ISSN   1004-0595

CN  62-1224/O4

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气体和液体润滑条件下圆凹坑织构的流体动压仿真分析及承载力图

Simulation Analysis and Load-carrying Capacity Map of Dimple Textures under Gas and Liquid Lubrication Conditions

  • 摘要: 为了探讨气体润滑的织构设计准则,为热气机活塞环的优化设计提供参考,采用数值仿真的方法对圆凹坑织构在气体和液体润滑条件下的承载力差异进行了对比. 分析了润滑介质黏度和可压缩性对承载能力的影响,并改变织构的半径、面积率和深径比,做出了2种润滑条件下的织构承载力图,寻找适用于气体和液体润滑的最佳参数. 结果表明:2种润滑条件下织构都能提高承载力,但作用机制存在显著差异:液体润滑的额外承载力主要源于空化效应,而气体润滑则依赖于高低压区的压力差. 液体润滑的最佳深径比范围为0.01至0.02. 气体润滑的最佳深径比为0.005至0.010. 气体的可压缩性使得高压区的持续范围较大,即使面积率较小(如10%)时也能产生较大的承载力,因此气体润滑在10% ~ 50%的面积率范围内都可以产生较大的承载力,且通过交错排列织构或增大间距可进一步提升承载力,而液体润滑不适用这些方法,并且需要更大的面积率,最佳面积率范围约为30% ~ 60%. 该研究对热气机活塞环的表面织构化设计具有一定的参考意义.

     

    Abstract: The Stirling engine is an externally heated combustion engine that uses gas as the working medium. It has the advantages of high thermal efficiency, low noise, and low pollution. To prevent the contamination of the gas medium, the engine uses an oil-free lubrication design. The PTFE-based piston rings operate under high temperatures, high pressure, and varying loads, making them prone to wear, which can reduce sealing performance, increase leakage, lower engine efficiency and shorten the engine’s lifespan, or even damage the entire engine. Therefore, improving the wear resistance of the piston rings in Stirlingr engines has become an urgent issue. Surface texturing, as an effective method to reduce friction and improve lubrication, has been widely used for tribo-pairs such as the internal combustion engines with oil lubrication. By conducting a comparative analysis of the load-carrying capacity of the dimple textures under gas and liquid lubrication conditions, this study aims to explore the differences between gas lubrication and liquid lubrication, summarize design guidelines for texture parameters under gas lubrication, and provide references for the textured design of piston rings in Stirling engines. A numerical simulation approach considering the deformation of the rings and the compressibility of the working medium was adopted to compare the effects of surface textures under both gas and liquid lubrication conditions. By varying parameters such as dimple diameter, area ratio and depth-to-diameter ratio, the load-carrying capacity map was drawn for dimple textures under both gas and liquid lubrication conditions, using the depth-to-diameter ratio and area ratio as coordinates, the influence mechanisms of dimple textures on gas and liquid lubrication were discussed, and the optimal parameters for each lubrication condition have been identified. The results showed there were significant differences between gas and liquid lubrication conditions. The load-carrying capacity in liquid lubrication mainly relied on the suppression of pressure drop through cavitation effects, while in gas lubrication, it primarily arises from the pressure difference between high-pressure and low-pressure regions. The load-carrying capacity maps indicated that the optimal depth-to-diameter ratio under liquid lubrication was larger, with values between 0.01 and 0.02, while for gas lubrication, it was smaller, around 0.005 to 0.010. The compressibility of gas allowed a larger high-pressure zone to be sustained, enabling significant load-carrying capacity even from a small area ratio 10% to a large area ratio 50%. Additionally the load-carrying capacity could be further enhanced by using an interlaced texture arrangement or increasing the spacing between textures, these two methods could provide a larger sustained range for high-pressure areas. In contrast, liquids were incompressible, high-pressure zone could not be sustained, thus liquid lubrication does not supported these methods and required a larger area ratio, with an optimal value around 40%.

     

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