高速水润滑动压螺旋槽轴承电主轴动力学设计理论与方法研究

The water-lubricated motorized spindle supported by hydrostatic bearing is a new and attractive machine tool spindle being superior to conventional one in many performances. However, an issue is that an expensive water supplied system must be equipped for the hydrostatic bearing, which restricts its wide application in industry. Therefore, a water-lubricated hydrodynamic bearing should be developed and used as the support for the spindle, which may be the basic solution for this issue. .A high speed water-lubricated dynamic spiral groove bearing is developed by three means, which are, a Ta-Si nano composite coating is prepared on the steel by double cathode metal-non-metallic plasma sputtering deposition technology, bearing bush is developed by using a special graphite, a micro anti-drag groove is designed on the working surface of the bearing. The gas-liquid coupling lubricated model for the high speed water-lubricated dynamic spiral groove bearing is established by using the multiphase flow hydromechanics, transport theory of statistics mechanics, theory of energy dissipation and fluid lubrication theory, and the dynamic performance of the bearing is analyzed with this model. The dynamic design method is proposed for the water-lubricated spindle with the high speed dynamic spiral groove bearing, and a motorized spindle with the new bearing is developed for the test study. We think that the new water-lubricated dynamic spiral groove bearing can start safely (low friction and micro wear), and run smoothly at a high speed (low power loss and anti-cavitation erosion), meanwhile, this bearing has many advantages, i.e., the speed for the formation of the full film is low, the load-carrying capacity is large, and dynamic stability is good. This project will lay a foundation for industrial applications of water lubricated dynamic spiral groove bearing spindle.

水润滑静压轴承电主轴是近年来发展起来一类新型机床主轴单元技术，其突出优势是动态性能优良，但是必须配套昂贵的高压供水系统，严重制约其走向工业应用。研发高速精密水润滑动压轴承电主轴，是解决问题有效与根本的途径。本项目基于表面等离子溅射沉积技术、特碳石墨自润滑材料、微沟槽表面减阻技术等，提出并研究新型高速水润滑动压螺旋槽轴承技术；综合运用多相流流体力学、统计力学输运理论、能量耗散理论和流体润滑理论等，揭示高速水润滑动压螺旋槽轴承气液耦合润滑机理，建立轴承润滑模型；研究并建立高速水润滑动压螺旋槽轴承电主轴动力学设计理论与方法，研发高速大功率电主轴试验样机。本项目的实施，可望获得一类既可以安全（低摩擦、微磨损）启动，又能高速（低功耗、抗空蚀）运行，同时成膜转速低、承载能力大、动态性能好的高速水润滑动压螺旋槽轴承电主轴技术。

水润滑静压轴承电主轴是近年来发展起来一类新型机床主轴，其突出优势是动态性能优良，但是水润滑静压轴承电主轴必须配套价格不菲的高压供水系统，严重制约该类电主轴其走向工业应用。研究高速精密水润滑动压轴承电主轴，是解决问题的有效途径。.本项目集成表面等离子溅射沉积技术、特碳石墨自润滑材料、微沟槽表面减阻技术等，提出了新型高速水润滑动压螺旋槽轴承，继而提出研发高速水润滑动压螺旋槽轴承电主轴的新构思。综合运用多相流流体力学、统计力学输运理论、能量耗散理论和流体润滑理论等，揭示高速水润滑动压螺旋槽轴承气液耦合润滑机理，研究建立高速水润滑动压螺旋槽轴承空化流模型；提出了水润滑动压螺旋轴承静、动态特性计算方法；研制了高速水润滑动压螺旋槽轴承性能测试装置；开展了轴承空化与静动态参数的测试研究；揭示了高速水润滑动压螺旋槽轴承空化机制与静动态特性规律。制备了水轴承抗空蚀系列涂层；研制了超声波振动空蚀与电化学性能测试系统；完成了水轴承抗空蚀涂层的抗空蚀试样与台架试验研究；揭示了涂层的抗空蚀机理。建立了高速水润滑动压螺旋槽轴承电主轴柔性转子动力学模型与刚性转子动力学模型；提出了电主轴动力学设计理论与方法；研制了转速24000rpm高速电主轴试验样机；完成了电主轴的切削模拟试验。.通过本项目的实施，获得了一类新型水润滑动压轴承，既可以安全（低摩擦、微磨损）启动，又能高速（低功耗、抗空蚀）运行，同时成膜转速低、承载能力大、动态稳定性好；建立了高速水润滑动压螺旋槽轴承电主轴的动力学设计与摩擦学设计的理论与方法，为新型电主轴走向工业应用奠定理论基础。