高性能先进舰船活塞组件-缸套系统的主动表面织构及服役性能评估研究

This project aims to provide theoretical and experimental investigation of the active surface texture and service performance evaluation of the piston assembly-cylinder liner system, which is usually supposed to run with premium efficiency and service performance under abnormal conditions inside the main power equipment of the advanced high performance warships. A self-adaptive multi-objective optimization method will be proposed to achieve 3D optimization of the hone cross-hatch textured structure of the piston assembly-cylinder liner system, and consequently the optimization design criteria for the surface texture of piston assembly-cylinder liner system will be put forward. The quantitative relationship between 3D profile of the textured hone cross-hatch cylinder liner and different parameters of the honing & abrasive stick will be established while considering the multi-parameter and multi-fields coupling, and consequently the honing material removal mechanism and generating mechanism of 3D profile produced by honing will be investigated. Based on the image feature extraction method of the fast discrete curvelet transform algorithm, the geometry profile of textured hone cross-hatch cylinder liner can be defined quantitatively. A service performance evaluation model of the piston assembly-cylinder liner system in the whole life cycle will be established under the condition of small sample data and zero failure data. A method for extracting feature of dynamic response signals will be presented, and consequently the quantitative relationship among the index will be established. Therefore, evolution of system reliability in service life cycle will be unveiled. The present research will be of value not only to the fundamental theory and but also to the key issues to the processing quality control and service performance evaluation of the piston assembly-cylinder system inside main power equipment of advanced high performance warships.

本项目围绕高性能舰船主动力装备的活塞组件-缸套系统，针对其在向着极端工况、高效率和高服役性能方向发展时提出的要求，从理论分析方法的构造和实验研究两个方面着手，进行主动表面织构和服役性能评估研究。针对活塞组件-缸套系统，提出珩磨网纹织构的3D自适应变步长多目标优化方法，建立系统珩磨网纹织构的优化设计准则；通过建立多因素多场耦合时加工参数和油石参数与网纹织构缸套珩磨表面3D形貌特征的定量关系模型，研究珩磨加工的材料去除机理和3D形貌创成机理；构建基于快速离散曲波变换算法的图像特征提取方法，实现网纹织构缸套珩磨表面纹理几何特征的定量表征；建立小样本和无失效数据条件下系统全生命周期内的服役性能评估模型，研究动态响应信号特征空间的提取方法及其与可靠性指标间的相互定量关系，揭示系统服役期内可靠性的演变规律。为高性能先进舰船动力推进装置的加工过程质量控制与系统服役性能评估提供有价值的基础理论和核心技术。

针对高性能舰船主动力装备在向着高服役性能方向发展时对其核心部件活塞组件-缸套系统提出的要求，围绕活塞组件-缸套系统在实际服役工况下的热流体动力润滑、主动表面减摩织构及织构优化、织构表面加工及其形貌表征、全生命周期内服役性能评估展开研究。主要内容包括：（1）通过考虑系统服役工况实际物理行为，建立了表面织构压缩环-缸套系统的热流体动力润滑模型，揭示了润滑油供给条件和缸套变形等因素对摩擦学性能的影响规律。（2）提出了压缩环表面织构几何结构和轮廓形状的Pareto多目标协同优化方法，研究了织构形状、几何结构和分布形式等对摩擦学性能的影响规律。（3）基于珩磨油石的运动特性和珩磨网纹表面的创成原理，提出了珩磨油石磨粒空间轨迹的3D重构方法，研究了不同珩磨往复速度、旋转速度等工艺参数下磨粒轨迹的空间分布规律，通过研究珩磨工艺参数对缸套表面粗糙度与形位误差的影响规律，优选了珩磨加工工艺参数。（4）基于减摩织构表面的灰度图像信息，给出了织构表面灰度图像基准面的稳健求解方法，实现了灰度图像高频信息的重构。基于ELM-SLFN方法构建了灰度图像高频信息的Abbott-Firestone曲线特征参数与3D粗糙度之间的映射关系模型，实现了减摩织构3D粗糙度特征的机器视觉感知与评估。（5）针对减摩织构表面的多尺度和各向异性特征，运用离散曲波变换方法对织构表面的灰度图像信息进行了多尺度分解，提取了与织构物理特征相关的灰度图像信息，研究了减摩织构物理特征与分形维数之间的关联关系，实现了活塞组件-缸套系统表面减摩织构物理特征的定量表征。（6）提出了粒子群优化的模糊支持向量回归缸套磨损评估方法，研究了缸套磨损随时间的演变规律，构建了缸套磨损性能退化非线性自适应剩余寿命预测模型，实现了缸套磨损运行时间与剩余寿命预测的定量描述。为高性能舰船动力装备的主动表面织构和服役性能评估提供了有价值的基础理论和核心技术支持。