摘要
微动损伤被喻为现代工业机械部件的癌症,在许多工业重要部门已成为一些配合零部件失效的主要因素之一。微动损伤机制之一的微动磨损致使机械部件精度失效、构件咬合、松动、功率损失、噪声增加或形成污染源。工业实践中,振动源通常无法避免而使得微动磨损总是存在,因此研究减缓微动磨损的各种措施意义重大,油、脂润滑作为减缓微动磨损的重要措施已引起研究者的高度重视。
本文采用高精度的PLINT微动试验机,对不同种类、性能的润滑油和脲基润滑脂润滑下的GCrl 5轴承钢球／GCrl5轴承钢块和GCrl5轴承钢球／45号钢块摩擦副的微动特性进行研究。试验条件为位移幅值／D=5μm～80μm、频率户1-5 Hz、循环次数N=1-3×104、法向负荷Fn=50～100 N、试验室的温度和湿度分别为15℃-20℃和40%±10%。借助光学显微镜(OM)、激光共聚焦扫描显微镜(LCSM)、扫描电子显微镜(SEM)、AMBIOS XP-2台阶仪、MVK-H21显微硬度仪和能谱仪(EDX)对磨痕进行分析,磨损表面用浓度4%的硝酸酒精溶液进行腐蚀以观察磨痕表面层变化；分析了四种合成油和自制脲基润滑脂润滑对钢材料微动磨损影响的作用机理；找出了影响油、脂润滑减缓微动磨损效果的主要因素。取得的主要结果和结论如下：
1.油润滑下钢材料的微动磨损与微动位移幅值密切相关。在低位移幅值的部分滑移区,油排出接触区后在接触边缘形成油罩,阻止了大量空气进入摩擦表面而增大了金属间的粘着效应,导致稳态摩擦系数比干摩擦下更高,且增大了部分滑移区,使干摩擦下的运行工况微动图分区右移；因微滑区很小,油排出接触界面后难以再次渗入到摩擦表面,不同种类、性能的油润滑对磨损几乎没有影响；在中等位移幅值的混合区,油罩同样使得稳态摩擦系数比干摩擦下大。油渗入到磨痕的裂纹中,在高切应用力作用下油被挤压而加速了材料的剥落,产生比干摩擦下更深的磨坑；在大位移幅值的完全滑移区,油渗入到摩擦界面形成了混合润滑状态,且降低了氧化腐蚀,因此显著地降低了摩擦系数和表面磨损。
2.四种合成油在中等位移幅值的“挖坑效应”以及在更高位移幅值下减缓摩擦和磨损的效果与合成油的理化性能密切相关。在中等位移幅值的混合区,最低表面张力的硅油Silicone 68在微裂纹中的渗透性最强,极性的聚醚PAG68和合成酯PETO在微裂纹中的金属表面附着性更大,在反复切应力作用下产生比聚a-烯烃PAO 10和矿油350 SN润滑下更深的磨坑。在完全滑移区,Silicone 68最低的表面张力和压粘系数、以及最大的可压缩性,形成的油膜最薄而金属直接接触面积最大,降低摩擦和减缓磨损的效果最差；极性的PAG68和PETO在摩擦表面形成边界吸附膜,摩擦系数比PAO 10和350SN润滑下的值低；PAO 10润滑初期形成的高硬度白层致使其润滑下的磨损最小,其磨痕深度和体积不及Silicone 68润滑下的1／2。
3.微动下磨损面积与磨损体积的相关性不显著。在微动混合区,油润滑时的磨痕面积比干摩擦下小,但磨痕深度却比干摩擦下大；在微动完全滑移区,PAO 10润滑时的磨痕面积比其它油润滑时大,但其磨损体积却最小。
4.在大位移幅值的微动完全滑移区,脲基润滑脂润滑下摩擦系数随微动。循环周次的变化与润滑膜的存在、破裂和再形成密切相关。在微动初期,因微动的自清洗作用使润滑脂被排出接触区,脂膜破裂,摩擦系数增大到最大值。此时高的切应力导致磨坑和磨痕表面白层的形成；接触区周围的脂罩因微动而剪切分油,分出的基础油渗入到磨坑形成了混合润滑状态,摩擦系数向下振荡到低的稳态值,其值约为干摩擦下的1／6；脲基润滑脂润滑下的磨损量仅约为干摩擦下的1／24,且磨损主要发生在微动初期阶段。分油量越大,减缓磨损效果越显著。另外,氧化腐蚀的降低,以及微动初期在磨痕表面形成的高硬度白层,因低的稳态切应力基本上未剥落,它们也有助于减缓磨损。气泡对磨损几乎没有影响。
5.工业上,如果微动处于大位移幅值工况条件,采用油、脂润滑减缓钢材料微动磨损是很好的措施。对于减缓效果,油的理化性能和脂的分油是首先要考虑的因素。另外,油、脂在滑动下的摩擦特性与微动下不具有相关性。
As one of main factors of failure of matching components in many industry departments, fretting damage has been known as the cancer of modern industry. Fretting wear, one of the mechanisms of fretting damage, has resulted in precision failure, component occlusion and looseness, power loss, noise and pollution. In industry, the fretting wear exists usually because the vibration source can't always be avoided, and different kinds of methods have been developed to alleviate fretting wear. Among them, oil and grease lubrication as one of the effective method has been highly emphasized by the researcher.
The fretting behavior has been performed on high precision PLINT fretting device with the GCr15 bearing steel ball/GCrl5 bearing steel flat and GCrl5 bearing steel ball/ 45 steel flat using different types of oils and urea grease lubrication. The displacement amplitude, frequency, number of cycles, normal load, temperature and relative humidity were 5～80μm,1～5 Hz, 1～3×104, 50～100 N,15～20℃and 30～70%, respectively. The wear scar was studied by using optical microscope (OM), laser confocal scanning microscopy (LCSM), AMBIOS XP-2 surface profilometer, MVK-H21 micro-hardness tester, scanning electron microscopy (SEM) and EDX. Surface layer of the wear scar was observed by etching the worn surface in a solution containing 4% HNO3 in ethanol. The mechanism of palliating fretting wear of different types of synthetic oils and urea grease made in the laboratory was analyzed, and the main factors which affect the palliating effect of oils and greases were investigated. Main conclusions are drawn as follows:
1. The fretting wear under oil lubrication is related closely to the fretting displacement amplitude. At lower displacement amplitude, the fretting is in the partial slip regime. The oil is ejected out of the contact surface, which can only be found in the contact edge and forming oil shield. Due to isolation between air and contact surface by it, the oxidation effect decreases and adhesion increases, so the steady state coefficient of friction is higher than that under dry condition and the partial slip regime range is increased. The border line between the partial slip regime and the mixed regime moves towards the right in the running condition fretting map compared to that of dry condition. The micro-slip area is very small, and the oil is hard to penetrate into the contact surface again after discharging. As a result, little difference in wear topography is observed under different types of oil lubrication. At intermediate displacement amplitude, the fretting is in the mixed regime. Similar to the partial slip regime, the oil shield results in the steady state coefficient of friction being higher than that under dry condition. The oil penetrates into the micro-cracks of worn surface, and accelerates the detachment of particles owing to the extrusion effect of oil during fretting. The fretting mark is deeper than that under dry condition. At higher displacement amplitude, the fretting is in the slip regime. The oil penetrates into the friction interface to form the mixed lubrication regime and reduces the oxidation corrosion, so the steady state coefficient of friction and wear are remarkably reduced.
2. The digging effect at intermediate displacement amplitude and the palliating effect at higher displacement amplitude of different synthetic oils are related closely to the chemical and physical properties of synthetic oil. At intermediate displacement amplitude, the ability of penetration into the cracks of silicone oil Silicone 68 is the biggest because of the lowest surface tension and the adsorption of polyalkylene glycol PAG 68 and synthetic ester PETO to the metal surface of the cracks is stronger owing to polarity, so they form deeper wear cavity than that in Polyalphaolefin PAO 10 and mineral oil 350SN lubrication. At higher displacement amplitude, the palliation effect of silicone 68 is the poorest due to the lowest surface tension and pressure-viscosity, as well as the maximum compressibility resulting in the thinnest lubricating film and the maximum direct contact area between metals. The polar PAG 68 and PETO may form the adsorption film at the metal contact surface, as a result the maximum and steady state coefficient of friction is lower than those under PAO 10 and 350SN lubrication. The high hardness white layer formed at initial stage of fretting under PAO lubrication leads to the lowest wear. The wear depth and volume for the PAO 10 lubrication are less than half of them for the Silicone 68 lubrication.
3. There isn't apparent relation between wear area and wear volume for fretting. At the mixed regime of fretting, the wear scar under oil lubrication exhibited smaller wear area but higher wear depth comparing to the dry condition. At the slip regime of fretting, the wear area under PAO 10 lubrication is larger than that under other oil lubrication, but the wear volume is the smallest.
4. At higher displacement amplitude, the fretting is in the slip regime. The evolution of coefficient of friction with the number of cycles is closely related to the forming, the breaking and the forming again of lubrication film under grease lubrication. At the early stage of fretting, the coefficient of friction increases to the maximum value owing to grease ejectment from the contact zone which results in the breakdown of grease film, and then the high shear stress gives rise to the formation of wear cavity and white layer on the wear scar surface. Base oil separated from the grease penetrates into the wear cavity, and then the mixed lubrication regime is formed, thus the coefficient of friction fluctuates down to a low steady state value, only about 1/6 of that under dry condition. Under urea grease lubrication, wear volume is only about 1/24 of that under dry condition, and the wear occurs mainly at the initial stage of fretting. The more base oil separated from the grease, the better palliation effect for wear. Besides, both the high hardness white layer which hasn't been destroyed on a large scale because of the low steady status shear stress and the reducing of oxidation corrosion under grease lubrication conduce to suppressing wear. The bubbles have little influence on the fretting wear.
5. In industrial practice, oil and grease lubrication is a very good method to palliate fretting wear if the fretting is at higher displacement amplitude. For palliation effect, the chemical and physical properties of oils and the oil separation of grease should be taken into account at first. In addition, the effection of oil and grease lubrication on the friction behavior of steel is different for fretting and sliding condition.
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