【作者】 乔玉鹏；

【导师】 关德林； 李冰梅；

【作者基本信息】 大连海事大学 ， 轮机工程， 2004， 硕士

【摘要】 台架磨合是柴油机出厂前的最后一道关键工序，对柴油机的可靠性和使用寿命有重要影响。制定合理的磨合工艺是达到磨合目的的先决条件。目前国内柴油机生产厂家在磨合工艺的制定方面仍以现场实验摸索为主，缺少系统的理论指导。 本课题在实验室内，通过实验模拟研究了柴油机主要摩擦副气缸套／活塞环和曲轴颈／轴瓦的台架磨合过程，应用表面粗糙度分析、光谱分析、铁谱分析、表面硬度分析以及扫描电镜观察等方法，重点研究了影响磨合工艺制定的主要参数载荷、摩擦速度、润滑条件及不同磨合阶段对这两组摩擦副表面摩擦学特性的影响。 研究表明，载荷参数的选择对磨合过程有重要影响。在一定范围内增大载荷令磨合后气缸套的表面粗糙度降低，气缸套磨合的最佳载荷范围为30Mpa～35MPa；提高轴颈原始表面的加工质量使磨合以后轴瓦的表面质量更好，适合轴瓦磨合的载荷为5Mpa～6Mpa。摩擦速度对气缸套的磨合过程有较大影响，较低载荷下提高摩擦速度对磨合产生更好的作用。轴承合金在磨合过程中以复杂的动态过程向轴颈表面转移，这可能是磨合初期轴颈和轴瓦表面形貌变化不稳定的根本原因。 研究也证明，润滑油的光谱分析和铁谱分析可以对磨合状况做出有效的判断。综合运用两种方法使分析结果更为准确可靠；相比于普通润滑油，康胜磨合油对磨合过程的作用更为明显，可以增大载荷承受能力、拓宽速度适应范围、加快磨合进程并使相同条件下摩擦副表面质量更好。 本文采用的研究手段和研究成果具有广泛适应性，这对于柴油机台架磨合工艺的改进及磨合质量的提高无疑具有一定的参考价值和指导意义。更多还原

【Abstract】 Running-in, as a last process in manufacturing of diesel engine, plays a very important role and has a remarkable effect on the reliability and the lifetime of a diesel engine. So the design of a rational running-in program was considered as key process for running-in quality. Presently, most of manufacturers carry out mostly their running-in by way of the experience, what is lack of guidance based on systematic theoretical and experimental study.Through some experiments in laboratory, the process of diesel engine’s running-in have been simulated and the tribological characters of cylinder/piston ring and shaft neck/bearing have been studied by means of surface roughness analysis, spectrographic analysis and ferrographic analysis of lubricant, surface hardness measure as well as scanning electronic microscope observation. Therefore some conclusions based on the research have been drawn as follow:The surface roughness of cylinder reduced as load was increased in a certain range. The appropriate load for cylinder was confirmed as 30MPa~35MPa; The surface quality of bearing after running-in has been better improved when the initial roughness of shaft neck was lower, the suitable load for bearing is about 5MPa~6MPa. At the beginning of running-in, the dynamic transfer and recycling of bearing alloy between bearing and shaft neck are so complicated that these can lead to a result of fluctuation of friction pair’s surface quality. The friction speed has a considerable effect on the running-in process of cylinder; increasing friction speed is in favor of the running-in of cylinder. Besides, it is shown that the spectrographic analysis and ferrographic analysis of lubricant can be taken as a judging criterion for the running-in process, synthesizing of both method makes the result more accurate and reliable. Compared to common lubricant, Kangsheng oil makes the friction pair to undertake a larger load and more rapid friction speed, as result, to accelerate running-in process and to make surface quality better.The results can be taken as a guidance and reference for the improvement of running-in or design of running-in program.更多还原