Abstract
The high pressures in gasoline direct injection technology lead to structural damage in some hydraulic components, especially annular damage on the contact area of the valve ball and on the valve seat of the spherical unloading valve in the high-pressure pump. In previous study, the authors have analyzed the damage on the unloading valve and demonstrated that it is caused neither by static damage nor fatigue damage and have put forward the hypothesis of fretting wear. This paper is based on the establishment of the statically indeterminate structure of the unloading valve. The micro friction parameters (stress, friction coefficient, etc.) required for the numerical iterative calculation of fretting wear are calculated. In addition, based on the grid adaptive technology and a modified Archard wear model, the fretting wear is calculated quantitatively and is in good agreement with experimental results. Based on that verification, the wear laws of the valve ball and valve seat under the same hardness, different contact angles, and different assembly stresses, are analyzed in detail, and reasoned suggestions for the structural design and assembly design of the ball valve are given.
概要
目的:汽油直喷技术的高压化趋势会导致泵阀组件磨损、振动、噪声、气蚀等严重问题。研究实践中发现高压泵卸荷阀的阀球与阀座接触面存在环形损伤。作者的前期研究已指出损伤非静力或疲劳所致,而是在微观形貌上更具有微动磨损的特点。基于微动磨损的假设,本文首先针对卸荷阀超静定结构进行建模分析,获得磨损仿真边界条件,基于微动磨损数学模型与数值仿真网格自适应技术定量分析磨损量伴随结构参数的变化规律,并提出结构改进的建议。 创新点:1. 基于超静定结构建模解析,建立准确的微动磨损数值仿真边界条件;2. 基于网格自适应技术复现了磨损过程,结合实验验证证实损伤的微动磨损机制。 方法:1. 通过构建模块化的实验系统并搭建模拟微动磨损行为的实验台获得球阀微动磨损的实验数据(图3和4);2. 通过理论推导,构建球阀微动磨损超静定受力模型,得到仿真计算所需微动边界条件(公式(1)~(10));3. 通过对Archard磨损模型进行改进获得适用于有限元计算的磨损公式,并结合迭代加速计算方法和网格自适应技术建立球阀微动磨损定量数值计算模型(图11)。4. 模型解析获得规律,提出结构改进建议。 结论:1. 微动磨损的实验结果与仿真结果具有良好的一致性,证明了球阀微动磨损仿真数值计算模型的准确性;2. 阀球的磨损宽度和磨损深度都随着接触半角的增大而减小;3. 阀球的磨损宽度和磨损深度都随着阀球半径的增大而减小。
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Liang LU and Qi-long XUE designed the research. Man-yi ZHANG, Liang-liang LIU, and Zhong-yu WU provided the experiment equipment and measured data. Yin-peng XU and Liang LU processed the corresponding data. Yin-peng XU wrote the first draft of the manuscript. Meng-ru LI helped to organize the manuscript. Yin-peng XU revised and edited the final version.
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Liang LU, Yin-peng XU, Meng-ru LI, Qi-long XUE, Man-yi ZHANG, Liang-liang LIU, and Zhong-yu WU declare that they have no conflict of interest.
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Lu, L., Xu, Yp., Li, Mr. et al. Analysis of fretting wear behavior of unloading valve of gasoline direct injection high pressure pump. J. Zhejiang Univ. Sci. A 23, 314–328 (2022). https://doi.org/10.1631/jzus.A2100685
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DOI: https://doi.org/10.1631/jzus.A2100685