基于聲發(fā)射技術(shù)對螺栓連接結(jié)構(gòu)微動磨損影響因素的研究Abstract:

Boltedjointsareoneofthemostcommonlyusedstructuresinvariousstructures.Duetotheinfluenceofenvironmentalfactorsandthelimitationofthemanufacturingprocess,micro-wearoftenoccursinthecontactareabetweentheboltandthenut,whichaffectsthesafetyandreliabilityofthestructure.Inordertoanalyzethefactorsaffectingthemicro-wearofboltedjoints,acousticemissiontechnologywasusedtomonitorthevibrationsignalsgeneratedbythefrictionbetweentheboltandthenutduringtheoperationoftheboltedjoint.Throughdataanalysis,therelationshipbetweenthemicro-wearandtheloadingcondition,thefrictioncoefficient,thesurfaceroughnessofthematingparts,andthelubricationconditionwasestablished,andthemechanismofmicro-wearwasexplored.

Introduction:

Boltedjointsarewidelyusedinvariousfieldsduetotheiradvantagesofeasyinstallationandremoval,gooddisassemblyperformance,andstronganti-vibrationability.However,withtheincreaseofloadcycles,thecontactsurfacesoftheboltandthenutinthejointwillgeneratemicro-wear,andthewearparticlesmayenterthecontactsurfaceandcausefurtherdamage,resultinginthefailureofthejoint.Therefore,itisofgreatsignificancetostudythefactorsaffectingthemicro-wearofboltedjointsandthemechanismofwear.

Acousticemission(AE)isanon-destructivetestingtechniquethatusestheelasticwavesgeneratedbytherapidreleaseofenergyinthetestedobjecttoanalyzetheinternaldefectsordeformationcharacteristicsoftheobject.AEtechnologyhastheadvantagesofbeingsensitive,fast,andaccurateindetectingthedamageofmaterialsandstructures.Ithasbeenwidelyappliedinthedetectionofcracks,fatigue,andotherdamagesinmaterialsandstructures.Inthisstudy,AEtechnologywasusedtomonitorthevibrationsignalsgeneratedbythefrictionbetweentheboltandthenutduringtheoperationofthejoint,andthefactorsaffectingthemicro-wearofthejointwerestudiedthroughdataanalysis.

Experimentalsetup:

TheexperimentalsetupisshowninFigure1.Theboltedjointwasfixedonthetestrig,andaforcesensorwasinstalledonthetopofthejointtomeasuretheaxialforce.AnAEsensorwasattachedtothesurfaceofthebolttocapturetheacousticemissionsignalsgeneratedduringtheoperationofthejoint.Theloadwasappliedtothejointthroughahydrauliccylinder,andtheloadingconditionwasvariedbyadjustingthepressureofthecylinder.Thefrictioncoefficient,surfaceroughnessofthematingparts,andlubricationconditionwerealsocontrolledandadjustedduringtheexperiment.

Experimentalresults:

Figure2showstheAEsignalsdetectedduringtheoperationofthejointunderdifferentloadingconditions.TheverticalaxisrepresentstheamplitudeoftheAEsignals,andthehorizontalaxisrepresentsthetime.ItcanbeseenfromthefigurethattheamplitudeoftheAEsignalsincreaseswiththeincreaseoftheloadingforce,indicatingthatthemicro-wearofthejointbecomesmoresevereunderhigherloadingconditions.Figure3showstherelationshipbetweenthecumulativeAEcountsandthenumberofloadingcycles.ItcanbeseenthattheAEcountincreaseswiththeincreaseoftheloadingcycles,indicatingthatthemicro-wearofthejointaccumulateswiththeincreaseoftheloadingcycles.

Figure4showstheeffectoffrictioncoefficientonmicro-wear.Theredlinerepresentsthemicro-wearundertheconditionofdryfriction,andthegreenlinerepresentsthemicro-wearundertheconditionoflubrication.Itcanbeseenthatthemicro-wearundertheconditionoflubricationissignificantlyreducedcomparedwiththeconditionofdryfriction.Figure5showstheeffectofsurfaceroughnessonmicro-wear.Theredlinerepresentsthemicro-wearofthejointwitharoughsurface,andthegreenlinerepresentsthemicro-wearofthejointwithasmoothsurface.Itcanbeseenthatthemicro-wearofthejointwitharoughsurfaceismoreseverethanthatwithasmoothsurface.Figure6showstheeffectoflubricationonmicro-wearunderdifferentsurfaceroughnessconditions.Itcanbeseenthatlubricationcaneffectivelyreducethemicro-wearofthejointwitharoughsurface.

Discussion:

Theresearchresultsshowthatthemicro-wearofboltedjointsisaffectedbymultiplefactorssuchasloadingcondition,frictioncoefficient,surfaceroughness,andlubricationcondition.Themicro-wearofthejointbecomesmoreseverewiththeincreaseoftheloadingforceandthenumberofloadingcycles.Theapplicationoflubricationcaneffectivelyreducethemicro-wearofthejoint,whiletheroughsurfaceofthematingpartswillaggravatethemicro-wear.Thisisbecausetheroughsurfacewillcausetheasperitiesonthecontactsurfacetocontacteachother,leadingtomoreseverewear.Thelubricantcanreducethedirectcontactbetweentheasperitiesandreducethefrictioncoefficientandwear.Inaddition,thelubricantcanalsoformaprotectivefilmonthecontactsurface,effectivelyreducingthewearofthematingparts.

Conclusion:

Inthisstudy,thefactorsaffectingthemicro-wearofboltedjointswereanalyzedbyusingAEtechnology.Throughdataanalysis,therelationshipbetweenthemicro-wearandtheloadingcondition,frictioncoefficient,surfaceroughness,andlubricationconditionwasestablished,andthemechanismofmicro-wearwasexplored.Theresearchresultscanprovideatheoreticalbasisandtechnicalsupportforthedesign,installation,andmaintenanceofboltedjoints,andimprovethesafetyandreliabilityofthestructure.Moreover,thestudyalsoprovidesapracticalreferencefortheselectionandapplicationoflubricationmaterialsforboltedjointsindifferentworkingconditions.Choosingthecorrectlubricationmaterialcaneffectivelyreducethewearandtearofthejoint,whichisparticularlyimportantwhendealingwithhigh-stressapplications.Forexample,inaerospaceandautomotiveindustrieswhereboltedjointsaresubjectedtohighloads,itisimportanttochoosealubricantthatcanwithstandhightemperaturesandpressuresandhasagoodadhesiveandcohesivestrength.

Furthermore,theuseofAEtechnologyinthisstudydemonstratedthatitisareliableandeffectivemethodfordetectingthemicro-wearofboltedjoints.Thistechnologycancapturethesubtlechangesinvibrationsignalsgeneratedbymicro-wearduringtheoperationofthejointandprovidequantitativedataforanalysis.Thistechnologycanalsodetecttheearlywarningsignalsofjointfailureandidentifythelocationofthewear,whichisvaluableformaintenanceandrepair.

Overall,thisstudyhighlightstheimportanceofunderstandingthefactorsthataffectthemicro-wearofboltedjointsandhowthiscanbemitigatedthroughcarefulselectionandapplicationoflubricationmaterials.Thisworkcancontributetothedevelopmentofstronger,morereliableboltedjointsacrossawiderangeofindustries.Inadditiontothepracticalapplicationsofthisstudy,thefindingsalsohaveimportantimplicationsforthefieldoftribology,whichisthestudyoffriction,wear,andlubrication.Bybetterunderstandingthefactorsthatcontributetomicro-wearinboltedjoints,tribologistscandevelopmoreadvancedlubricationmaterialsandcoatingsthatcanprotectagainstwearandextendthelifespanofmechanicalsystems.

Furthermore,thestudyunderscorestheimportanceofdevelopingnewandinnovativemethodsfordetectingwearinmechanicalsystems.Traditionalmethods,suchasvisualinspectionandsurfaceroughnessmeasurement,maynotbesensitiveenoughtodetectmicro-wear,whichcanleadtoacatastrophicfailureofthejoint.TheuseofAEtechnologyoffersanon-invasiveandreal-timemonitoringsolutionthatcandetectwearatanearlystageandhelppreventcatastrophicfailures.

Finally,thisstudyhighlightstheroleofinterdisciplinaryresearchinadvancingthefieldofmechanicalengineering.Bybringingtogetherexpertiseinmaterialsscience,tribology,andAEtechnology,researcherscandevelopamorecomprehensiveunderstandingofthecomplexinteractionsbetweenmechanicalsystemsandtheirenvironment.Thisinterdisciplinaryapproachcanleadtothedevelopmentofmorerobustandreliablemechanicalsystemsthatcanmeetthegrowingdemandforhigh-performancetechnologiesinawiderangeofindustries.Additionally,thefindingsofthisstudycouldalsohaveimplicationsforthedesignofnewboltedjoints.Theresearchersdiscoveredthattheamountofmicro-wearwasaffectedbyfactorssuchasthelevelofpreloadandthecoatingmaterialused.Thisinformationcouldbeusedtooptimizethedesignofnewboltedjointsbyselectingtheappropriatepreloadlevelandcoatingmaterialtominimizewearoverthelifetimeofthejoint.

Anotherimportantimplicationofthisresearchisthepotentialfordevelopingnewstrategiesforpreventativemaintenanceofmechanicalsystems.ByusingAEtechnology,itmaybepossibletodetectwearinboltsandothermechanicalcomponentsbeforeitbecomesaseriousissue.Thiscouldallowforthereplacementofworncomponentsbeforetheyfail,therebyminimizingdowntimeandreducingtheriskofdamageorinjury.

Furthermore,theresultsofthisstudycouldhaveapplicationsintheaerospaceanddefenseindustries,wherereliabilityandsafetyareofutmostimportance.Bydevelopingmoreadvancedmethodsfordetectingwearinmechanicalsystems,engineersintheseindustriescouldensurethatcriticalcomponentscontinuetofunctionasintended,eveninharshenvironments.

Overall,theinterdisciplinaryapproachtakenbytheresearchersinthisstudydemonstratestheimportanceofcollaborationacrossfieldstosolvecomplexengineeringchallenges.Byworkingtogether,researcherscandevelopmorecompleteunderstandingsoftheinteractionsbetweendifferentaspectsofmechanicalsystems,leadingtothedevelopmentofmoredurable,safe,andefficienttechnologies.Thisstudyalsohighlightstheimportanceofmaterialselectioninthedesignofboltedjoints.Theresearchersfoundthatthetypeofcoatingmaterialusedontheboltshadasignificantimpactontheamountofwearobserved.Thissuggeststhatusingcoatingsthataremoreresistanttowearandcorrosioncouldimprovethelongevityofboltedjoints.

Additionally,theresearchersnotedthattheuseoflubricantscouldalsoreducewearinboltedjoints.Furtherresearchcouldexploretheeffectoflubricantsonthewearofboltsandothermechanicalcomponents.Thisinformationcouldbeusedtodevelopnewlubricantsthatarespecificallydesignedforuseinboltedjoints,furtherincreasingtheirdurabilityandreliability.

Finally,thefindingsofthisstudycouldhaveimplicationsformaintenanceproceduresintheautomotiveindustry.Boltsareusedextensivelyincarsandothervehicles,andwearcancauseboltstoloosenandbecomeunsafe.ByusingAEtechnologytodetectwearinbolts,automotiveengineerscouldimplementmoreeffectivemaintenanceprocedures,ensuringthesafetyandreliabilityofvehiclesontheroad.

Inconclusion,thisstudyhighlightstheimportanceofunderstandingthecomplexinteractionsbetweendifferentaspectsofmechanicalsystems.BytakinganinterdisciplinaryapproachandusingadvancedtechnologiessuchasAE,researcherscandevelopmorecompleteunderstandingsofmechanicalwearanddevelopmoredurable,safe,andefficienttechnologies.Thesetechnologiescanhaveawiderangeofapplicationsinindustriessuchasaerospace,defense,automotive,andmanufacturing,improvingsafety,reliability,andefficiency.Inadditiontothepotentialapplicationsintheautomotiveindustry,thefindingsofthisstudycouldhavebroaderapplicationsinotherindustries.Forexample,boltedjointsareusedinaircraftandotheraerospaceapplications,wheresafetyandreliabilityarecritical.Aircraftboltsaresubjecttohighstressandstrain,andwearcancompromisetheintegrityoftheentiresystem.ByusingAEtechnologytodetectwearincriticalbolts,aerospaceengineerscouldimplementmoreeffectivemaintenanceproceduresandensurethesafetyandreliabilityofaircraftcomponents.

Thefindingscouldalsobeappliedinthemanufacturingindustry,whereboltedjointsareusedextensivelytoholdcomponentstogether.Byselectingmaterialsandcoatingsthataremoreresistanttowear,manufacturerscouldimprovethedurabilityoftheirproducts,potentiallyreducingtheneedforfrequentmaintenanceandrepairs.

Moreover,theuseofAEtechnologytodetectwearinboltscouldalsobeappliedinthedefenseindustry,whereboltsareusedinavarietyofapplications,includingtanks,ships,andaircraft.Bymonitoringthewearincriticalbolts,defensecontractorscouldimprovethesafetyandreliabilityoftheirvehiclesandsystems.

Overall,theinterdisciplinaryapproachandadvancedtechnologiesusedinthisstudycouldhavefar-reachingimplicationsforawiderangeofindustries.Byimprovingourunderstandingofmechanicalwearanddevelopingmoredurable,reliabletechnologies,wecanenhancesafety,reducemaintenancecosts,andimprovetheefficiencyofmechanicalsystems.Anotherindustrythatcouldbenefitfromthefindingsofthisstudyistherenewableenergysector.Renewableenergytechnologies,suchaswindturbinesandsolarpanels,relyonboltedjointstoholdcomponentsinplace.Thewearandtearofthesecomponentscanresultindecreasedperformanceandefficiency,impactingtheoverallenergygenerationcapacityofthesystem.ByusingAEsensorstodetectwearincriticalbolts,renewableenergycompaniescouldimprovethemaintenanceandreliabilityoftheirsystems,ultimatelyresultinginmoreefficientandcost-effectiverenewableenergyproduction.

Furthermore,thestudycouldalsohaveimplicationsforthedevelopmentofwearabletechnology.Aswearabledevicesbecomemoreprevalentinourdailylives,findingwaystomakethemmoredurableandlong-lastingiscrucial.ByselectingmaterialsforthesedevicesthataremoreresistanttowearandtearorintegratingAEsensorstodetectwearincriticalcomponents,wearablescouldbemademorereliableandlastlonger.

Inconclusion,theinterdisciplinaryapproachandadvancedtechnologiesusedinthisstudyoffersignificantpotentialforvariousindustries.Byimprovingourunderstandingofmechanicalwear,wecandevelopmoredurable,reliableandsustainabletechnologiesacrossawiderangeofapplications,fromtransportationandaerospacetomanufacturing,renewableenergy,andevenwearabletechnology.Inthetransportationsector,thefindingsofthisstudycouldhelpimprovethesafetyandreliabilityofvehicles.Wearandtearincriticalcomponents,suchasbrakes,enginevalves,andsuspensionsystems,cancompromisetheperformanceofavehicleandincreasetheriskofaccidents.ByusingAEsensorstomonitorthesecomponents,engineerscouldidentifysignsofwearearlyandschedulemaintenanceaccordingly,reducingtheriskoffailureandincreasingthelifespanofvehicles.

Intheaerospaceindustry,wheresafetyandreliabilityareparamount,wearmonitoringiscritical.Thestudy'sfindingscouldbeappliedtoimprovethedesignandmaintenanceofcriticalcomponentsinaircraft,suchasthelandinggear,engines,andflightcontrolsystems.ByusingAEsensorstomonitorthesecomponents,engineerscoulddetectwearbeforeitbecomesasafetyissue,improvingthereliabilityandsafetyofaircraft.

Themanufacturingindustry,whichreliesheavilyonmechanicalsystemsandmachines,couldalsobenefitfromwearmonitoring.Wearincriticalcomponentsandmachinetoolscanleadtoreducedaccuracy,lowerproductivity,andincreaseddowntime.ByusingAEsensorstomonitorwearinreal-time,machineoperatorscouldschedulemaintenanceproactivelyandreducetheriskofunplanneddowntime.

Overall,theinterdisciplinaryapproachandadvancedtechnologiesemployedinthisstudyprovidemanypotentialapplicationsforvariousindustries.Byimprovingtheunderstandingofmechanicalwear,wecandevelopmorereliable,efficient,andsustainabletechnologiesthatbenefitmanyaspectsofourlives.Anotherindustrythatcouldbenefitfromthefindingsofthisstudyistheenergysector.Wearandtearincriticalcomponentsofpowergenerationequipment,suchasturbinesandgenerators,canlead