目的 甲醇发动机工作时因其燃料特性易导致润滑油稀释、酸值升高,生成甲酸、甲醛等腐蚀性产物,严重恶化缸套-活塞环的摩擦性能,导致摩擦损耗增多,此时珩磨缸套网纹形貌能起到一定的抑制作用。方法 为探明这种影响机理,在缸套网纹形貌设计的基础上建立缸套-活塞环摩擦副的有限元数值计算模型,探究了缸套-活塞环摩擦副在不同表面形貌特征下磨损量、摩擦应力的变化规律。选用MMW-1000型立式万能摩擦磨损试验机进行销-盘摩擦副试验研究,验证有限元仿真分析结果的可靠性和准确性,研究分析在不同转速与载荷条件下,表面形貌特征对摩擦副摩擦性能的影响。结果 在甲醇燃料导致的润滑稀释前提下,不同转速与载荷的珩磨缸套网纹表面的摩擦系数整体低于光滑表面,珩磨角度为45°时的磨损量为0.001 4 g,表面磨损量较光滑表面降低了39.13%,相较于其他珩磨角度的数据更为优异。结论 珩磨网纹形貌设计显著降低了缸套表面的磨损量和应力应变程度。其中珩磨角度为45°时表现出更好的摩擦学特性,为甲醇发动机缸套-活塞环摩擦副的珩磨形貌设计提供了理论依据。
Abstract
To address the critical issue where in methanol engines, owing to inherent fuel properties, trigger lubricating oil dilution, elevated acid value, and the formation of corrosive byproducts (e.g. formic acid and formaldehyde), which ultimately exacerbate wear of the cylinder liner-piston ring friction pair, this study focuses on the effect of honing crosshatch angle on the tribological performance of the friction pair. A synergistic approach combining numerical simulation and experimental validation is employed to determine the optimal honing parameters and elucidate their intrinsic mechanism of action.
Based on Archard's wear theory, a finite element model of the cylinder liner-piston ring friction pair is established to simulate the variations in wear volume and friction stress for four distinct honing angles (35°, 45°, 55°, 65°) and a smooth surface under methanol-induced lubrication dilution conditions. Using the control variable method, honed crosshatch specimens with the aforementioned angles are fabricated via a laser marking machine. Laser processing parameters are precisely calibrated as follows: power of 30 W, scanning speed of 200 mm/s, frequency of 20 kHz, and a single scanning pass, ensuring consistent crosshatch depth and width across all specimens. A pin-on-disk friction pair is configured, with the upper specimen made of GCr15 and the lower specimen of 40Cr. A mixture of methanol and 10W-40 lubricating oil is utilized to replicate the degraded lubrication environment inherent to methanol engines. Tribological performance tests are conducted on an MMW-1000 vertical universal friction and wear tester, covering a load range of 10-25 N and a rotational speed range of 150-600 r/min, to validate the reliability and accuracy of the simulation results.
Simulation results demonstrate that the wear volume of honed crosshatch surfaces is significantly lower than that of the smooth surface. Specifically, the 45° honing angle yields the minimum wear volume (1.12×10-13 mm3), representing a 32.11% reduction compared with the smooth surface. Furthermore, this angle exhibits the optimal friction stress stability, with a maximum friction stress of only 10.44 MPa, which is lower than those of the other angles and the smooth surface (13.41 MPa for the smooth surface). Experimental results are highly consistent with the simulation outcomes: the wear volume of the specimen with a 45° honing angle is 0.001 4 g, a 39.13% decrease relative to the smooth surface (0.002 3 g). Under varying load and rotational speed conditions, the friction coefficient of honed crosshatch surfaces is generally lower than that of the smooth surface, and the 45° angle surface demonstrates the most stable friction coefficient during the steady wear stage.
Key experimental insights reveal that honed crosshatches mitigate abrasive wear substantially by capturing wear debris and storing lubricating oil in micro-grooves to enable secondary lubrication, an effect particularly prominent under methanol-lubricated dilution conditions. The 45° honing angle achieves an optimal balance between the oil storage capacity of micro-grooves and hydrodynamic lubrication effects, facilitating the formation of a stable hydrodynamic oil film and effectively suppressing fluctuations in friction stress. Under high loads, honed crosshatches enhance hydrodynamic effects through squeeze lubrication, thereby preventing a significant increase in the friction coefficient with increasing load. At high rotational speeds, centrifugal force drives lubricating oil from the micro-grooves to replenish the contact surface, whereas the smooth surface exhibits elevated friction coefficients due to lubricant loss. This study confirms that the design of honed crosshatch morphology significantly reduces the wear volume and stress-strain levels of the cylinder liner surface. Notably, the 45° honing angle exhibits superior tribological properties, and its unique friction and wear reduction mechanism is systematically clarified. These findings provide a robust theoretical foundation for the optimization of honing morphology design for cylinder liner-piston ring friction pairs in methanol engines.
关键词
甲醇发动机 /
缸套 /
珩磨网纹 /
珩磨角度 /
摩擦磨损 /
摩擦性能
Key words
methanol engine /
cylinder liner /
honing crosshatch /
honing angle /
friction and wear /
friction performance
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