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Researches and modeling of tribological phenomena occurring in the seat insert – lightweight valve – guide system for valvetrains of internal combustion engines
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Abstrakty
W pracy zaproponowano rozwiązanie problemów tribologicznych w układach z lekkimi zaworami w krzywkowych i bezkrzywkowych rozrządach tłokowych silników spalinowych. Pierwszym problemem jest zużycie przylgni zaworu i gniazda. Drugim są opory ruchu i zużycie trzonka i prowadnicy zaworu. Rozwiązanie tych dwóch problemów osiągnięto poprzez rozpoznanie procesów i zjawisk tribologicznych we wspomnianych węzłach ciernych lekkich zaworów wykonanych ze stopów tytanu i z ceramiki, napędzanych krzywkowo i bez-krzywkowo. Przeprowadzono na drodze eksperymentalnej i teoretycznej analizę istotnych zjawisk zachodzących podczas procesu zużywania przylgni gniazda i lekkiego zaworu oraz procesu tarcia mieszanego i zużycia między trzonkiem lekkiego zaworu i jego prowadnicą, przy zmieniającym się udziale tarcia płynnego. W efekcie tej analizy zaproponowano charakterystykę oporów ruchu i zużywania w ramach jednego modelu, z uwzględnieniem zjawisk sprzężonych. Pozwala ona dobierać wolnozmienne parametry geometryczne i materiałowe oraz szybkozmienne wymuszenia w układzie prowadnica-lekki zawór-gniazdo, w sposób warunkujący racjonalny (z możliwością optymalizacji) przebieg pracy lekkiego zaworu podczas przebiegu międzynaprawczego silnika. Jako kryterium optymalizacji zaproponowano minimalizację sumy przepływów mediów między przylgniami zaworu i gniazda oraz w szczelinie między trzonkiem zaworu i prowadnicą, w obrębie ustalonego cyklu roboczego silnika. W pracy dokonano krytycznej oceny opisanych w literaturze modeli tarcia, na podstawie której wybrano dwa, uwzględniające obecność warstwy ochronnej na powierzchniach zaworu i/lub gniazd i prowadnic. Pierwszy model umożliwia wykonywanie symulacji oporów ruchu między trzonkiem zaworu i prowadnicą w warunkach zbliżonych do rzeczywistości, przy małej angażowanej mocy obliczeniowej. Drugi szybki, oparty na sieciach neuronowych, może być wykorzystywany w algorytmie sterowania napędu zaworu, głównie do kompensacji tarcia. Opracowano modułowy model zużywania zaworu, gniazda i prowadnicy uwzględniający istnienie warstwy ochronnej na powierzchniach zaworu i/lub gniazd i prowadnic. Umożliwia on wykonywanie symulacji procesu zużywania w warunkach zbliżonych do rzeczywistości, przy małej angażowanej mocy obliczeniowej. Opracowano sieci jednoznacznych powiązań między modelem oporów ruchu i modelem zużywania elementów układu gniazdo-zawór-prowadnica. Wyznaczono dopuszczalne prędkości osiadania zaworu w jego gnieździe ze względu na zużycie i hałaśliwość pracy. Dobrano racjonalne materiały trzonka i prowadnicy ze względu na ich zużycie przy założeniu ograniczonego smarowania. W pierwszej części pracy wskazano konsekwencje, jakie powstaną w różnych silnikach spalinowych w wyniku zastąpienia klasycznych, pełnych zaworów stalowych przez zawory z lekkich materiałów. W drugiej części pracy podano cel, zakres i tezę pracy. W kolejnej części omówiono układ prowadnica-zawór-gniazdo jako system tribologiczny. Potraktowano go jako obiekt analizy, omówiono elementy składowe, wymuszenia i zachodzące między nimi relacje. Podano zależności matematyczne opisujące te relacje. W kolejnej części pracy omówiono stosowane materiały, powierzchnie ochronne i parametry geometryczne lekkich zaworów oraz współpracujących z nimi prowadnic i gniazd. W następnej części pracy przeprowadzono dyskusję istniejących modeli tarcia, efektem której był wybór jednego z nich do symulacji oporów ruchu trzonka lekkiego zaworu względem prowadnicy, drugiego zaś do kompensacji tarcia w algorytmie sterowania bezkrzywkowego napędu zaworu. W modelach tarcia uwzględniono istnienie warstwy ochronnej na powierzchni zaworu, prowadnicy i gniazda. Podano przykładowe obliczenia oporów ruchu. Omówiono stosowane metody kompensacji tarcia w algorytmach sterowania urządzeń mechatronicznych, do których należy bezkrzywkowy napęd zaworu. Przedstawiono model fizyczny i matematyczny tarcia między trzonkiem lekkiego zaworu i prowadnicą. W kolejnej części pracy omówiono proces zużywania par ciernych systemu HSZG-TSZP ( grzybek zaworu-Smar-Zanieczyszczenie-Gniazdo-Trzonek zaworu-Smar-Zanieczyszczenie-Prowadnica). Omówiono rodzaje zużycia i parametry na nie wpływające. Przeprowadzono dyskusję istniejących modeli zużywania zaworu, prowadnicy i gniazda i w wyniku opracowano własne fizyczne i matematyczne modele zużywania elementów systemu HSZG-TSZP. Opracowano też model uwzględniający występowanie nagana i model poziomu ogólnego hałasu podczas uderzeń zaworu o gniazdo. W kolejnej części pracy omówiono przeprowadzone badania eksperymentalne. Przedstawiono opracowane stanowiska badawcze, obiekt, przebieg badań, uzyskane wyniki i analizę błędów pomiarów. W kolejnej części pracy przedstawiono model symulacyjny oporów ruchu i zużycia elementów systemu HSZG-TSZP. Zamieszczono przykładowe wyniki obliczeń symulacyjnych. W przedostatniej części pracy przedstawiono zależności matematyczne, uzależniające sumę przepływów mediów w szczelinie między trzonkiem zaworu i prowadnicą oraz między przylgniami gniazda i zaworu od zużycia elementów systemu HSZG-TSZP. W ostatniej części przedstawiono wnioski i zalecenia dotyczące przyszłych kierunków badań.
The solution to tribological problems in systems with lightweight valves in cam and camless valvetrain in internal combustion engines has been proposed in the book. The first problem is the seat wear of valve and its seat insert. The second is friction and wear of valve stem and valve guide. The solution to these two problems is achieved by recognition of tribological processes and phenomena in the mentioned friction contact zones for these lightweight valves made from titanium alloys and ceramics, driven by cam and camless drive. It has been performed the experimental and theoretical analysis of the major phenomena that occur during the process of seat wear for lightweight valve and its seat insert and the process of mixed friction and wear between the lightweight valve stem and its guide, at the changing participation of lubricated friction. As a result of the analysis, it has been proposed the models of motion resistance and of wear. It allows to choose the slowly varying geometric and material parameters and rapidly changing force in the system guide - lightweight valve –seat insert, in a way allowing optimal operation of lightweight valve during the inter-repairing period of combustion engine. As the optimization criterion is proposed to minimize the sum of the media flow between the seats of valve and its seat insert and in the gap between the valve stem and its guide, within a fixed cycle engine. It has been done the critical evaluation of models described in the literature of friction. On that basis the models have been developed, taking into account the presence of a protective layer on the surface of the valve and/or its seat insert and guide. The first model is to perform simulations of motion resistance between the stem and the guide in conditions close to reality. The second one being fast, based on neural networks can be used in the control algorithm, valve drive, mostly to friction compensation. It has been developed the modular model for wear of valve, its guide and seat insert taking into account the existence of a protective layer on the surface of the valve and / or its seat insert and guides. It allows to perform simulation of wear process in conditions close to reality. It has been developed the network clearly linking between the wear model and the model of motion resistance for components of the seatvalve-guide assembly. It has been elaborated the acceptable settling velocity of the valve in respect to its seat insert due to the wear and noise emissions. Rational materials have been chosen for valve stem and its guide due to assumed limited use of the lubrication. Experimental studies have been performed. Elaborated research stands, object, research process, obtained results and analysis of measurement errors have been shown in the book. It has been elaborated the simulation model of motion resistance and of wear for the TSZP-HSZG (namely: Valve stem T – grease S – contamination Z – valve guide P – valve head H – grease S – contamination Z – seat insert G) system and of the media flow in the gap between the stem and the guide and between the seats of valve and its seat insert during wear process of TSZP-HSZG system.
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Tom
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1--224
Opis fizyczny
Bibliogr. 264 poz., fot. kolor., wykr.
Twórcy
autor
- Politechnika Łódzka. Wydział Mechaniczny, Katedra Konstrukcji Precyzyjnych
Bibliografia
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Typ dokumentu
Bibliografia
Identyfikator YADDA
bwmeta1.element.baztech-f7056207-a58d-427c-9aa8-220d4d9b7572