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，如齿侧接触，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来调节。摩擦学系统的性能对摩擦、磨损和疲劳性能有显著影响。轧制强度受材料、边缘区性能、表面光洁度以及滑移和总速度等操作参数的影响较大。摩擦是由接触中的润滑状态产生的，这种状态取决于润滑剂、温度、表面粗糙度和结构。为了减少摩擦，特别是提高高载荷滚动接触的可持续性，最新研究分析了表面形貌作为优化参数。通过优化最后加工步骤的表面结构，提高了滚动接触的成膜性，提高了双盘试验的使用寿命。与抛光表面相比，像平杯结构这样的确定性表面纹理在摩擦结果方面产生了改进的行为。电火花加工可以通过形成工艺固有的凹坑景观来产生这样的表面结构。在初步研究中可以发现，在线切割过程中，通过应用合适的精加工切削，可以设置良好的摩擦学表面结构。当使用现代工艺时，在进行可持续性测试时，与地面齿轮相比，侵蚀线的点蚀场强在时间上的可容忍载荷循环次数增加了三倍。该项目的目标包括为电火花加工参数与加工部件表面完整性之间的关系推导基于知识的过程模型。根据放电区物理特性，建立了放电区描述模型，为火花侵蚀边缘区域和表面结构的优化提供了基础。在此基础上，实验研究了双盘模拟条件下的摩擦磨损行为，并将随机表面结构纳入摩擦接触的滚动疲劳计算，扩展了现有的摩擦接触疲劳计算。为了集成，将现有的润滑方法具体扩展到变形的交叉影响。最后，将理论计算的电火花加工和磨削表面结构的轧制载荷与实验结果进行匹配，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