面向产业化工艺链的内燃机激光微织构技术应用研究

发布时间：2018-12-23 18:14

【摘要】：摩擦磨损一直制约着全球工业的可持续发展,是能源危机的一个重要源头。其中航空航天设备、农业设备、轨道交通、船舶、能源化工装置、冶金机械、汽车工业是摩擦磨损的重点领域,汽车工业所占比例最大。缸孔-活塞环是内燃机中最重要的摩擦副,其对内燃机节能减排的影响极其关键,缸孔激光表面微织构技术是实现内燃机节能减排的先进表面技术之一。缸孔激光微织构技术所涉及的润滑理论研究成果丰富,各种台架试验结果已经表明其润滑减摩的效果显著。但是,激光与物质相互作用机理和表面织构改善机械效率的机理缺少系统微观层面阐述;分区异化设计准则和单脉冲同点间隔多次工艺的产业化应用都还需要进一步完善;相关的缸孔激光微织构产业化加工专机有待在样机的基础上不断改进;激光微织构缸孔的产业化一体式在线检测设备有待开发;产业化加工过程和加工设备的稳定性和可靠性缺乏评估考核体系;产业化过程中开发的新型激光微织构发动机需要相匹配的智能市场推广平台。本文即针对上述一些关键问题研究,主要内容如下:首先,详细分析了激光与物质的作用机理及过程,由此划分确定微凹腔结构的热影响区、边缘硬化区及中心加工区;针对缸孔激光微织构技术提出分区异化思想,对比分析单脉冲同点间隔多次技术的优势和影响因素。然后论证了数控机械珩磨工艺的必要性,并通过工艺试验,确定前道镜面工艺的评定参数、范围,以及后处理抛光工艺的参数和具体工时。其次,选取某款四缸汽油机为研究对象,确定产业化整体规划设备布局,开展产业化激光微织构装备和数控机械珩磨装备的研制。以光学、机械、电气、控制四个主要模块为基础,系统集成激光微织构装备。剖析方波信号的产生、信号匹配和脉冲重叠之间的关系,提出实现光学、机械与控制三位一体的联动协调控制方法。以机械、液压、辅助、控制四个关键模块为基础,系统集成数控机械珩磨装备,采用德国BECKOFF系统,实现手动、半自动、自动不同模式的控制加工。再次,通过测量分析缸孔激光微织构加工表面质量问题,提出新型表面微织构形貌的测量原理,并据此设计了一体式在线检测装置。测量装置主要包括运动控制、定位夹紧及测量三个部分。通过LabVIEW对数据进行显示、处理和分析,利用Matlab提取测量结果的特征轮廓,实现轮廓曲线中的二维点数值的三维重现,形成拟合的曲面,最终获取微织构三维形貌,并且通过测量实验,验证了新型测量系统的准确性和快速性。从次,基于加工质量固有和非固有波动的特征,需要强化加工过程的质量策划、质量保证、质量控制。本文系统介绍了质量体系的组成和基本理论,针对加工系统,将激光微织构装备和数控机械珩磨装备作为一个整体,进行机器能力和过程能力评估;对于测量系统,根据产品测量的参数运算相关评估指数,独立分析其相关质量性能。评估结果符合基本理论要求,产业化生产的稳定性得到保证。最后,为加快激光微织构技术在汽车发动机行业的产业化进程,构建市场化的推广平台,作为连接企业与客户的重要纽带,是实现大规模产业化的关键举措。本文以横向维度、纵向维度和综合评价三个模块为基础,以建立多样化、定制化、智能化的产业链为目标,开发了一套基于eCATALOGsolutions的推广应用平台体系,用于满足市场需求。
[Abstract]:The friction and wear have always restricted the sustainable development of the global industry, and it is an important source of the energy crisis. in which the aerospace equipment, the agricultural equipment, the rail transit, the ship, the energy chemical device, the metallurgical machinery and the automobile industry are the key fields of the friction and wear, and the automobile industry accounts for the largest proportion. Cylinder bore-piston ring is the most important friction pair in internal combustion engine. It is very important to the energy-saving and emission reduction of internal combustion engine. The research results of the lubrication theory involved in the laser micro-structure of the cylinder hole are rich, and the results of various bench tests have shown that the lubricating and friction-reducing effect is remarkable. However, the mechanism of the interaction between the laser and the material and the mechanism of the surface-woven structure to improve the mechanical efficiency are lack of the system micro-level. The relevant cylinder-hole laser micro-weaving machine special machine is to be continuously improved on the basis of the prototype; the integrated on-line detection equipment of the industrialization of the laser micro-woven cylinder hole needs to be developed; and the stability and the reliability of the industrial processing and processing equipment lack an evaluation and assessment system; The new type of laser micro-woven engine developed in the process of industrialization needs to be matched with the intelligent marketing platform. The main contents of this paper are as follows: First, the mechanism and process of the action of laser and substance are analyzed in detail, and the thermal influence area, edge hardening area and central processing area of the micro-cavity structure are determined. In this paper, the author puts forward the idea of partition dissimilation aiming at the laser micro-weaving technology of the cylinder hole, and compares the advantages and the influence factors of the multi-technology of the single-pulse and the same-point interval. Then, the necessity of the mechanical polishing process is demonstrated, and the parameters and working hours of the process of post-processing and polishing are determined by the process test. Secondly, a four-cylinder gasoline engine is selected as the research object, and the layout of the industrial overall planning equipment is determined, and the development of the industrial laser micro-weaving equipment and the mechanical and mechanical polishing equipment is carried out. Based on the four main modules of optical, mechanical, electrical and control, the system integrates the laser micro-structure equipment. The relationship between the generation of square wave signal, signal matching and pulse overlap is analyzed, and the coordinated control method of optical, mechanical and control is proposed. Based on the four key modules of mechanical, hydraulic, auxiliary and control, the system integrates the mechanical and mechanical polishing equipment of the system, and adopts the German BECKOFF system to realize the control and processing of manual, semi-automatic and automatic different modes. Thirdly, by measuring the surface quality of the laser micro-woven structure of the cylinder hole, the measuring principle of the new surface micro-structure is put forward, and the integrated on-line detection device is designed accordingly. The measuring device mainly includes three parts: motion control, positioning and clamping and measuring. the data is displayed, processed and analyzed by the LabVIEW, the characteristic profile of the measurement result is extracted by the Matlab, the three-dimensional reconstruction of the two-dimensional point numerical value in the contour curve is realized, the fitted curved surface is formed, the three-dimensional shape of the micro-woven structure is obtained, and the experiment is adopted, and the accuracy and the rapidity of the novel measuring system are verified. It is necessary to strengthen the quality planning, quality assurance and quality control of the process from time to time, based on the inherent and non-inherent fluctuation of the processing quality. In this paper, the composition and basic theory of the quality system are introduced. For the processing system, the laser micro-weaving equipment and the mechanical and mechanical polishing equipment are used as a whole to evaluate the machine and process capability. For the measurement system, the relevant evaluation index is calculated according to the parameter of the product measurement. independent analysis of its associated quality performance. The result of the evaluation is in accordance with the basic theory, and the stability of the industrial production is guaranteed. Finally, in order to speed up the industrialization process of the laser micro-weaving technology in the automobile engine industry, to construct the market-oriented extension platform, as an important link between the connecting enterprise and the customer, it is the key measure to realize the large-scale industrialization. Based on the three modules of transverse dimension, vertical dimension and comprehensive evaluation, this paper has developed a set of application platform system based on eCATALOG, which is used to meet the market demand.
【学位授予单位】：江苏大学
【学位级别】：硕士
【学位授予年份】：2016
【分类号】：TK406

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