，并集成了不同尺度的仿真模型。从轴承的制造和设计中得到的知识最终在摩擦学试验台上得到验证。为了评估模拟结果，有必要在带有径向轴承的试验台上进行试验工作。特别是在轴承磨合和混合润滑状态下，需要对摩擦学行为进行研究。实验工作的另一个方面是车削工艺的开发，该工艺必须产生可再现的纳米晶次表面层和优化的形貌。通过摩擦学实验研究了内切削过程参数对摩擦学性能的影响，并通过仿真研究了摩擦学接触过程。因此，在不同的长度尺度上检查摩擦过程。通过WBK对最终加工进行模拟，可以获得关于接触的两个物体的初始属性的信息。这些结果以及IAM-ZBS的模拟结果定义了有限元模拟所使用的值，该数值显示了滑动轴承运行期间的地形发展及其对摩擦的影响。