Surface-roughness measurement using dry friction noise

A new technique for determining surface roughness is introduced. It is based upon measuring the generated noise due to dry friction of a metallic blade which travels over the surface under consideration. If the frictional force is made small enough to excite the blade, and not the entire system, then the noise will be proportional to surface roughness, and independent of the measured specimen size and material. A prototype acoustic device was designed and constructed and then used to substantiate the technique. Several specimens were machined by different machining processes to obtain a wide range of roughnesses. The specimen surface roughness was measured by a widely used commercial instrument (Talysurf 10), and the prototype transducer. A straight line correlation (on a logarithmic graph) between sound pressure levels (SPL), obtained from the transducer, and roughnesses, obtained from the Talysurf instrument, was found over the range from 0.025 to 100 m. The coefficient of correlation between the measured values of SPL and roughness was as high/as 98 percent. Therefore, the technique could be adopted for measuring roughness and the prototype may thus be considered as a new roughness measuring device.The prototype device has the advantages of being sensitive, accurate and compact. It also has the capability of measuring the roughness of almost any type of surface regardless of its shape, material and complexity. Hence it is considered adequate for most engineering applications.     

Thermal contact conductance of nominaly flat surfaces

The variation of thermal conductance of contact has been investigated as a function of apparent contact pressure experimentally. Experimental data has been obtained for steel, brass, copper and aluminum test pieces having different surface roughness over a wide range of contact pressures. Experimental results are compared with the theoretical predictions of an existing theory. Comparison revealed good agreement of trend with the experimental data, however, numerical values vary widely. Theory can predict the experimental results within an over-all error of less than 35%. An erratum to this article can be found at     

The Effect of Isopropyl Alcohol and Non-Ionic Surfactant Mixtures on the Wetting of Porous Coated Paper

The influence of isopropyl alcohol and non-ionic surfactant solutions on aqueous droplet wetting behaviour on porous coated paper was determined. Paper coatings provide a micro- and nano-porous surface structure, which strictly speaking cannot be described in simple roughness terms as sub-surface lateral absorption directly impacts on the apparent contact angle. It is this very deviation from an idealised system that leads to novel wetting phenomena. Isopropyl alcohol and surfactant-based systems, both of which are commonly used in the printing industry, show differences in wetting behaviour, on both short and long timescales, with changes in the relative composition of the mixtures. Small variations of 0.1?wt% in surfactant concentration have a dramatic influence on the dynamic surface tension, and thus the wetting. It was observed that the wetting kinetics for isopropyl alcohol and surfactant solutions were different in terms of both wetting area and the penetration rate, even in cases where the dynamic surface tension of the solutions was kept the same. Different stages in the wetting and following drying processes could be observed with near infrared spectral imaging. In addition, the surfactant chemistries such as their degrees of hydrophilicity and molecular weights generated comparative differences in the wetting kinetics. The dominating factor affecting the wetting was, as expected, the solid?Cliquid interfacial energy defined on the practical porous substrate, which differed from the direct comparison with dynamic surface tension, thus exemplifying the deviation from idealised surface roughness behaviour when considering porous materials. An apparent ??equivalent?? surface roughness value for the porous material was determined, and it was seen that an increase in this equivalent parameter enhanced the rate of wetting behaviour with decreasing solution surface tension, and so also affected the wetting evolution. The wetting was enhanced by cavities in the coating layer, which were enlarged by the penetrating liquids.     

滤波截止频率对粗糙点接触机理影响研究

使用基于快速傅里叶变换和共轭梯度法的接触程序,分析了滤波截止频率对粗糙点接触机理的影响.计算结果表明:粗糙表面形貌数据再处理时使用的滤波器滤波截止频率,对力-接近量关系有着明显的影响;滤波截止频率越小,接触面积越大,接触压力越小;滤波截止频率的改变会导致Von M ises应力的显著改变,这种改变在接触面上特别明显.因此,在实际研究粗糙表面的接触机理时,选择合适的滤波截止频率是非常必要的.     

Friction measurement at low sliding speed using a servohydraulic tension-torsion machine

A method is presented for the determination of the coefficient of friction at low sliding speeds down to 3 nm/s. It is also possible to vary the contact pressure. The maximum average contact pressure is 40 MPa in the present test configuration, where a servohydraulic tension-torsion machine is used. The method, involving test equipment, measurement and the principles of evaluation, is exemplified by a study where the variation of the coefficient of friction with sliding velocity contact pressure and surface roughness is investigated for the material combination steel and concrete. The measurements have been performed as a 2³ factorial design. An error analysis was performed and the relative measurement uncertainty when determining the coefficient of friction was estinated to be 1.2 percent.     

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.     

磨合表面形貌特征参数的提取及分析

在销-盘式摩擦磨损试验机上对船用柴油机活塞环-缸套材摩擦副进行磨合磨损试验,采用光学显微镜对不同磨损阶段的磨损表面形貌进行观察分析,应用小波分析和奇异值分解提取磨损表面统计特征的低频特征参数和高频特征参数.结果表明:低频特征参数和高频特征参数刻画了磨合表面的形貌特征,可以作为磨合表面的特征参数;低频特征参数反映了磨合表面的接触面积,其值愈大,接触面积愈大;高频特征参数反映了磨合表面的粗糙度,其值愈大,粗糙度愈小.     

电梯轮轨耦合高频振动计算模型研究

电梯导轮和导轨相互作用产生的高频振动是电梯噪音的主要来源之一,本文基于导轨、导轮和电梯框架等各柔性构件的频响函数,建立了耦合振动系统的频域计算模型。分析了导轨表面粗糙度、导轮偏心和扁疤等激励对电梯高频振动的影响。通过与实测数据进行比较．验证了计算模型的有效性．从而为电梯的减振降噪设计提供了有用的分析工具。     

摩擦材料应用方式对超声波电机驱动特性的影响

摩擦材料是超声波电机的关键零件,其应用方式直接影响超声波电机的驱动特性.以行波超声波电机为研究对象,将摩擦材料分别应用到转子和定子上,与相应的定子和转子组合,模拟超声波电机的接触方式,研究了超声波电机的负载和磨损特性随摩擦材料应用方式的变化规律.借助于阻抗仪测试了摩擦材料应用到定子齿面前后的阻抗特性,采用精密粗糙度仪和金相显微镜评价了超声波电机定子和转子接触界面磨损前后的形貌变化及其磨损模式.结果表明:当摩擦材料应用到定子齿面时,定子的谐振频率略微降低;当2台超声波电机空载转速相同时,摩擦材料应用到定子齿面与金属转子配副时可获得较大的堵转力矩,定子摩擦材料表面呈现抛光的磨损特征,而当摩擦材料应用到转子表面与金属定子配副时,转子摩擦材料表面呈现较严重的犁沟磨损.     

An interpretation of the stability of a turbulent shear flow near a rough wall

A conventional, small perturbation, stability analysis has been applied to a fully developed turbulent shear flow in a parallel duct with rough walls. This is an attempt to detect the inherent state of flow stability to quasi-regular disturbances emanating from the surface roughness elements. The surface roughness is represented by the usual roughness Reynolds number; it is fed into the analysis through an assumed mean velocity profile valid between the viscous sublayer and the inner (wall) region. An eddy viscosity model is used to secure the equation closure and the final equation for the perturbation amplitude has been solved numerically using the techniques developed for the Orr-Sommerfeld equation.Within the domain of realistic flow conditions, and for a range of surface roughness amplitudes, a local minimum of stability in terms of the longitudinal wave number has been found. However, it is not implied that it is a minimum minomorum, as only a limited range of surface roughnesses has been tried.     

基于分形理论的双渐开线齿轮接触应力研究

综合考虑接触面粗糙度、材料特性等因素对齿轮接触应力的影响,基于分形理论和经典Hertz接触理论建立双渐开线齿轮分形接触模型. 该模型中,影响载荷和实际接触面积的主要因素包括分形维数、粗糙度幅值和材料特性参数. 理论分析表明:分形维数一定时,真实接触面积随着载荷的增大而增大;载荷一定时,接触面积随着粗糙度幅值的增大而减小;随着材料特性参数值的增加,在一定程度上加强了软材料轮齿承载能力,同时会使得微凸体由弹性变形到塑性变形的临界面积减小. 对比分形接触模型和有限元模型两种计算双渐开线齿轮轮齿接触应力方法,结果证明了分形接触模型计算双渐开线齿轮接触应力的有效性.      

考虑界面粗糙度动态变化的点接触弹流润滑特性研究

针对点接触弹流润滑的粗糙度效应,建立了考虑表面粗糙度动态变化的点接触弹流润滑模型,实现了油膜厚度和压力分布的快速求解. 对点接触弹流润滑下的粗糙表面弹性变形进行了定性和定量研究,同时分析了表面均方根粗糙度、载荷、相对运动速度和滑滚比对最小膜厚和最大压力的影响,以及表面形貌动态变化对膜厚比的影响. 结果表明:形貌变化改变了弹流油膜和压力分布特性,相对于光滑表面,表面粗糙度总体上提高了最大接触压力、降低了最小膜厚,在轻载工况下表面粗糙度对油膜厚度的削弱更加显著,而不同速度下粗糙度的影响程度基本相同,呈现线性变化趋势,膜厚比随载荷增大呈现先增后减的变化趋势,并在530 MPa左右达到峰值.      

涂层表面粗糙性对流体噪声的影响

在铝合金回转体表面涂上一定粗糙度的低表面能涂层，涂层表面的不平度平均高度在６．３～１０．０μｍ时，涂层模型表面为光滑水力壁，这时表面粗糙所引起的那部分流噪声可忽略不计．在光滑（Ｒｚ＝３．２～６．３μｍ）的铝合金模型表面喷涂涂层后，涂层表面较粗糙（Ｒｚ＝１０．０～２０．０μｍ）时，同样在相应的频率范围内涂层模型仍有降噪的效果，而且对不同涂层材料其表面粗糙度对流噪声的影响也不相同．     

马氏体钢表面磁控溅射类金刚石薄膜滚动接触疲劳失效机理

采用磁控溅射技术在马氏体钢基体表面制备类金刚石(DLC)薄膜,应用扫描电镜、Raman光谱仪和划痕测试仪等对薄膜进行表征. 基于对失效表面及截面微观特征的详细分析,研究了DLC薄膜在接触疲劳载荷下的失效特征和机理. 结果表明:DLC薄膜试样的滚动接触疲劳(RCF)寿命比基体的寿命显著提高,且薄膜磨损后试样的剩余寿命仍比原基体寿命长. 薄膜厚度3 μm,处于接触最大应力分布的15 μm范围内. DLC薄膜是从基体表面粗糙峰处产生微裂纹进而导致薄膜剥落,基体材料裸露,最终试样失效.      

Spanwise variations in nominally two-dimensional rough-wall boundary layers

Laboratory experiments have been conducted in two separate boundary layer facilities to investigate steady spanwise variations in mean velocity discovered during studies of developing flows over regular arrays of large roughness elements. Regular spanwise variation was found with a steady wavelength, moderated by the growing boundary layer, which was an integer multiple of the repeating unit of roughness. Amplitude variations greater than ±5% in the mean were found over the roughness and greater than ±10% in turbulence quantities. Due to the dominating nature of this phenomena throughout the layer, care should be taken in undertaking local measurements aimed at identifying flow variations caused by roughness heterogeneity.     

An adhesive wear model of fractal surfaces in normal contact

A generalized adhesive wear analysis that takes into account the effect of interfacial adhesion on the total load was developed for three-dimensional fractal surfaces in normal contact. A wear criterion based on the critical contact area for fully-plastic deformation of the asperity contacts was used to model the removal of material from the contact interface. The fraction of fully-plastic asperity contacts, wear rate, and wear coefficient are expressed in terms of the total normal load (global interference), fractal (topography) parameters, elastic–plastic material properties, surface energy, material compatibility, and interfacial adhesion characteristics controlled by the environment of the interacting surfaces. Numerical results are presented for representative ceramic–ceramic, ceramic–metallic, and metal–metal contact systems to illustrate the dependence of asperity plastic deformation, wear rate, and wear coefficient on global interference, surface roughness, material properties, and work of adhesion (affected by the material compatibility and the environment of the contacting surfaces). The analysis yields insight into the effects of surface material properties and interfacial adhesion on the adhesive wear of rough surfaces in normal contact.     

Experimental investigation of thermal contact conductance for nominally flat metallic contact

A unique experimental set-up was fabricated to carry out axial heat flow steady state experiments for the assessment of thermal contact conductance (TCC) at the interface of two materials. Three different materials (copper, brass and stainless steel) were selected for the experiments considering their mechanical and thermal properties. Heat transfer experiments were performed in vacuum environment (0.045 torr) to find out solid spot contact conductance for nominally flat surfaces with different surface roughness (1–5 μm) for each specimen under several load conditions (0.6–15 MPa). A precise estimation of TCC for the interface of sets of similar materials was one of the most important results of this research. The effects of the surface roughness, the material properties and the load conditions (nominal interface pressure) have been studied and documented. Furthermore, the experimental results of solid spot contact conductance were compared with four theoretical models, showing their limitations to make a precise estimation of the TCC in the range of the used parameters.