湿式多片换挡离合器温度场综合优化方法

doi:10.12382/bgxb.2024.0699

摘要/Abstract

摘要：

为解决湿式多片换挡离合器摩擦元件径向温差过大产生的热翘曲等热失效问题,开展了摩擦元件径向接触压力均匀化和摩擦系数梯度化的数值仿真和试验研究。首先基于离合器的紧凑结构,设计并拓扑优化了压板结构,提升了压板刚度,减轻了摩擦元件的变形趋势,使定工况下各摩擦元件的最大压差和温差分别降低了28.64%和28.48%;然后对摩擦片表面进行织构处理和试验,发现摩擦系数随织构线密度增大而减小,提出了织构密度沿摩擦片径向递减的梯度化设计方法,使定工况下最大温差降低17.69%。最后综合应用优化压板和织构摩擦片,使径向接触压力均匀化和摩擦系数沿径向递减,相比于原始设计,摩擦元件的最大温差和热弯矩分别降低了41.73%和45.33%。研究为更高功率密度离合器设计提供了理论基础。

关键词: 多片离合器, 接触压力, 结构优化, 摩擦系数, 温度场

Abstract:

In order to solve the thermal failures such as thermal buckling caused by excessive radial temperature difference of friction elements in the wet multi-disc shifting clutch,the numerical simulation and experimental research are made on the homogenization of radial contact pressure and the gradient design of friction coefficient of friction elements.Firstly,based on the compact structure of clutch,a back plate is designed and topologically optimized.The stiffness of the optimized back plate is improved and the deformation trend of friction elements is reduced,thereby reducing the maximum pressure difference and temperature difference of friction elements by 28.64% and 28.48%,respectively.Then the texture treatment and test are carried out on the surface of friction plate.It is found that the friction coefficient decreases with the increase in the texture line density.A gradient design method for the texture density decreasing along the radial direction of friction plate is proposed,reducing the maximum temperature difference by 17.69%.Finally,the optimized back plate and textured friction plate are comprehensively applied to homogenize the radial contact pressure and decrease the radial friction coefficient.Compared with the original design,the maximum temperature difference and thermal bending moment are reduced by 41.73% and 45.33%,respectively.This study provides a theoretical basis for the design of higher power density clutches.

Key words: multi-disk clutch, contact pressure, structure optimization, coefficient of friction, temperature field

赵钦, 郑怡扬, 于亮, 刘宇键, 党国强, 董懿. 湿式多片换挡离合器温度场综合优化方法[J]. 兵工学报, 2025, 46(7): 240699-.

ZHAO Qin, ZHENG Yiyang, YU Liang, LIU Yujian, DANG Guoqiang, DONG Yi. Comprehensive Optimization of Temperature Field of Wet Multi-disc Shifting Clutch[J]. Acta Armamentarii, 2025, 46(7): 240699-.

图/表 26

图1 湿式多片换挡离合器示意图

Fig.1 Schematic diagram of wet multi-disc shifting clutch

图2 摩擦元件的径向热流密度

Fig.2 Radial heat flux density of friction components

图3 离合器有限元模型

Fig.3 Finite element model of clutch

表1 摩擦元件的材料和结构参数

Table 1 Material and geomatic parameters of friction components

摩擦元件	内径/ mm	外径/ mm	厚度/ mm	泊松比	弹性模量/ GPa
活塞	86	125	6	0.3	216
钢片	86	125	2	0.3	216
摩擦衬层	86	125	0.6	0.16	4
摩擦芯材	86	125	2	0.3	216
压板	86	125	5	0.3	216
卡簧	116	125	3	0.3	216

表2 网格独立性检验

Table 2 Grid independence check

网格	特征	节点数	计算时间/min	接触压力变化/%
A	整圆	202972	900
B	1/6圆	22656	18	2.2~6.8
C	1/6圆	31054	39	0.6~2.0
D	1/6圆	69174	158	0.2~1.0
E	1/6圆	77006	230	0.05~0.1

图4 初始设计径向接触压力

Fig.4 Radial contact pressure distribution of original design

图5 拓扑优化流程图

Fig.5 Flow chart of topology optimization

图6 压板凸台形状

Fig.6 Shape of back plate boss

图7 不同质量目标下的压板设计

Fig.7 Back plate designs under different qualities

图8 压板形状图

Fig.8 Shape of the back plate

图9 遗传聚合拟合效果

Fig.9 Fitting results of genetic aggregation

表3 压板的优化结构参数

Table 3 Optimized structural parameters of the back plate

参数	x₁	x₂	x₃	x₄	x₅
尺寸/mm	2.7	2.4	6.9	7.0	7.0

图10 优化压板的各摩擦副径向压力分布

Fig.10 Radial contact pressure distribution of friction pairs with optimized back plate

表4 初始与优化压板接触压力系数标准差

Table 4 Standard deviation of initial and optimized designs

项目	S₁	S₂	S₃	S₄	S₅	S₆	S₇
初始设计	0.1130	0.1282	0.1484	0.1873	0.2144	0.3491	0.3753
优化压板	0.0854	0.0968	0.1125	0.1404	0.1633	0.2491	0.2798
优化程度	24.3%	24.5%	24.2%	25.0%	23.8%	28.7%	25.4%

图11 织构摩擦片

Fig.11 Textured friction plate

表5 织构片试验工况

Table 5 Test conditions of textured friction plates

样件	线密度/(个·mm^-1)	压力/N	转速/(r·min^-1)
无织构	0	30,80,150	1000
轻载	0.5,0.45,0.4, 0.35,0.3	30
中载		80
重载		150

图12 不同工况下的织构片摩擦系数

Fig.12 COFs under different working conditions

图13 等比例织构摩擦片

Fig.13 1:1 textured friction plate

图14 试验方法

Fig.14 Experimental approach

表6 温度试验工况

Table 6 Conditions of temperature tests

序号	特征	活塞压力/ kPa	转速/ (r·min^-1)	环境温度/℃	滑摩时间/s
T-1	初始设计	100	300	40	13
T-2	仅优化压板
T-3	仅织构摩擦片
T-4	综合优化

图15 优化压板温度场试验结果

Fig.15 Temperature field experimental results of optimized back plate

图16 优化压板仿真与试验结果对比

Fig.16 Comparison between experimental and simulated results of optimized back plate

图17 织构摩擦片温度场试验结果

Fig.17 Temperature field experiment results of textured friction plate

图18 综合优化设计温度场试验结果

Fig.18 Temperature field experiment results after comprehensive optimized design

表7 综合优化表现

Table 7 Performance of compressive optimization

项目	SP1/%	SP2/%	SP3/%	SP4/%
最大温差减小	32.69	30.73	29.64	41.73
热弯矩减小	30.94	32.38	32.45	45.33

图19 摩擦转矩试验结果图

Fig.19 Experimental results of friction torque

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