金属圈弹塑性接触计算与密封性能分析

doi:10.12382/bgxb.2024.0371

摘要/Abstract

摘要：

金属密封圈在各种机械产品中广泛应用,其主要依靠粗糙表面弹塑性接触变形实现密封。针对传统的粗糙表面微观接触有限元仿真方法计算效率低、弹塑性接触变形收敛困难的问题,提出有限元-边界元耦合的金属密封圈弹塑性微观接触计算方法。建立金属密封结构宏观有限元模型,精确求解密封面接触应力分布;建立密封面微观形貌,在弹塑性接触等效的基础上,以宏观接触应力分布作为边界条件,提出残余形变量和残余应力场叠加的弹塑性接触计算边界元方法,求解粗糙表面弹塑性变形的接触状态。同时,对密封面微观接触等效建模方法进行验证,并与粗糙表面微观接触的有限元仿真方法进行对比,证明所提有限元-边界元耦合仿真方法与有限元方法计算精度相当,但是计算效率提高了近8倍。采用四联通网格模型求解密封面泄漏通道,作为密封性能评价指标,系统研究材料参数、接触应力、表面粗糙度、粗糙表面参数等因素对金属圈密封性能的影响规律。搭建密封实验台对金属圈的泄漏率进行测量,获得了金属圈实际泄漏率随法向载荷的变化规律,仿真结果与实验规律趋势一致。

关键词: 金属密封圈, 有限元, 边界元, 接触计算, 泄漏通道

Abstract:

Metal sealing rings are widely used in various mechanical products,mainly achieving the sealing effect through the elastic-plastic contact deformation of rough surfaces.The traditional finite element simulation method for the microscopic contact of rough surfaces has the low computational efficiency and difficult convergence of elastic-plastic contact deformation.An elastic-plastic contact calculation method based on coupled finite element and boundary element methods is proposed.A macro-finite element model of metal ring seal structure is established to accurately solve the contact stress distribution of sealing surfaces,and the micro-morphology of sealing surfaces is established.A boundary element method for elastic-plastic contact calculation with the superposition of residual deformation and residual stress fields is proposed by taking the macroscopic contact stress distribution as the boundary condition.The boundary element method is used to solve the contact state of sealing surfaces under elastic-plastic deformation.Meanwhile,the micro-contact equivalent modeling method of sealing surfaces is verified,and compared with the finite element simulation method for the microscopic contact of rough surfaces.The results show that the calculational accuracy of the finite element-boundary element coupling simulation method is equivalent to that of the finite element method,but its calculational efficiency is improved by nearly 8 times.The leakage channels of sealing surfaces are solved by the four-connection grid model and used as the evaluation index of sealing performance.The effects of material parameters,contact stress,surface roughness and rough surface parameters on the sealing performance of metal sealing ring are systematically studied.A sealing test equipment is built to measure the leakage rate of metal sealing ring,and the variation law of the actual leakage rates of metal sealing ring with the normal load is obtained.The simulated results are consistent with the experimental trend.

Key words: metal sealing ring, finite element, boundary element, contact calculation, leakage channel

中图分类号:

O344

王凯, 郑孟伟, 巩浩, 刘检华, 赵有磊, 刘少丽. 金属圈弹塑性接触计算与密封性能分析[J]. 兵工学报, 2025, 46(6): 240371-.

WANG Kai, ZHENG Mengwei, GONG Hao, LIU Jianhua, ZHAO Youlei, LIU Shaoli. Elastic-plastic Contact Calculation and Sealing Performance Analysis of Metal Sealing Ring[J]. Acta Armamentarii, 2025, 46(6): 240371-.

图/表 30

图1 紫铜垫圈密封结构

Fig.1 Copper gasket sealing structure

图2 有限元-边界元耦合的金属密封圈接触计算与密封性能分析流程

Fig.2 Flowchart of contact calculation and sealing performance analysis of metal sealing ring based on coupled finite element-boundary element method

图3 紫铜垫圈密封结构有限元模型

Fig.3 Finite element model of copper gasket sealing structure

表1 不同材料的材料属性

Table 1 Material properties of different materials

材料	屈服强度/ MPa	弹性模量/ GPa	切线模量/ MPa	泊松比
30CrMnSiA	835	206	2553	0.30
TC11钛合金	900	107.8	1 814	0.34
T2紫铜	70	108	868	0.35

图4 边界条件设置和载荷加载

Fig.4 Boundary condition setting and force loading

图5 紫铜垫圈接触面压力分布云图

Fig.5 Pressure distribution cloud chart of copper gasket contact surface

图6 紫铜垫圈密封面压力分布曲线

Fig.6 Pressure distribution curve of copper gasket sealing surface

图7 宏观密封面近似处理

Fig.7 Approximate treatment of macroscopic sealing surface

图8 不同粗糙度下的表面微观形貌

Fig.8 Micro-morphologies of surfaces with different roughnesses

图9 接触问题的等效简化

Fig.9 Equivalent simplification of contact problem

图10 等效前(左)后(右)的粗糙表面接触有限元模型

Fig.10 Finite element models of rough surface contact before(left) and after(right) equivalence

表2 等效前后的材料属性

Table 2 Material properties before and after equivalence

等效前后		弹性模量/ GPa	泊松比	屈服强度/ MPa	切线模量/ MPa
等效前	表面1	120	0.3	1200	10000
等效前	表面2	120	0.3	500	10000
等效后		60	0.3	500	10000

图11 等效前(左)后(右)弹塑性有限元计算结果对比

Fig.11 Comparison of elastic-plastic finite element calculation results before(left) and after(right) equivalence

图12 有限元方法(左)和有限元-边界元耦合方法(右)的接触计算示意图

Fig.12 Contact calculation diagrams of finite element method(left) and finite element-boundary element coupling method(right)

图13 有限元方法(左)和有限元-边界元耦合方法(右)的接触间隙分布计算结果

Fig.13 Calculated results of contact gap distribution obtained by finite element method(left)and finite element-boundary elementcoupling method(right)

图14 四联通网格模型

Fig.14 Four-connection grid model

图15 接触状态演示矩阵

Fig.15 Contact state demonstration matrix

图16 金属密封圈屈服极限和接触面积比之间的关系

Fig.16 Relationship between yield limit of metal sealing ring and contact area ratio

图17 不同金属密封圈屈服极限下的密封面接触状态

Fig.17 Contact states of sealing surfaces under different yield limits of metal sealing rings

图18 被压件弹性模量和接触面积比之间的关系

Fig.18 Relationship between elastic modulus of pressed component and contact area ratio

图19 不同被压件弹性模量下的密封面接触状态

Fig.19 Contact states of sealing surfaces under different elastic moduli of pressed component

图20 不同接触压力对接触面积比的影响

Fig.20 Influences of different contact pressures on contact area ratio

图21 不同接触压力下的密封面接触状态

Fig.21 Contact states of sealing surfaces under different contact pressures

图22 不同表面粗糙度对接触面积比的影响

Fig.22 Influences of different surface roughness on contact area ratio

图23 不同表面粗糙度下的密封面接触状态

Fig.23 Contact states of sealing surfaces under different surface roughnesses

图24 不同表面纹理的密封面泄漏通道

Fig.24 The leakage channels of sealing surfaces with different surface textures

图25 密封实验台示意图

Fig.25 Schematic diagram of sealed experimental platform

图26 实验工装模型

Fig.26 Experimental tooling model

图27 实验现场图

Fig.27 Experimental site

图28 垫圈受到的法向载荷与泄漏率的关系

Fig.28 The relationship between the normal load on the gasket and the leakage rate

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