Tribological Performance of Rolling Contacts Produced by EDM

EDM 生产的滚动接触件的摩擦学性能

• 批准号: 387674136
• 负责人: Professor Dr.-Ing. Thomas Bergs, since 7/2019
• 金额: --
• 依托单位: Werkzeugmaschinenlabor - WZL
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2017
• 资助国家: 德国
• 起止时间: 2016-12-31 至 2019-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/387674136?language=en
• 关键词: Tribological; Performance; Rolling; Contacts; Produced

Heavily loaded rolling contacts such as the tooth flank contact, are complex tribological systems whose characteristics adjust itself through the interactions between the contact partners, the lubricant and the surrounding medium. The properties of the tribological system significantly affect the application behavior in terms of friction, wear and fatigue. The rolling strength is significantly influenced by the material, the rim zone properties, surface finish, as well as the operating parameters of slip and total velocity rate. The friction results from the state of lubrication in the contact which is established in dependence on the lubricant, the temperature and the surface roughness and structure. To reduce friction and increase sustainability of highly loaded rolling contacts in particular, the surface topography is analyzed as optimization parameters in the latest research. A key result is that the filming in the rolling contact and the service life canbe improved for studies on the two-disc test by an optimized surface structure of the final processing step. Deterministic surface textures like flat cup structures yield an improved behavior in terms of friction results compared to polished surfaces. The Electric Discharge Machining EDM can produce such a surface structure through the formation of the process inherent crater landscape. In preliminary studies it could be found that tribologically favorable surface structures can be set during wire cutting through the application of suitable finishing cuts. When using a modern process a tripling of the tolerable number of load cycles in the time field strength for pitting of wire-eroded compared to ground gears occurred when sustainability test were conducted. The objective of the project includes the deduction of a knowledge-based process model for the relationship between the parameters of EDM and the resulting surfaceintegrity of the machined component. Based on physical characteristics of discharge regimes a description model is built, which forms the basis for optimizing spark erosion rim zones and surface structures. Based on this, the aim is to investigate the tribological behavior experimentally in the two-disc analogy setup and to expand the existing calculation regarding rolling fatigue on the tribological contact by including the stochastic surface structures. For integration the existing lubricant approach is extended specifically to the cross influence of deformation. Finally, the match takes place between the theoretically calculated rolling loads for EDM and grinding surface structures and experimental results to determine the future potential for optimization.

重载滚动接触（如齿面接触）是复杂的摩擦学系统，其特性通过接触伙伴、润滑剂和周围介质之间的相互作用进行自我调节。摩擦学系统的性能显著影响摩擦、磨损和疲劳方面的应用行为。轧制强度受材料、边缘区特性、表面光洁度以及滑移率和总速度率等操作参数的显著影响。摩擦是由接触中的润滑状态引起的，该润滑状态取决于润滑剂、温度以及表面粗糙度和结构。为了减少摩擦，提高高负荷滚动接触的可持续性，在最新的研究中，表面形貌作为优化参数进行了分析。一个关键的结果是，在滚动接触中的膜和使用寿命可以通过优化的表面结构的最后加工步骤的两盘试验的研究提高。与抛光表面相比，确定性表面纹理（如平杯结构）在摩擦结果方面产生改进的行为。电火花加工可以产生这样的表面结构，通过工艺形成固有的火山口景观。在初步研究中，可以发现，摩擦学上有利的表面结构，可以设置在线切割过程中，通过应用适当的精加工切割。当使用现代工艺时，在进行可持续性测试时，与接地齿轮相比，线腐蚀点蚀的时间场强的可容忍负载循环次数增加了两倍。该项目的目标包括推导基于知识的工艺模型之间的关系，电火花加工参数和所产生的表面完整性的加工部件。根据放电区域的物理特性建立了描述模型，为优化电火花烧蚀边缘区域和表面结构奠定了基础。在此基础上，其目的是调查的摩擦学行为实验在两盘模拟设置和扩展现有的计算滚动疲劳的摩擦接触，包括随机表面结构。对于集成，现有的润滑剂方法被专门扩展到变形的交叉影响。最后，匹配发生在理论计算的电火花和磨削表面结构和实验结果之间的滚动载荷，以确定未来的优化潜力。

项目成果

Load Capacity of Rolling Contacts Manufactured by Wire EDM Turning

线切割车削制造的滚动接触件的负载能力

• DOI: 10.1016/j.procir.2020.02.111
• 发表时间: 2020
• 期刊: Procedia CIRP
• 作者: Tombul;Mevissen;Brimmers
• 通讯作者: Brimmers

Analysis of Characteristic Process Parameters to Identify Unstable Process Conditions during Wire EDM

分析特征工艺参数以识别线切割加工过程中的不稳定工艺条件

• DOI: 10.1016/j.promfg.2018.11.018
• 发表时间: 2018
• 期刊: Procedia Manufacturing
• 作者: Tombul;Herrig;Olivier;Klocke
• 通讯作者: Klocke

Calculation of mixed friction conditions in large-Scale rolling-Sliding contacts for different surface structures

不同表面结构大规模滚动滑动接触混合摩擦条件计算

• DOI: 10.1007/s10010-019-00377-y
• 发表时间: 2019
• 期刊: Forschung im Ingenieurwesen
• 作者: Mevissen;Löpenhaus
• 通讯作者: Löpenhaus