Research on dry friction and wear characteristics of SiC/AZ91D composites based on Archard wear mode
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摘要:
颗粒增强镁基复合材料在活塞制造中具有重要意义，活塞使用寿命与其材料的摩擦磨损性能关系密切，为预测镁基复合材料活塞耐磨性。基于Archard磨损模型结合自适应网格技术，建立SiC/AZ91D镁基复合材料及其基体有限元模型，探究其在不同载荷下的磨损行为，考察其应力场分布、磨损深度，进行了试验验证，揭示磨损机制。结果表明：在不同载荷下，盘销的接触面均表现出距盘轴心最近与最远处应力值较大，其他径向区域较小。随着载荷增加，盘销接触区域各处均表现出应力值增大。在不同载荷下，盘销接触面均表现出距盘轴心最近处磨损深度较小，离盘轴心径向距离增加，磨损深度越来越大。随着载荷增加，盘销接触区域各处均表现出磨损深度数值增大。但复合材料的磨损深度小于基体，表现出较好的耐磨性能。磨粒磨损和剥层磨损为复合材料主要磨损机制，粘着磨损为基体合金的主要磨损机制，模拟结果与试验结果吻合较好。
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关键词:
- 镁基复合材料 /
- 有限元模拟 /
- 摩擦磨损 /
- Archard磨损模型 /
- 磨损机制
Abstract:The particle reinforced magnesium matrix composite is of great significance in the manufacture of piston. The service life of piston is closely related to the friction and wear properties of the material, so it can predict the wear resistance of magnesium matrix composite piston. Based on Archard wear model and adaptive mesh technology, a finite element model of SiC/AZ91D magnesium matrix composite and its matrix was established to explore its wear behavior under different loads, investigate its stress field distribution and wear depth, and conduct experimental verification to reveal the wear mechanism. The results show that, under different loads, the stress values of the nearest and furthest distance from the disc axis are larger on the contact surface of the disc pin, while other radial regions are smaller. With the increase of load, the stress values in all parts of the disc and pin contact area increase. Under different loads, the wear depth of the contact surface of the disc pin is smaller at the closest point to the disc axis, and the wear depth is larger and larger with the increase of the radial distance from the disc axis. With the increase of load, the wear depth increases in all parts of the disc and pin contact area. However, the wear depth of the composite is less than that of the matrix, which shows better wear resistance. Abrasive wear and peeling wear are the main wear mechanisms of the composite, adhesive wear is the main wear mechanism of the matrix alloy, and the simulation results are in good agreement with the experimental results.
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图 4 不同载荷下SiC/AZ91D试样Von Mises应力分布：(a) 10 N；(b) 6 N；(c) 3 N
Figure 4. Von Mises stress distribution of SiC/AZ91D samples under different loads: (a) 10 N; (b) 6 N; (c) 3 N
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图 5 不同载荷下AZ91D试样Von Mises应力分布：(a) 10 N；(b) 6 N；(c) 3 N
Figure 5. Von Mises stress distribution of AZ91D samples under different loads: (a) 10 N; (b) 6 N; (c) 3 N
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图 6 不同载荷下SiC/AZ91D (a)与AZ91D (b)试样的磨损深度与径向距离关系
Figure 6. Relationship between wear depth and radial distance of SiC/AZ91D (a) and AZ91D (b) samples under different loads
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图 7 不同载荷下SiC/AZ91D (a)与AZ91D (b)试样的摩擦系数与磨损时间关系
Figure 7. Relationship between friction coefficient and wear time of SiC/AZ91D (a) and AZ91D (b) samples under different loads
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图 8 SiC/AZ91D复合材料与AZ91D基体平均摩擦系数与载荷关系
Figure 8. Average friction coefficient and load relationship between SiC/AZ91D composite material and AZ91D matrix
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图 9 10 N载荷下SiC/AZ91D复合材料(a)与AZ91D基体(b)摩擦磨损面的SEM图像
Figure 9. SEM images of friction and wear surface between SiC/AZ91D composite (a) and AZ91D matrix (b) under 10 N load
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图 10 SiC/AZ91D复合材料与AZ91D基体磨损轮廓三维效果图
Figure 10. 3D rendering of wear profile between SiC/AZ91D composite and AZ91D matrix
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图 11 相同载荷下SiC/AZ91D复合材料与AZ91D基体磨损深度模拟与实验对比
Figure 11. Comparison of simulated and experimental wear depth between SiC/AZ91D composite and AZ91D matrix under the same load
表 1 材料的基本参数
Table 1 Basic parameters of the materials
Material ρ/(kg·m−3) σs/MPa μ E/MPa HB GCr15 7.18 518.5 0.3 20800 248 SiC/AZ91D 1.84 204 0.35 62000 65 AZ91D 1.82 160 0.3 44800 58 Notes: ρ—Material density; E—Modulus of elasticity; μ—Poisson's ratio; σs—Yield strength; HB—Brinell hardness number. 
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表 2 实验条件
Table 2 Experiment condition
No. Load/N Rotation speed/
(rad·min−1)Time/min Material 1 3 200 20 SiC/AZ91D 2 6 200 20 SiC/AZ91D 3 10 200 20 SiC/AZ91D 4 3 200 20 AZ91D 5 6 200 20 AZ91D 6 10 200 20 AZ91D
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其他类型引用(1)
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其他相关附件
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目的
SiC/AZ91D镁基复合材料广泛应用于航空制造，汽车生产，电子封装等领域，活塞使用寿命与其材料的摩擦磨损性能关系密切，为预测镁基复合材料活塞耐磨性。建立SiC/AZ91D镁基复合材料及其基体有限元模型，探究其在不同载荷下的磨损行为，考察其应力场分布、磨损深度。
方法使用Abaqus有限元分析软件1.建模：在Abaqus中建立销盘摩擦副的几何模型。包括定义模型几何尺寸、几何形状、材料属性以及接触边界条件等。2.网格划分：对销-盘摩擦副进行网格划分，将其划分为有限数量的单元，以便进行数值计算。网格划分的质量对于模拟结果的准确性至关重要。3.材料定义：定义销盘摩擦副中所使用的材料的力学性质，包括材料的弹性模量、泊松比、屈服强度等。材料的属性将影响模拟结果。此类数据采用实验方法取得。4.接触定义：对销盘摩擦副中的接触面进行定义。由于摩擦、接触和磨损问题通常涉及非线性行为，因此本文使用Abaqus的非线性求解器进行求解5.加载和约束：定义销盘摩擦副的加载和约束条件。6.求解：使用Abaqus的求解器对销盘摩擦副进行求解。求解过程将根据所定义的几何、材料、接触和加载条件进行数值计算，并得出相应的力学响应结果。7.后处理：计算磨损深度使用UMESHMOTION子程序，通过该程序完成网格单元的磨损节点的位移问题。同时，通过ALE(Arbitrary Lagrangian Eulerian)自适应网格技术实现模型网格的更新。在一个载荷增量步中，首先更新应力，然后再更新磨损量。
结果从有限元模拟得出的结果分析可得出不同载荷对复合材料与基体金属的应力场分布、磨损深度，可分为以下几点：①在相同载荷条件下，SiC/AZ91D复合材料和基体均表现出接触面距盘轴心最近与最远处应力值较大，而其他区域应力值较小的特性。这种现象主要由于接触面在边缘处突变，导致接触面两侧应力集中。对SiC/AZ91D复合材料而言，接触面应力值均大于AZ91D基体。由于高模量和高硬度SiC颗粒存在使得复合材料具有比基体更高的硬度和弹性模量 。因此在相同载荷作用下，复合材料比基体变形更小，应力值更大；②在实验所选载荷条件下，复合材料和基体的磨损深度与径向距离关系均表现出，随盘轴心径向距离增加，磨损深度增大。因为接触面距盘轴心最远处应力与相对运动速度的乘积大于最近处，通过UMESHMOTION子程序提取节点应力值，输入Archard磨损模型得出随盘轴心径向距离增加，磨损深度增大。但是复合材料的磨损深度均小于基体磨损深度，表现出更好的耐磨性能。
结论(1)盘销接触面应力值在径向区域分布不均匀，接触面均表现出距盘轴心最近与最远处应力值较大，其它径向区域较小。当载荷为10N时，复合材料距盘轴心最近与最远处应力值比基体金属分别高9.86%与10.1%；复合材料中心区域应力平均值比基体金属高39.5%。当载荷为6N时，复合材料距盘轴心最近与最远处应力值比基体金属分别高9.8%与3.7%；复合材料中心区域应力平均值比基体金属高23.1%；当载荷为3N时，复合材料距盘轴心最近与最远处应力值比基体金属分别高3.65%与1.18%；复合材料中心区域应力平均值比基体金属高16.7%。(2)在不同载荷下，盘销接触面均表现出距盘轴心最近处磨损深度较小，离盘轴心径向距离增加，磨损深度越来越大。基体合金的磨损深度明显大于复合材料。当载荷为10N时，复合材料距盘轴心最近与最远处磨损深度值比基体金属分别低51.7%与32.5%；复合材料中心区域磨损深度值比基体金属低41.5%。当载荷为6N时，复合材料距盘轴心最近与最远处磨损深度值比基体金属分别低65.2%与48.5%；复合材料中心区域磨损深度值比基体金属低54.7%；当载荷为3N时，复合材料距盘轴心最近与最远处磨损深度值比基体金属分别低62.9%与40.3%；复合材料中心区域磨损深度值比基体金属低59.1%。(3)磨粒磨损和剥层磨损为复合材料主要磨损机制，粘着磨损为基体合金的主要磨损机理。
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镁合金材料因其耐磨性能不佳，在需频繁参与摩擦的工业产品零部件(如低负荷轴承齿轮、离合器活塞等)方面很少被采用。为了改善其耐磨性能，在镁合金中添加高硬质SiC颗粒，能有效提升SiC颗粒增强镁基复合材料的摩擦磨损性能。研究摩擦磨损特性的方法主要有实验和数值模拟。采用Archard模型研究摩擦磨损行为对金属基复合材料研究较少。
本文基于Archard磨损模型结合自适应网格技术，建立SiC/AZ91D镁基复合材料及其基体有限元模型，探究其在不同工况下的磨损行为，考察其应力场分布、磨损深度。从图中可以看出，在不同载荷下，盘销接触面应力值在径向区域分布不均匀，接触面均表现出距盘轴心最近与最远处应力值较大，其它径向区域较小。随着载荷增加，盘销接触面应力场差异明显。
在不同工况下，复合材料和基体的磨损深度与径向距离关系均表现出，随盘轴心径向距离增加，磨损深度增大。因为接触面距盘轴心最远处应力与相对运动速度的乘积大于最近处，通过UMESHMOTION子程序提取节点应力值，输入Archard磨损模型得出随盘轴心径向距离增加，磨损深度增大。但复合材料的磨损深度均小于基体磨损深度，表现出更好的耐磨性能。
图(1)、图(2)为不同载荷下SiC/AZ91D复合材料与基体的Von Mises应力分布 (a) 10N (b)6N (c)3N不同载荷下
SiC/AZ91D试样的磨损深度与径向距离关系图
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