基于接触特性分析的滚动轴承固体润滑涂层失效模式预测方法研究

With the rapid development of materials science and surface engineering technology, the solid lubricating coatings have been widely applied to solve the lubrication problems of tibo-parts of aerospace products, which operates under a complex operating condition characterized with high and low temperature, high vacuum and intense radiation. However, the tribological application and design of solid lubricating coatings is still lack of a generally accepted design method and criteria. The ‘trial-type’ method, which is based on empirical knowledge and tests, has a certain blindness, and the practical effect of its application is full of large randomness and uncertainty. This project will focus on the application and design problems of solid lubricating coatings used in rolling bearings. A quasi-static model of rolling bearings considering the effect of solid coating on the contact deformation, a three dimensional point contact model of gradient coatings with elasticity modulus varying arbitrarily along the thickness direction of the coating, and a characterization method of bearing capacity of solid coating based on the contact stress in the subsurface will be established in this project. The objective of this project is to establish a failure modes prediction method of solid lubricating coatings used in rolling bearings based on contact behavior analysis by developing a calculation and analysis method, which can be applied to simulate the contact behavior in the micro contact area of rolling bearings provided that the operating load of rolling bearing is given. The research of this project is expected to provide a theoretical basis for the application and design of solid lubricating coatings used as lubricant in rolling bearings.

随着材料科学和表面工程技术的快速发展，固体润滑涂层已被广泛应用于解决工作在高低温、高真空和强辐射等复杂工况环境下的航空航天产品活动部件的润滑问题。但固体润滑涂层的摩擦学应用设计至今仍缺乏公认的和行之有效的设计方法与准则，以经验知识和试验为基础的“试凑法”具有一定的盲目性，其实际应用效果具有较大随机性。本项目针对滚动轴承的固体润滑涂层的应用设计问题，以建立考虑固体涂层对接触变形影响的滚动轴承拟静力学模型、涂层弹性模量沿涂层厚度方向任意变化的梯度涂层三维点接触分析模型及基于次表层接触应力的固体涂层承载能力的表征方法等为主要研究内容，旨在通过发展一种从滚动轴承载荷工况到滚动轴承接触微区接触特性的计算分析方法来建立基于接触特性分析的滚动轴承固体润滑涂层失效模式的预测方法，为滚动轴承固体润滑涂层的应用设计提供理论依据。

随着材料科学和表面工程技术的快速发展，固体润滑涂层已被广泛应用于解决工作在高低温、高真空和强辐射等复杂工况环境下的航空航天产品活动部件的润滑问题。但固体润滑涂层的摩擦学应用设计至今仍缺乏公认的和行之有效的设计方法与准则，以经验知识和试验为基础的“试凑法”具有一定的盲目性，其实际应用效果具有较大随机性。本项目针对滚动轴承的固体润滑涂层的应用设计问题，首先基于半解析方法建立了多层梯度涂层体系接触分析模型，研究揭示了多层涂层体系梯度结构模式对其接触力学行为的影响；基于多层梯度涂层体系接触分析模型计算获取固体润滑轴承套圈与钢球在一系列接触载荷下的接触变形，并通过最小二乘非线性拟合获得接触力载与接触变形的幂函数关系；基于钢球与内外套圈的接触力载与接触变形关系式，进一步建立了考虑涂层影响的固体润滑滚动轴承拟静力学分析模型，构建了一种从服役工况→内部力载分配→微区接触特性的固体润滑滚动轴承服役行为计算分析方法，并研究揭示了多层梯度涂层梯度结构模式对轴承内部力载分配、刚度以及微区接触特性的影响；在轴承钢表面制备了DLC类金刚石固体润滑涂层，基于Rtec多功能摩擦学实验机测试分析了DLC类金刚石涂层的摩擦学特性，通过球头纳米压痕试验测试获取涂层失效载荷，结合接触分析结果获取了表征涂层承载能力的临界应力值，形成了以固体润滑轴承服役行为计算分析方法以及涂层承载能力应力表征方法为基础的滚动轴承固体润滑涂层失效模式预测方法；并应用滚动轴承拟工况试验台开展了试验验证。本项目的研究成果可以为固体润滑滚动轴承的服役行为分析与失效模式预测提供理论方法，为滚动轴承固体润滑涂层的应用设计提供理论基础。项目已累计发表论文11篇，申请专利5项，已授权发明专利1项，获软件著作权2件。