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Surface morphology of the components is a key factor that influences the quality and performance of precision systems. The influence of different morphologies on the contact performance of mating surfaces may be studied by simulating a real rough surface and calculating the contact performance. First, the micro-geometric characteristics of the surfaces of the machined parts are measured by a 3D surface profilometer (NV5000 5022S), and the distribution law of the surface micro-geometric characteristics is obtained by statistical and characterization methods. Second, the rough surface conforming to this law is simulated by a non-Gaussian mathematical algorithm, and the contact model between the mating parts with micro-geometric characteristics of the simulated surface is reconstructed using reverse engineering. Finally, the mechanical properties of the mating surfaces are obtained using a numerical algorithm based on Yoshimura's integral method and tests. The comparison of mechanical properties obtained from numerical analysis and test shows that the maximum errors in the contact stiffness obtained by the two methods are 9.4% (grinding surface) and 11.5% (milling surface), respectively. Therefore, it is feasible to use a non-Gaussian simulation method and Yoshimura's integral method to realize an effective simulation of the micro-geometric characteristics of the surface and the analysis of the contact performance of the mating surface respectively. The results obtained from this study is thus important as a reference for the analysis of the surface morphology and mechanical properties between the matching parts.
Xiaokai Mu; Wei Sun; Chong Liu; Yunlong Wang; Bo Yuan; Qingchao Sun. Study on Rough Surfaces: A Novel Method for High-Precision Simulation and Interface Contact Performances Analysis. Precision Engineering 2021, 1 .
AMA StyleXiaokai Mu, Wei Sun, Chong Liu, Yunlong Wang, Bo Yuan, Qingchao Sun. Study on Rough Surfaces: A Novel Method for High-Precision Simulation and Interface Contact Performances Analysis. Precision Engineering. 2021; ():1.
Chicago/Turabian StyleXiaokai Mu; Wei Sun; Chong Liu; Yunlong Wang; Bo Yuan; Qingchao Sun. 2021. "Study on Rough Surfaces: A Novel Method for High-Precision Simulation and Interface Contact Performances Analysis." Precision Engineering , no. : 1.
In order to accurately and effectively obtain the contact performance of the mating surface under the material surface topography characteristics, a numerical simulation method of rough surface based on the real topography characteristics and a multi-scale hierarchical algorithm of contact performance is studied in this paper. Firstly, the surface topography information of materials processed by different methods was obtained and characterized by a measuring equipment; Secondly, a non-Gaussian model considering kurtosis and skewness was established by Johnson transform based on Gaussian theory, and a rough surface digital simulation method based on real surface topography was formed; Thirdly, a multi-scale hierarchical algorithm is given to calculate the contact performance of different mating surfaces; Finally, taking the aeroengine rotor as the object, the non-Gaussian simulation method was used to simulate the mating surfaces with different topographies, and the multi-scale hierarchical algorithm was used to calculate the contact performance of different mating surfaces. Analysis results showed that the normal contact stiffness and elastic–plastic contact area between the mating surfaces of assembly 1 and assembly 2 are quite different, which further verifies the feasibility of the method. The contents of this paper allow to perform the fast and effective calculation of the mechanical properties of the mating surface, and provide a certain analysis basis for improving the surface microtopography characteristics of materials and the product performance.
Yunlong Wang; Xiaokai Mu; Cong Yue; Wei Sun; Chong Liu; Qingchao Sun. A High Precision Modeling Technology of Material Surface Microtopography and Its Influence on Interface Mechanical Properties. Materials 2021, 14, 2914 .
AMA StyleYunlong Wang, Xiaokai Mu, Cong Yue, Wei Sun, Chong Liu, Qingchao Sun. A High Precision Modeling Technology of Material Surface Microtopography and Its Influence on Interface Mechanical Properties. Materials. 2021; 14 (11):2914.
Chicago/Turabian StyleYunlong Wang; Xiaokai Mu; Cong Yue; Wei Sun; Chong Liu; Qingchao Sun. 2021. "A High Precision Modeling Technology of Material Surface Microtopography and Its Influence on Interface Mechanical Properties." Materials 14, no. 11: 2914.
This paper presents a numerical simulation method to determine the surface morphology characteristics of metallic materials. First, a surface profiler (NV5000 5022s) was used to measure the surface, and the morphology data thereof were characterized. Second, fractal theory was used to simulate the surface profile for different fractal dimensions D and scale coefficients G, and statistical analyses of different surface morphologies were carried out. Finally, the fractal dimension D of the simulated morphology and the actual morphology were compared. The analysis showed that the error of fractal dimension D between the two morphologies was less than 10%; meanwhile, the comparison values of the characterization parameters of the simulated morphology and the actual morphology were approximately equal, and the errors were below 6%. Therefore, the current method used to evaluate the surface morphologies of parts processed by the grinding/milling method can be replaced by the simulated method using the corresponding parameters. This method makes it possible to theorize about the surface morphologies of machined parts, and provides a theoretical basis and reference value for the surface morphology design of materials, with the potential to improve the assembly quality of products.
Xiaokai Mu; Wei Sun; Chong Liu; Bo Yuan; Yunlong Wang; Qingchao Sun. Numerical Simulation and Accuracy Verification of Surface Morphology of Metal Materials Based on Fractal Theory. Materials 2020, 13, 4158 .
AMA StyleXiaokai Mu, Wei Sun, Chong Liu, Bo Yuan, Yunlong Wang, Qingchao Sun. Numerical Simulation and Accuracy Verification of Surface Morphology of Metal Materials Based on Fractal Theory. Materials. 2020; 13 (18):4158.
Chicago/Turabian StyleXiaokai Mu; Wei Sun; Chong Liu; Bo Yuan; Yunlong Wang; Qingchao Sun. 2020. "Numerical Simulation and Accuracy Verification of Surface Morphology of Metal Materials Based on Fractal Theory." Materials 13, no. 18: 4158.