制动盘材料表面织构化处理对摩擦噪声影响的试验分析

在列车制动盘材料表面加工出径向均匀分布的具有不同宽度的沟槽,采用列车制动片为配副材料,在面-面接触模式下对其进行了销-盘式摩擦噪声试验研究,探讨织构表面对摩擦尖叫噪声特性的影响及其作用机理.结果表明:具有特定合理尺寸参数的织构表面能有效地抑制摩擦尖叫噪声.表面沟槽的存在,一方面能提高界面的排屑效率,抑制尖叫噪声的产生,另一方面沟槽棱角与摩擦片平面的碰击能有效地抑制界面摩擦自激振动的高频成分,并达到降低噪声的效果.沟槽的棱角在整个试验过程中保持完好,其降噪作用寿命时间较长.     

时变接触特性表面对界面摩擦学行为的影响

通过在锻钢基材表面沟槽中分别填充灰铸铁HT300、Mn-Cu合金和Mn-Cu阻尼合金材料获得具有时变接触特性的表面,并对锻钢光滑表面试样和时变接触特性表面进行摩擦学试验,研究不同时变接触特性表面对界面摩擦学行为(摩擦噪声、摩擦振动以及磨损行为)的影响. 结果表明:填充HT300的时变接触特性表面缓解了界面磨损,有效延续摩擦系统的稳定状态,抑制摩擦振动和噪声的产生;相反,填充Mn-Cu合金和填充Mn-Cu阻尼合金的时变接触特性表面加剧了界面磨损,加速了摩擦系统不稳定状态的出现,进而激发出高强度的摩擦振动和噪声. 在本研究中,摩擦系统失稳引起摩擦振动和噪声主要归因于摩擦磨损过程中黏着撕裂和犁削等界面作用,填充材料的阻尼特性未能起到减振降噪的效果.      

表面粗糙度对摩擦尖叫噪声特性的影响

采用不同结构刚度的测量装置,对光滑表面和喷砂处理表面进行滑动摩擦噪声对比试验,研究不同粗糙度表面在不同试验装置上的摩擦尖叫噪声特性及其对摩擦尖叫噪声的影响和作用机理.结果表明:摩擦表面粗糙度和磨损情况对摩擦尖叫噪声的产生及演变具有重要的影响,表面粗糙度越大的喷砂处理表面能更明显地抑制界面摩擦尖叫噪声的产生.本试验条件下,磨屑堆积和黏着剥落等磨损特征对应的黏着撕裂作用更易引起摩擦力高频成分的产生并导致较高强度的尖叫噪声,而喷砂处理的粗糙表面能减轻这些界面因素的形成,削弱摩擦力高频成分,抑制摩擦尖叫噪声的产生.     

沟槽表面填充材料对界面摩擦振动噪声的影响

采用机械加工方式,在基体(蠕墨铸铁)表面加工出平行且等间距的沟槽,并在沟槽中分别填满铝材料和锻钢材料,对该填充材料试样和基体试样进行界面摩擦噪声试验,并采用数值模拟方法加以分析,得出界面摩擦振动噪声行为在不同沟槽填充材料下的变化特性,并将不同界面摩擦磨损行为与振动噪声动态关联起来.试验及数值模拟结果表明,在沟槽中填充铝材料加剧界面磨损,增大摩擦系数,并加速系统不稳定振动的产生,增大噪声强度,而在沟槽中填充钢材料能有效延缓界面不稳定振动和摩擦尖叫噪声信号的产生.此外,计算结果表明,界面磨擦磨损行为导致的界面接触非线性特性是产生多频率不稳定振动和噪声的重要因素.     

接触共振频率与摩擦噪声频率之间关系的试验研究

在金属往复滑动试验机上用2种尺寸不同和结构略有差别的球-平面摩擦副系统,对接触共振与摩擦噪声的相关性进行了试验研究.结果表明:摩擦系统的接触共振频率非常接近于摩擦噪声频率,两者相对误差不大于2%~5%.对发生尖叫噪声的磨痕形貌进行SEM扫描电镜分析发现:摩擦噪声的发生与摩擦过程中微凸体之间的锤击相互作用有着密切的联系,通过接触共振试验可以辨识实际滑动摩擦系统中最容易发生摩擦噪声的模态频率.     

沟槽型织构化表面摩擦噪声特性试验研究

用电火花加工方法在制动盘蠕墨铸铁材料表面加工出不同沟槽宽度和间距的沟槽型表面织构,在自行研制的新型摩擦噪声试验装置上,采用球-平面接触方式,选取直径10 mm的GCr15球为对摩副,对沟槽型织构表面和光滑表面进行摩擦噪声对比试验,研究沟槽型织构对摩擦噪声的影响.结果表明:本试验条件下沟槽型表面织构的尺寸及分布对摩擦噪声具有重要影响,一定尺寸及分布的织构表面可明显降低摩擦噪声.本试验条件下的摩擦噪声产生主要归因于接触表面的不平顺、磨屑层不均匀分布以及犁削作用等界面因素,这些因素导致了界面摩擦力高频成分的产生,当其与系统的自然频率耦合时,将引起摩擦系统强烈的自激振动并最终产生摩擦噪声.而摩擦界面存在尺寸分布合理的沟槽型表面织构,将能提高界面排屑能力并打断摩擦界面连续的接触,扰乱摩擦系统的自激振动,抑制摩擦噪声的产生.     

盘-销摩擦系统摩擦接触力测试与特性分析

测量分析动态摩擦接触力是研究摩擦振动与噪声发生机理的关键.本文中建立了盘-销系统摩擦尖叫试验台架,成功再现了摩擦尖叫.采用三向力传感器对有无摩擦尖叫条件下的动态摩擦接触力进行了测量,并利用小波信号分解、概率密度函数、功率谱密度函数、时频分析等方法进行了分析和讨论.研究发现:在发生摩擦尖叫时,动态摩擦力和法向力发生高频波动,是系统噪声的激励源;无摩擦尖叫时的摩擦力和法向力的动态分量为典型的白噪声随机过程,呈非高斯分布;有摩擦尖叫时的摩擦力和法向力为窄带高频类谐波信号,摩擦力呈非高斯分布,而法向力近似为高斯分布;模态耦合是导致盘-销系统发生动态接触力高频波动以及摩擦尖叫的原因.     

摩擦粒子填充材料对高速列车闸片制动性能的影响

在自行研制的制动缩比试验台上,对中心孔填充不同材料的高速列车制动闸片摩擦粒子进行拖曳制动试验,并采用有限元分析方法进行制动系统复特征值和接触应力分析,探讨填充不同材料对磨损特性、振动噪声和热分布的影响. 结果表明:原始摩擦粒子中心孔填充材料后,对制动系统的摩擦系数和模态耦合特性未产生显著影响,但对界面磨损行为和系统振动噪声特性产生明显影响. 填充粉末冶金后排屑行为下降,磨损行为更为复杂,制动系统产生的噪声增大;而填充紫铜、石墨和铸铁后的制动噪声均有所降低,尤其填充铸铁后表面磨损相对均匀,其摩擦学性能相较于其他粒子得到一定的改善. 填充材料产生的磨屑及相应的界面磨损行为是影响制动摩擦振动噪声和表面热分布的关键因素,填充合理的材料有助于降低制动噪声和改善制动界面磨损行为及表面热分布.      

盘式制动器摩擦噪声特性的试验分析

盘式制动器制动时产生的摩擦噪声不仅影响车辆的驾乘舒适性,还会带来严重的环境噪声污染. 摩擦噪声具有瞬时性与不确定性的特点,至今尚未形成对制动器摩擦噪声机理的统一论断. 基于盘式制动器声振试验台,研究了摩擦系数、摩擦力波动系数和等效A声级三个参数在不同制动压力和制动初速度下的变化规律,结合对摩擦片微观特性的试验分析,从摩擦学角度揭示了盘式制动器摩擦噪声的发生规律及机理. 结果表明:摩擦噪声随制动初速度的增大而减小,随制动压力的增加而先增大后减小;制动摩擦噪声由于摩擦系统不稳定而产生,其产生原因是因为摩擦副表面的沟壑与黏着引起,沟壑与黏着程度与噪声的声压与频率呈正相关关系. 研究结果对于解释制动器摩擦噪声发生机理、控制制动器噪声污染具有重要理论意义和实际价值.      

摩擦磨损的接触界面势垒理论研究

根据系统和能量的观点,从摩擦界面的微观相互作用出发,提出摩擦磨损的接触界面势垒理论,研究接触界面势垒和标准接触界面势垒的计算方法,并推导出摩擦力、摩擦系数以及粘着磨损量的计算公式.研究表明,界面的摩擦磨损性能取决于接触界面势垒的大小和分布,用标准接触界面势垒作为表征摩擦副材料摩擦磨损特性的指标具有较好的独立性和稳定性.利用已有的实验数据进行计算,结果与超高真空原子力显微镜实验结果基本符合,验证了所提出理论和方法的可行性.     

Modeling of Solute Transport in a 3D Rough-Walled Fracture–Matrix System

Fluid flow and solute transport in a 3D rough-walled fracture–matrix system were simulated by directly solving the Navier–Stokes equations for fracture flow and solving the transport equation for the whole domain of fracture and matrix with considering matrix diffusion. The rough-walled fracture–matrix model was built from laser-scanned surface tomography of a real rock sample, by considering realistic features of surfaces roughness and asperity contacts. The numerical modeling results were compared with both analytical solutions based on simplified fracture surface geometry and numerical results by particle tracking based on the Reynolds equation. The aim is to investigate impacts of surface roughness on solute transport in natural fracture–matrix systems and to quantify the uncertainties in application of simplified models. The results show that fracture surface roughness significantly increases heterogeneity of velocity field in the rough-walled fractures, which consequently cause complex transport behavior, especially the dispersive distributions of solute concentration in the fracture and complex concentration profiles in the matrix. Such complex transport behaviors caused by surface roughness are important sources of uncertainty that needs to be considered for modeling of solute transport processes in fractured rocks. The presented direct numerical simulations of fluid flow and solute transport serve as efficient numerical experiments that provide reliable results for the analysis of effective transmissivity as well as effective dispersion coefficient in rough-walled fracture–matrix systems. Such analysis is helpful in model verifications, uncertainty quantifications and design of laboratorial experiments.     

渐缩平板间的缓变流

通过数值模拟方法探讨了渐缩平板间的不平行流动和缓变流的关系.分析了倾斜板的倾角对流动的影响.对采用EXP(C_ES)方式得到的数据,在板倾角为5.455°时不平行流动相对平行流动的偏差达1%,在13.26°时偏差达10%.这里取1%的偏差所对应的5.455°作为本文探讨的缓变流的临界角.最后讨论了数值模拟结果的合理性和可靠性.     

Closed-form expression of the similarity solutions for an air-filled, heavy membrane tube section on an incline

In this study, an air-filled, heavy membrane tube section resting on an incline is considered. The shape of the tube section is determined by the equilibrium of its weight and the transmural pressure. All quantities are normalized to obtain similarity solutions. A system of nonlinear ordinary differential equations with undetermined boundary conditions is solved analytically. The closed-form solutions are expressed in terms of the non-dimensional pressure for a given inclination angle. Using the results of this study, one can estimate the shape and characteristic values of a tube section without the burden of numerical calculations.     

Interaction of a plane shock wave with slitted wedges

An experimental and numerical study was made of shock wave transition over slitted wedges. Experiments were conducted in a shock tube by using double exposure holographic interferometry. Shock Mach numbers ranged from 1.07 to 3.03 in air. Slitted wedge models having perforation ratios of 0.34 and 0.4 were installed in the test section. The critical transition angle was obtained analytically by the shock polar analysis where effects of boundary conditions, wall suction, and surface roughness were empirically taken into account. As the results, it was found that for stronger shock waves and a perforation ratio of 0.4, the critical transition angle was decreased by about 10° in comparison to the detachment criterion. A flow visualization study clarified various wave interaction mechanisms associated with the wall suction. The critical transition angle was successfully explained by the shock polar analysis. The PLM numerical simulation was also conducted. The numerical result agreed very well with the experimental findings.     

Nonlinear stability analysis of a disk brake model

It has become commonly accepted by scientists and engineers that brake squeal is generated by friction-induced self-excited vibrations of the brake system. The noise-free configuration of the brake system loses stability through a flutter-type instability and the system starts oscillating in a limit cycle. Usually, the stability analysis of disk brake models, both analytical as well as finite element based, investigates the linearized models, i.e. the eigenvalues of the linearized equations of motion. However, there are experimentally observed effects not covered by these analyses, even though the full nonlinear models include these effects in principle. The present paper describes the nonlinear stability analysis of a realistic disk brake model with 12 degrees of freedom. Using center manifold theory and artificially increasing the degree of degeneracy of the occurring bifurcation, an analytical expression for the turning points in the bifurcation diagram of the subcritical Hopf bifurcations is calculated. The parameter combination corresponding to the turning points is considered as the practical stability boundary of the system. Basic phenomena known from the operating experience of brake systems tending to squeal problems can be explained on the basis of the practical stability boundary.     

Impact of contact stiffness heterogeneities on friction-induced vibration

It is well-known that the occurrence of squeal depends on numerous phenomena still relatively unknown. Furthermore, squeal is affected by several factors on both the micro and macro scales. The present paper proposes some potential interactions between stiffness heterogeneities of the contact surface and the potential for triggering the squeal.     

Sensitivity analysis and Kriging based models for robust stability analysis of brake systems

This paper presents a global strategy for the prediction of brake squeal. This approach is based on the global sensitivity analysis combined with Kriging modeling. The main aim is to assess the pertinence of using this strategy to build suitable and efficient instability predictors that can be potentially associated with numerical optimization schemes and/or robustness analysis algorithms for a robust design of brake systems. Through the use of a simplified brake system, the global sensitivity analysis is, firstly, shown to be essential for obtaining great insight on how design parameters influence individually and/or collectively the stability behavior. The latter is characterized by the distance of all the systems eigenvalues from the imaginary axis. It is shown that the so-called Sobol indices help for an objective quantification of the importance of taking parameter uncertainty into account in the whole design process. Based on these conclusions, Kriging modeling is, secondly, proposed to robustly predict friction induced instabilities. Its efficiency is then demonstrated. Consequently, the global sensitivity analysis and Kriging modeling give a very promising strategy helping for squeal prediction and, more generally, for optimal and robust design of brake systems.     

Characterisation of rough ground using an accelerometer for measurement

Rapid and accurate characterization of rough ground is essential for work concerning stability against overturning of agricultural tractors. This paper describes an accelerometer method of measuring ground roughness and develops the ideas necessary to ensure accurate interpretation of the results. These ideas follow from the conclusion, presented elsewhere, that the spectral density of random surface roughness will always fall off according to the square of frequency and that a single roughness constant will completely characterize the roughness. A method of estimating the roughness constant is presented. There is considerable discussion on sources of error, their numerical significance and methods of avoiding them.