Influence of Strand Structure on Fretting Friction and Wear Characteristics between Spiral Contact Steel Wires
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摘要:
钢丝间微动磨损会加剧提升钢丝绳的疲劳损伤，降低钢丝绳的使用寿命，严重威胁矿井提升安全. 为了研究绳股结构对螺旋接触钢丝间微动摩擦磨损特性的影响，在自制试验台上开展了拉伸-扭转耦合力作用下钢丝微动磨损试验. 结果显示：随着接触力增加，相同直径接触对下钢丝间摩擦系数从0.748减小到0.646，而不同直径接触对下钢丝间摩擦系数从0.941减小到0.911；相比于凹接触对，凸接触对下钢丝表面磨损更加严重，并且不同直径钢丝间磨损深度和磨损系数明显大于相同直径钢丝间磨损深度和磨损系数；钢丝间主要磨损机理为磨粒磨损、黏着磨损和疲劳磨损，并且不同直径接触对下钢丝表面疲劳磨损特征更加严重；钢丝疲劳断口的瞬断区存在大量二次裂纹和韧窝形貌，钢丝疲劳断裂失效机理主要为韧性断裂.
Abstract:As the key component of mine hoisting system, hoisting wire rope is responsible for lifting coal, gangue, personnel and equipment. In the working process, the fretting wear between steel wires will aggravate the fatigue damage of hoisting wire rope, reduce the service life of wire rope, and seriously threaten the safety of the mine hoisting. In order to study the influence of strand structure on the fretting friction and wear characteristics of spiral contact steel wires, the fretting wear tests of steel wires under tension-torsion coupling force were carried out on a self-made test rig. The micro wear characteristics of steel wire surface were observed by the scanning electron microscope (SEM), and the fretting wear mechanism and fracture failure behavior of spiral contact steel wires under different strand structures were revealed. The results show that with the increase of contact force, the frictional coefficient between steel wires under the same diameter contact pairs decreases from 0.748 to 0.646, while that under different diameter contact pairs decreases from 0.941 to 0.911. The friction degree between steel wires under different diameter contact pairs is obviously greater than that under the same diameter contact pairs. In addition, in the stable stage, the friction coefficient between steel wires under the same diameter contact pairs presents a horizontal change trend, while that under different diameter contact pairs shows a slight upward trend. Under different working conditions, the depth and width of wear scars increase with increasing the contact force. For the same contact force, the wear depth of steel wires under the convex contact pairs is significantly greater than that under the concave contact pairs, and the greater the contact force is, the more obvious the difference of wear depth of steel wires under different contact forms is. Whether the diameter of the loading wire and the fatigue wire is the same or not, the wear coefficient of steel wires under different contact forms decreases with the increase of the contact force. The wear depth and coefficient of steel wires under different diameter contact pairs are significantly greater than that under the same diameter contact pairs. For the microscopic wear characteristics of steel wires, compared with the same diameter contact pairs, the worn surface of steel wires under the different diameters contact pairs presents more serious wear characteristics, and the worn surface of steel wires under the concave contact pairs is rougher than that under the convex contact pairs. Furthermore, there are a lot of wear characteristics on the surface of worn steel wire, such as wear debris, material adhesion, plastic deformation, fine scratches, material delamination, micro cracks and furrows. Therefore, the main wear mechanisms between steel wires are abrasive wear, adhesive wear and fatigue wear, and the fatigue wear of steel wires under different diameter contact pairs are more serious, which is caused by the "cutting" effect between thin steel wire and thick steel wire. As the contact force increases, the fatigue life of steel wires under different strand structures decreases gradually. And for the same contact force, the fatigue life of steel wires under different diameter contact pairs is obviously smaller than that under the same diameter contact pairs. The fracture surface of steel wires is obviously divided into fatigue source region, crack propagation region and final fracture region. Abundant secondary cracks and dimples exist in the final fracture region, and the fatigue fracture failure mechanism of steel wires is mainly ductile fracture.
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Keywords:
- steel wire /
- strand structure /
- fretting wear /
- wear mechanism /
- fracture failure
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图 1 (a)钢丝绳结构；(b)钢丝间接触形式
Figure 1. (a) Structure of wire rope; (b) contact form between steel wires
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图 4 自制摩擦试验台：(a)整体结构；(b)凸加载机构；(c)凹加载机构；(d)拉伸-旋转机构；(e)钢丝接触区域放大图
Figure 4. Self-made friction test rig: (a) overall structure; (b) convex loading mechanism; (c) concave loading mechanism; (d) tension-rotation mechanism; (e) enlarged view of the contact area
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图 5 钢丝间摩擦力随时间变化曲线
Figure 5. Variation curve of the frictional force between steel wires with time
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图 6 相同直径接触对下钢丝间摩擦系数随接触力变化规律：(a)摩擦系数变化曲线；(b)摩擦系数平均值
Figure 6. Variation of the frictional coefficient between steel wires with contact force under the same diameter contact pairs: (a) change curve of the frictional coefficient; (b) average value of the frictional coefficient
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图 7 不同直径接触对下钢丝间摩擦系数随接触力变化规律：(a)摩擦系数变化曲线；(b)摩擦系数平均值
Figure 7. Variation of the frictional coefficient between steel wires with contact force under different diameter contact pairs: (a) change curve of the frictional coefficient; (b) average value of the frictional coefficient
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图 8 不同接触形式下钢丝磨痕轮廓随接触力变化规律：(a)相同直径接触对-凸接触对；(b)相同直径接触对-凹接触对；(c)不同直径接触对-凸接触对；(d)不同直径接触对-凹接触对
Figure 8. Change law of wear scar profile of steel wire with contact force under different contact forms: (a) same diameter contact pairs - convex contact pairs; (b) same diameter contact pairs - concave contact pairs; (c) different diameter contact pairs - convex contact pairs; (d) different diameter contact pairs - concave contact pairs
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图 9 不同接触形式下钢丝磨损深度随接触力变化规律：(a)相同直径接触对；(b)不同直径接触对
Figure 9. Variation of the wear depth of steel wire with contact force under different contact forms: (a) same diameter contact pairs; (b) different diameter contact pairs
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图 10 不同接触形式下钢丝磨损系数随接触力变化规律：(a)相同直径接触对；(b)不同直径接触对
Figure 10. Variation of the wear coefficient of steel wire with contact force under different contact forms: (a) same diameter contact pairs; (b) different diameter contact pairs
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图 11 凸接触对下钢丝磨痕宏观形貌的SEM照片：(a)相同直径接触对；(b)不同直径接触对
Figure 11. SEM micrographs of morphology of wear scars under the convex contact pairs: (a) same diameter contact pairs; (b) different diameter contact pairs
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图 12 凹接触对下钢丝磨痕宏观形貌的SEM照片：(a)相同直径接触对；(b)不同直径接触对
Figure 12. SEM micrographs of macro morphology of wear scars under the concave contact pairs: (a) same diameter contact pairs; (b) different diameter contact pairs
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图 13 凸接触对下钢丝磨痕的微观形貌的SEM照片：(a~d)相同直径接触对；(e~h)不同直径接触对
Figure 13. SEM micrographs of micro morphology of wear scars under the convex contact pairs: (a~d) same diameter contact pairs; (e~h) different diameter contact pairs
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图 14 凹接触对下钢丝磨痕微观形貌的SEM照片：(a~d)相同直径接触对；(e~h)不同直径接触对
Figure 14. SEM micrographs of micro morphology of wear scars under the concave contact pairs: (a~d) same diameter contact pairs; (e~h) different diameter contact pairs
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图 15 不同绳股结构下钢丝疲劳寿命随接触力演变
Figure 15. Variation of the fatigue life of steel wire with contact force under different rope strand structures
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图 16 钢丝疲劳断口宏观形貌的SEM照片：(a)相同直径接触对；(b)不同直径接触对
Figure 16. SEM micrographs of micro morphology of fatigue fracture of steel wire: (a) same diameter contact pairs; (b) different diameter contact pairs
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图 17 钢丝疲劳断口裂纹扩展区微观形貌的SEM照片：(a)相同直径接触对；(b)不同直径接触对
Figure 17. SEM micrographs of micro morphology of crack propagation region of fatigue fractograph: (a) same diameter contact pairs; (b) different diameter contact pairs
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图 18 钢丝疲劳断口瞬断区微观形貌的SEM照片：(a)相同直径接触对；(b)不同直径接触对
Figure 18. SEM micrographs of micro morphology of final fracture region of fatigue fractograph: (a) same diameter contact pairs; (b) different diameter contact pairs
表 1 钢丝的化学组分
Table 1 Chemical composition of steel wire
w (Fe)/% w (Mn)/% w (Si)/% w (Ni)/% w (C)/% w (S)/% w (P)/% 98.71 0.42 0.02 0.01 0.83 0.001 ＜0.001 
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表 2 试验参数
Table 2 Test parameters
Parameters Specifications Parameters Specifications Diameter of fatigue wire 1.4 mm Number of cycles, N 3.0×104 Contact force, Fn 40 N; 60 N; 80 N; 100 N Frequence, f 3.0 Hz Displacement amplitude, δ 80 μm Torsion angle, θ 6.0° Crossing angle, α 30° Initial tensile force, Fpr 500 N Contact radius, R 50 mm Temperature 30±3 ℃
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期刊类型引用(1)
1. 常向东，彭玉兴，刘送永，程志红，黄坤. 钢丝绳摩擦学性能测试实验平台研制与教学应用. 实验技术与管理. 2024(11): 137-145 . 
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