激光微造型对偶片的反变形主动设计及液粘传动机理研究

The structure and surface properties of dual plate affect greatly the transmission performance and service life of hydroviscous speed regulation clutch. New idea was brought forward coupling the reverse deformation with laser texturing technology for the function-oriented structure design and surface micro texture on dual plate. Through this new method, the surface modification and structural optimization for dual plates can realize. The following scientific problems were investigated: the precision control for micro morphology of the dual plate surface, the temperature rise and deformation law of dual plate, the design criteria for reverse deformation of dual plate structure, and the new hydroviscous drive mechanism for new dual plate. By the laser texturing technology test and the hydroviscous drive test, process parameters database for surface morphology and distribution of dual plate can be developed. In the process of starting, speed control and synchronization, temperature rise and deformation law for dual plates was discussed. To meet the demand of minimum surface deformation, active design method of dual plate structure was investigated. With the theory of tribology, fluid dynamics and heat transfer, the influence of surface topography of the dual plate on the bearing force of the oil film, torque transfer capacity, cooling and chip removal were explored combined with experiment and numerical simulation. The hydroviscous transmission mechanism was studied for the coupling laser texturing and with reverse deformation of dual plate. Ultimately, the high performance and long life of dual plate can be achieved by active design, also the hydroviscous transmission with high efficiency and energy saving can be obtained.

对偶片的结构和表面性能对液粘调速离合器的传动性能和寿命具有至关重要的影响。本项目提出综合反变形和激光微造型技术对对偶片进行结构和表面微织构主动设计制造的新思路，实现对偶片表面的改形改性以及结构的优化。项目针对对偶片表面微观形貌的精确控制工艺、对偶片温升及变形规律、对偶片结构的反变形主动设计准则、以及新型对偶片的液粘传动机理等科学技术问题开展深入系统的研究。通过激光造型工艺试验和液粘传动试验，建立对偶片表面可控形貌及分布的工艺参数库；研究启动、调速、同步过程中对偶片温升及变形规律；以传动过程对偶片型面变形最小为优化目标，研究对偶片结构的主动设计方法；通过摩擦学、流体动力学和传热学，结合数值分析和实验探索对偶片表面形貌对摩擦副间油膜承载力、传递扭矩能力、散热和排屑的影响规律，研究耦合激光微造型和反变形的对偶片的液粘传动机理。最终达到高性能长寿命对偶片主动设计的目的，实现高效节能的液粘传动。

对偶片的结构和表面性能对液粘调速离合器的传动性能和寿命具有至关重要的影响。本项目提出综合反变形和激光微造型技术对对偶片进行结构和表面微织构的主动设计制造，围绕对偶片的液粘传动机理、对偶片温升及变形规律以及对偶片微观形貌设计等科学技术问题开展深入系统的研究。首先建立了油槽影响下油液流动的数学模型，得到了油液动压力的解析解，分析了油槽动压效应的演变过程及其对扭矩传递的影响规律，并提出油膜等效半径的计算模型。其次在摩擦副混合摩擦工况下建立了摩擦副三维导热模型，探索了热边界条件中的热流密度以及对流换热系数的计算模型，研究了摩擦副温度场理论求解过程，结合热机耦合方法，获得了摩擦副材料和油槽形貌对摩擦副应力分布和变形的影响规律。最后针对多组摩擦副间的油膜厚度不一致导致摩擦副扭矩传递的差异的现象，提出利用对偶片表面微织构技术增强油膜承载力的方法，并建立了带微凸体的油膜仿真模型，得到了织构参数对油膜承载力和扭矩传递的影响，并搭建可视化液粘调速离合器实验平台验证了理论分析的可靠性。最终达到高性能长寿命对偶片主动设计的目的，实现高效节能的液粘传动。成果在大型农业输送设备调速装置、石化用大型调速离合器等领域得到了应用。项目已录用及发表核心论文24篇（10篇SCI源刊，2篇EI检索），会议论文2篇，申请发明专利11件，授权发明专利11件，培养博士1名，硕士生6人，国际会议交流5人次，获省部奖二等奖3次，三等奖1次，协会奖1次。