基于可控表面微特征的冷锻摩擦微观机理及润滑改善方法研究

项目名称： 基于可控表面微特征的冷锻摩擦微观机理及润滑改善方法研究

项目编号： No.51475294

项目类型： 面上项目

立项/批准年度： 2015

项目学科： 机械、仪表工业

项目作者： 胡成亮

作者单位： 上海交通大学

项目金额： 80万元

中文摘要： 研发全新的环保型制造技术或提升现有先进制造技术的环保水平，已成为汽车装备制造业的发展新趋势；冷锻作为具有优异经济性的先进制造技术，提高其环保水平以促其内涵式发展，已成为学术界与工业界必须面临且迫切需要解决的重要问题。本项目拟开展系统研究，揭示基于表面微特征的冷锻成形接触摩擦的微观机理，探讨不同模具表面微特征与工件初始表面微特征对冷锻摩擦的影响规律，分析经冷锻变形后工件表面形貌的演化规律；形成一种金属表面可控微特征的加工方法，提出适用于表面微特征的定量描述方法，建立引入表面微特征参数的摩擦修正模型；形成冷锻成形摩擦条件的定量分析方法，设计并制造对冷锻润滑敏感的检测装置，建立冷锻摩擦与润滑的评价体系；分析表面微特征对冷锻润滑的影响效果，优选润滑剂与润滑方式，提出环境友好的替代或者部分替代传统磷皂化工艺的新型冷锻润滑策略与方法，提高冷锻工业生产的环保水平，更好地服务于我国汽车工业的宏观发展战略。

中文关键词： 冷锻摩擦；冷锻润滑；表面微特征；微观机理；数值模拟

英文摘要： To meet the challenges from environmental protection issues，development of novel environmentally friendly manufacturing techniques or upgrading of existing environmental standards of advanced manufacturing technology has become a new trend in the development of automotive industry. Cold forging is one of the advanced manufacturing technologies with excellent economic benefit, but the phosphating plus soaping treatment process, which is usually used as a lubricating method in the mass production of cold forging, is definitely damage the environment by the acid mist and heavy metal slug producing in the process. Therefore, how to improve its environmental level and to promote its connotative development, already become an important issue which must be directly faced and urgently needed to be solved by both the academia and industry sides. Based on the basic theory of tribology, plasticity mechanic and surface science, system research works will be conducted in this study. Firstly, considering the effect of surface micro-features, the microscopic mechanism of contact friction between workpice and tooling in cold forging would be revealed, and the effect of surface topography of workpiece and tooling on the friction behavior would be investigated, and the evolution of surface topography after cold forging would also be analyzed. Secondly, a manufacture process that could be used to form controlled micro-feature on metal surface should be put forward, and a quantitative description method for this micro-feature should be proposed correspondingly, then a modified friction model would be established according to the effect of surface micro-feature on the friction. Thirdly, quantitative determination method for friction conditions in cold forging and sensitive testing device for lubrication effect in cold forging should be carefully designed and critically evaluated, based on this the evaluation system for the friction and lubrication in cold forging would be established, and the effect of surface micro-features on lubrication result would be investigated by using the evaluation system, then better lubricant and lubricating method could be selected. Finally, a combined environmentally friendly lubricating strategy which could replace or partly replace the phosphating plus soaping treatment would be obtained, with this the environmental level of cold forging industry would be improved and which could greatly benefit the automobile industry.

英文关键词： Friction in cold forging;Lubrication system for cold forging;Surface micro-feature;Microscopic mechanism;Numerical simulation