Sun Wei,Zhang Shuting*,Du Kaiping,et al.Design and simulation research of electroplated coating on piston top of gasoline engine[J].Plating & Finishing,2023,(2):79-85.[doi:10.3969/j.issn.1001-3849.2023.02.013]
汽油机活塞顶面镀层的设计与仿真研究
- Title:
- Design and simulation research of electroplated coating on piston top of gasoline engine
- Keywords:
- piston ; composite coatings ; 3D thermodynamic coupling ; finite element analysis ; coating properties ; interfacial stress
- 分类号:
- TG 174.441
- 文献标志码:
- A
- 摘要:
- 基于有限元软件 ABAQUS 建立了镀层 - 活塞的三维几何模型,采用顺序热力耦合的有限元分析法,系统研究了镀层厚度、弹性模量和导热系数对活塞 - 镀层界面峰值应力的影响。结果表明:当镀层厚度在 100~200 μ m 时,活塞 - 镀层界面峰值应力随镀层厚度的增大而增加,从 163 MPa 增加至 212 MPa ,增大了 30.06 % ;当镀层弹性模量在 200~600 GPa 时,活塞 - 镀层界面峰值应力随镀层弹性模量的增大而增加,从 104 MPa 增加至 175 MPa ,增大了 68.27 % ;当涂层导热系数在 50~400 W·m -1 ·K -1 时,活塞 - 镀层界面峰值应力随镀层导热系数的增大而基本保持不变,约为 171 MPa 。综合考虑活塞顶面的性能需求,依据界面峰值应力与镀层结合状态的演变机理并结合实际电镀工艺:镀层厚度以 150 μ m 左右为宜,弹性模量以 SiC 类复合镀层材料的 400~600 GPa 为宜。导热系数对薄涂层活塞应力场的影响十分有限。
- Abstract:
- : The effects of the coating thickness , elastic modulus and thermal conductivity on the peak stress of the piston-coating interface were systematically studied by the finite element analysis method with sequential thermodynamic coupling. A three-dimensional geometric model of the coating and piston was established by using the finite element software ABAQUS. The simulation results show that when the coating thickness is 100?200 μ m , the peak stress of the interface increases from 163 MPa to 212 MPa with the increase of the coating thickness , increasing by 30.06 %. When the elastic modulus of the coating is 200?600 GPa , the peak stress of the interface increases from 104 MPa to 175 MPa with the increase of elastic modulus , increasing by 68.27 %. When the thermal conductivity of the coating is in the range of 50?400 W·m -1 ·K -1 , the peak stress of the interface almost remains unchanged with the increase of thermal conductivity of the coating , which is about 171 MPa. Considering the performance requirements of the piston top surface , the evolution mechanism of interface peak stress and coating bonding state , and the actual electroplating process , it can be concluded that the optimal coating thickness is about 150 μ m , and the optimal elastic modulus is 400?600 GPa of composite coatings with SiC. The influence of thermal conductivity on the stress field of thin-coated piston is very limited.
参考文献/References:
[1] Karthikeya S T. Performance and emission characteristics of the thermal barrier coated SI engine by adding argon inert gas to intake mixture[J]. Journal of Advanced Research, 2015, 6(6): 819-826.
[2] Deulgaonkar V R, Ingolikar N, Borkar A, et al. Failure analysis of diesel engine piston in transport utility vehicles[J]. Engineering Failure Analysis, 2021, 120: 105008.
[3] Venkatachalam G, Kumaravel A. Experimental investigations on the failure of diesel engine piston[J]. Materials Today: Proceedings, 2019, 16: 1196-1203.
[4] 胡成永 . 热机载荷对活塞应力与变形影响规律研究 [D]. 北京 : 北京理工大学 , 2015.
[5] Nicoletto G, Riva E, Filippo A D. High temperature fatigue behavior of eutectic Al-Si-alloys used for piston production[J]. Procedia Engineering, 2014, 74: 157-160.
[6] 曾志翔 , 王立平 , 陈丽 , 等 . 三价铬电镀硬铬及镀层性能的研究 [J]. 电镀与环保 , 2006(4): 11-13.
[7] 薛茂权 , 黄之德 , 倪贵华 , 等 . 活塞环表面处理及摩擦学性能研究进展 [J]. 电镀与涂饰 , 2020, 39(21): 1510-1513.
[8] Wang L, Kim D S, Nam K S, et al. Microstructure of electroplated hard chromium coatings after plasma nitrocarburizing[J]. Surface and Coatings Technology, 2005, 190(2-3): 151-154.
[9] 李家柱 , 林安 , 甘复兴 . 取代重污染六价铬电镀的技术及应用 [J]. 电镀与涂饰 , 2004, 23(5): 30-33.
[10] Espallargas N, Berget J, Guilemany J M, et al. Cr3C2-NiCr and WC-Ni thermal spray coatings as alternatives to hard chromium for erosion-corrosion resistance[J]. Surface and Coatings Technology, 2008, 202(8): 1405-1417.
[11] Low C T J, Wills R G A, Walsh F C. Electrodeposition of composite coatings containing nanoparticles in a metal deposit[J]. Surface and Coatings Technology, 2006, 201(1): 371-383.
[12] 张艳 , 田苗苗 , 刘蕾 , 等 . 用直流和脉冲电沉积制备 Ni-Cr 纳米复合镀层 [J]. 材料研究学报 , 2012, 26(4): 377-382.
[13] 张艳 , 彭晓 , 王福会 . Cr 颗粒含量对 Ni-Cr 纳米复合镀层组织结构的影响 [J]. 材料研究学报 , 2009, 23(6): 610-615.
[14] 黄嘉乐 , 王启伟 , 阳颍飞 , 等 . 替代电镀铬的碳化硅类复合电镀技术研究进展 [J]. 表面技术 , 2021, 50(1): 130-137.
[15] Nagayama T, Yamamoto T, Nakamura T, et al. Properties of electrodeposited invar Fe-Ni alloy/SiC composite film[J]. Surface and Coatings Technology, 2017, 322: 70-75.
[16] Pinate S, Lspas A, Leisner P, et al. Electrocodeposition of Ni composites and surface treatment of SiC nano-particles[J]. Surface and Coatings Technology, 2021, 406: 126663.
[17] Cai C, Zhu X B, Zheng G Q, et al. Electrodeposition and characterization of nano-structured Ni-SiC composite films[J]. Surface and Coatings Technology, 2011, 205(11): 3448 -3454.
[18] 齐艳飞 , 王波 , 张娜 , 等 . SiC 纳米颗粒增强型复合镀层的研究进展 [J]. 电镀与精饰 , 2016, 38(6): 25-30.
[19] Seidl W M, Bartosik M, Kolozsvári S, et al. Influence of coating thickness and substrate on stresses and mechanical properties of (Ti, Al, Ta) N/(Al, Cr) N multilayers[J]. Surface and Coatings Technology, 2018, 347: 92-98.
[20] 肖来荣 , 聂艳春 , 赵小军 , 等 . MoSi 2 涂层残余应力和结合强度的有限元分析 [J]. 表面技术 , 2020, 49(8): 203-209.
[21] Kajiwara H, Fujioka Y, Suzuki T, et al. An analytical approach for prediction of piston temperature distribution in diesel engines[J]. JSAE Review, 2002, 23(4): 429-434.
[22] 冯振宇 , 范保鑫 , 王纳斯丹 , 等 . 基于 UMATHT 子程序的玻璃纤维 / 乙烯基酯热响应数值模拟 [J]. 材料导报 , 2021, 35(2): 2191-2198.
[23] Pandian S G, Rengarajan S P, Babu T P, et al. Thermal and structural analysis of functionally graded NiCrAlY/YSZ/Al 2 O 3 coated piston[J]. SAE International, 2015, 8(2): 578-585.
[24] Yu Q M, He Q. Effect of material properties on residual stress distribution in thermal barrier coatings[J]. Ceramics International, 2018, 44(3): 3371-3380.
[25] Yang M, Zhu Y, Wang X, et al. Effect of five kinds of pores shape on thermal stress properties of thermal barrier coatings by finite element method[J]. Ceramics International, 2017, 43(13): 9664-9678.
[26] Buyukkaya E, Cerit M. Thermal analysis of a ceramic coating diesel engine piston using 3D finite element method[J]. Surface and Coatings Technology, 2007, 202(2): 398-402.
[27] 田永祥 , 张锡朝 , 张济勇 , 等 . 发动机活塞温度场三维有限元分析 [J]. 内燃机工程 , 2004(1): 62-65.
[28] 杨世铭 , 陶文绘 . 传热学 [M]. 北京 : 高等教育出版社 , 2006.
[29] 王开 . 功能梯度复合材料制动盘设计及制备成形工艺、组织与性能研究 [D]. 重庆 : 重庆大学 , 2008.
[30] 闫俊杰 . TC4 钛合金基体 SiC 涂层抗磨损性能分析 [D]. 长春 : 吉林大学 , 2019.
[31] 苏醒 . 基于热力学的柴油机活塞 - 缸套系统摩擦仿真研 [D]. 长春 : 吉林大学 , 2015.
[32] 牛小强 , 雷基林 , 邓晰文 , 等 . 活塞顶面热障涂层对活塞热负荷的影响 [J]. 中国机械工程 , 2018, 29(12): 1499-1506.
相似文献/References:
[1]沈岳军*,罗华江,王少营,等.温度对Ni-P/PTFE复合镀层性能的影响[J].电镀与精饰,2019,(8):1.[doi:10.3969/j.issn.1001-3849.2019.08.001]
SHEN Yuejun*,LUO Huajiang,WANG Shaoying,et al.Effect of Temperature on the Properties of Ni-P/PTFE Composite Coating[J].Plating & Finishing,2019,(2):1.[doi:10.3969/j.issn.1001-3849.2019.08.001]
[2]王晓丽,顾海,赵紫怡,等.电沉积金属基复合镀层制备研究进展[J].电镀与精饰,2021,(8):44.[doi:10.3969/j.issn.1001-3849.2021.08.010]
WANG Xiaoli,GU Hai,ZHAO Ziyi,et al.Research Progress of Fabricating Metal-Matrix Composite Coating by Electrodeposition[J].Plating & Finishing,2021,(2):44.[doi:10.3969/j.issn.1001-3849.2021.08.010]
[3]赵金国*,乔 勋,阎治安.热处理对Ni-P-BN(h)镀层硬度和自润滑性能的影响[J].电镀与精饰,2022,(1):63.[doi:10.3969/j.issn.1001-3849.2022.01.011]
ZHAO Jinguo*,QIAO Xun,YAN Zhian.Effect of Heat Treatment on Hardness and Self-Lubrication of Ni-P-BN(h) Composite Coating[J].Plating & Finishing,2022,(2):63.[doi:10.3969/j.issn.1001-3849.2022.01.011]
[4]姚伦芳,杨 强,刘定富*.纳米Al2O3颗粒掺杂对化学镀Ni-Cu-P镀层耐蚀性的影响[J].电镀与精饰,2023,(11):27.[doi:10.3969/j.issn.1001-3849.2023.11.004]
Yao Lunfang,Yang Qiang,Liu Dingfu*.Effect of nano-Al 2 O 3 doping on corrosion resistance of electroless Ni-Cu-P coating[J].Plating & Finishing,2023,(2):27.[doi:10.3969/j.issn.1001-3849.2023.11.004]
[5]周 鑫,王晓丽*,皇 磊,等.喷射复合电沉积技术研究进展[J].电镀与精饰,2024,(1):55.[doi:10.3969/j.issn.1001-3849.2024.01.009]
Zhou Xin,Wang Xiaoli*,Huang Lei,et al.Research progress of jet composite electrodeposition technology[J].Plating & Finishing,2024,(2):55.[doi:10.3969/j.issn.1001-3849.2024.01.009]
[6]刘元海,尹凤雷,慕仙莲,等.铜表面镍/银/铑复合镀层的制备及其耐腐蚀性研究?/div>[J].电镀与精饰,2024,(1):79.[doi:10.3969/j.issn.1001-3849.2024.01.012]
Liu Yuanhai,Yin Fenglei,Mu Xianlian,et al.Preparation and corrosion resistance of Ni/Ag/Rh composite coatings on copper surface[J].Plating & Finishing,2024,(2):79.[doi:10.3969/j.issn.1001-3849.2024.01.012]
[7]杜丹丹,田晓东*,卢嘉成.铝合金表面Ni-SiC-CaF2复合镀层的组织和性能研究[J].电镀与精饰,2024,(10):16.
Du Dandan,Tian Xiaodong,Lu Jiacheng.Microstructure and properties of Ni-SiC-CaF2 composite coatings on aluminum alloy surface[J].Plating & Finishing,2024,(2):16.
备注/Memo
收稿日期: 2021-12-29 修回日期: 2022-02-25 作者简介: 孙伟( 1997 —),男,硕士研究生, email : 2019315010104@mail.ncut.edu.cn * 通信作者: 张淑婷( 1978 —),女,博士,教授, email : zhangst@ncut.edu.cn 基金项目: 国家重点研发计划( 2018YFB2002000 );北京市基金 - 市教委联合资助项目( KZ201910009010 );北方工业大学高层次人才科研启动项目( XN277 ; 110051360002 );毓杰团队项目( XN212/009 )