摩擦焊柱塞的多体动力学特性及其对泵空化的改善

doi:10.12382/bgxb.2025.0334

摘要/Abstract

摘要： 针对高速旋转摩擦焊接工艺制备的重载流体传动机械零部件，介绍了重载泵新型柱塞的高速旋转摩擦焊流程及控制参数。以该工艺生产的空心封闭柱塞为对象，建立融合计算流体力学与刚柔耦合多体动力学的联合求解数值模型，通过数值模拟与试验，分析了摩擦焊柱塞的多体动力学特性及其对泵空化的改善效果。结果表明：吸油行程中，柱塞应力集中于球颈及球头侧芯杆，滑靴承受柱塞球头挤压力与回程盘截切力，靴底应力梯度方向与滑靴速度矢量正交；排油行程中，柱塞局部应力超 250 MPa 但分布分散，组件结构强度安全。压力与空化特性方面，相较传统大腔柱塞，摩擦焊柱塞与缸体形成的闭死容腔最小，容积效率高、响应快，其较小闭死容腔可避免吸油时油液惯性导致的中压冲击，减小空化射流强度，降低空蚀破坏风险。

关键词: 摩擦焊接工艺, 多体动力学, 计算流体力学, 柱塞, 重载柱塞泵, 空化

Abstract:

This paper introduces the high-speed rotational friction welding process and control parameters for new-type pistons in heavy-duty pumps，focusing on the heavy-duty fluid power mechanical components manufactured by this process.Taking the hollow closed piston made by high-speed rotational friction welding as the research object，a coupled numerical model integrating computational fluid dynamics and rigid-flexible coupled tmultibody dynamics is established.The multibody dynamics characteristics of friction-welded pistons and their effects on the improvement of pump cavitation are analyzed through numerical simulation and experiment.The results show that the，piston stress concentrates on the ball neck and the core rod near the ball head side during the suction stroke，the slipper is subjected by the squeezing force from the piston ball head and the cutting force from the return plate hole on the slipper rim，and the stress gradient direction at the slipper bottom is orthogonal to the velocity vector of slipper.Although the local stress in the friction-welded piston exceeds 250MPa during the discharge stroke，the distribution of stress concentration points is dispersed，ensuring the structural strength safety of the piston assembly.In terms of pressure and cavitation characteristics，compared with traditional large-cavity pistons，the friction-welded piston form the smallest dead volume with the cylinder block，achieving higher volumetric efficiency and faster response.The smaller dead volume avoids the medium-pressure impact caused by the oil inertia during oil suction，reduces the intensity of cavitating jets，and decreases the risk of cavitation erosion.

Key words: friction welding, multibody dynamics model, computational fluid dynamics, piston, heavy-duty piston pump, cavitation

廖文博, 周俊杰, 武艺, 陈泽, 郑志豪. 摩擦焊柱塞的多体动力学特性及其对泵空化的改善[J]. 兵工学报, 2025, 46(S1): 250334-.

LIAO Wenbo, ZHOU Junjie, WU Yi, CHEN Ze, ZHENG Zhihao. Multibody Dynamics Characteristics of Friction-welded Piston and Their Effect on Pump Cavitation Mitigation[J]. Acta Armamentarii, 2025, 46(S1): 250334-.

图/表 17

图1 旋转摩擦焊接以及柱塞

Fig.1 Rotational friction welding and piston

表1 焊接工艺参数与材料参数

Table 1 Welding process parameters and material parameters

名称	项目	数值
旋转摩擦焊工艺参数	主轴升速时间/ s	10.00
	主轴转速/rpm	4520
	摩擦产热压力/MPa	3.00
	摩擦产热时间/s	4.20
	急停制动时间/s	0.40
	顶锻粘合压力/MPa	8.50
	顶锻粘合时间/s	3.00
	熔化缩距/mm	4.20
	待焊面积/mm²	417.00
	峰值温度/℃	1140
待焊件（42CrMo）	密度/（kg·m^-3）	7.85
	杨氏模量/Pa	2.10×10⁵
	泊松比	0.300
	熔点温度/℃	1440
	待焊接端面粗糙度/μm	≤0.8
	待焊接端面硬度/HB	257~269
	屈服强度/MPa	≥930
	抗拉强度（调质后）/MPa	≥1080

表2 重载柱塞泵及柱塞技术参数

Table 2 Technical parameters of heavy-duty piston pumps and piston

图示	泵技术参数	数值
	额定压力/MPa	35
	最高压力/MPa	42
	额定转速/rpm	2400
	最大倾角/（°）	16
	排量/ml	145
	摩擦焊接柱塞的主要几何特征
	D=26.1mm	R=9.35mm
	d₃=3mm	L=94.2mm

表3 输入参数

Table 1 Input parameters

流体介质参数
参数	数值	参数	数值
动力粘度/Pa·s	0.04039	油液密度/（kg·m^-3）	870
弹性模量/MPa	1500	饱和蒸汽压/MPa	0.004
气体质量分数/%	0.00164	环境温度/K	328
刚体、柔性体材料参数
部件	密度/（kg·m^-3）	杨氏模量/Pa	泊松比
回程盘（刚）	7.85×10³	2.06×10⁵	0.280
球铰（刚）	8.5×10³	1.10×10⁵	0.330
滑靴（柔）	8.5×10³	1.10×10⁵	0.330
柱塞（柔）	7.85×10³	2.10×10⁵	0.300
缸体（刚）	7.85×10³	2.16×10⁵	0.269
斜盘（刚）	7.85×10³	2.07×10⁵	0.270

图2 联合求解过程

Fig.2 Joint solving procedure

图3 吸油行程柱塞应力分布

Fig.3 Stress distribution of piston during oil suction

图4 排油行程柱塞应力分布

Fig.4 Stress distribution of piston during oil discharge

图5 吸排油行程滑靴应力分布

Fig.5 Stress distribution of slipper during operation

图6 柱塞及闭死容腔的主要参数

Fig.6 Main parameters of pistons and their closed dead chamber

图7 试验和数值计算的输出流量

Fig.7 Experimental and calculated output flow rates

图8 高压行程的柱塞承受压力

Fig.8 The high-pressure process of the piston

图9 低压行程的柱塞承受压力

Fig.9 The low-pressure process of the piston

图10 监测点位置示意图

Fig.10 Schematic diagram of monitoring point location

图11 闭死容腔内各位置随时间的压力分布

Fig.11 Pressure distribution at various positions in a closed dead chamber over time at low-pressure section

图12 惯性压力回升

Fig.12 Rebound of inertial pressure

图13 柱塞球头位置

Fig.13 Position of piston ball head

图14 耐久试验后的斜盘

Fig.14 Cavitation corrosion of the swashplate for durability testing

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