Journal of Zhejiang University

Journal of Zhejiang University SCIENCE A

Accepted manuscript available online (unedited version)

Wear map-based wear prediction method for the piston–cylinder interface in axial piston machines

Author(s): Fei LYU, Xudong SHEN, Felix SCHLEGEL, Xiaolong ZHANG, Liangyu SONG, Junhui ZHANG, Katharina SCHMITZ, Bing XU
Affiliation(s): State Key Laboratory of Fluid Power & Mechatronic Systems, Zhejiang University, Hangzhou 310058, China; more
Corresponding email(s): zhang.xl@zju.edu.cn
Key Words: Wear map, Wear evolution, Mixed lubrication, Piston–cylinder interface (PCI), Axial piston machine (APM)

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Fei LYU, Xudong SHEN, Felix SCHLEGEL, Xiaolong ZHANG, Liangyu SONG, Junhui ZHANG, Katharina SCHMITZ, Bing XU. Wear map-based wear prediction method for the piston–cylinder interface in axial piston machines[J]. Journal of Zhejiang University Science A,in press.Frontiers of Information Technology & Electronic Engineering,in press.https://doi.org/10.1631/jzus.A2500501

@article{title="Wear map-based wear prediction method for the piston–cylinder interface in axial piston machines",
author="Fei LYU, Xudong SHEN, Felix SCHLEGEL, Xiaolong ZHANG, Liangyu SONG, Junhui ZHANG, Katharina SCHMITZ, Bing XU",
journal="Journal of Zhejiang University Science A",
year="in press",
publisher="Zhejiang University Press & Springer",
doi="https://doi.org/10.1631/jzus.A2500501"
}

%0 Journal Article
%T Wear map-based wear prediction method for the piston–cylinder interface in axial piston machines
%A Fei LYU
%A Xudong SHEN
%A Felix SCHLEGEL
%A Xiaolong ZHANG
%A Liangyu SONG
%A Junhui ZHANG
%A Katharina SCHMITZ
%A Bing XU
%J Journal of Zhejiang University SCIENCE A
%P 569-582
%@ 1673-565X
%D in press
%I Zhejiang University Press & Springer
doi="https://doi.org/10.1631/jzus.A2500501"

TY - JOUR
T1 - Wear map-based wear prediction method for the piston–cylinder interface in axial piston machines
A1 - Fei LYU
A1 - Xudong SHEN
A1 - Felix SCHLEGEL
A1 - Xiaolong ZHANG
A1 - Liangyu SONG
A1 - Junhui ZHANG
A1 - Katharina SCHMITZ
A1 - Bing XU
J0 - Journal of Zhejiang University Science A
SP - 569
EP - 582
%@ 1673-565X
Y1 - in press
PB - Zhejiang University Press & Springer
ER -
doi="https://doi.org/10.1631/jzus.A2500501"

Abstract
Chinese Summary
Academic Network
Reviewer Comment

Abstract: Understanding the wear behavior of the piston–cylinder interface (PCI) is critical for improving the reliability and service life of axial piston machines (APMs). Existing PCI wear prediction methods often rely on one or two predefined wear models, for example, the Archard model with simplified mechanism switching. However, the PCI inherently experiences multiple coexisting contact states. In this paper, we propose a wear map-based wear prediction method. The operating conditions that can comprehensively represent the contact states across the entire interface are simulated by a mixed lubrication model and are then used as a matrix input into tribometer tests to measure a map of the wear rate. The wear map establishes the quantitative correlations between the contact states and the wear rate and can be embedded into an existing PCI wear prediction framework. An APM wear test showed that our proposed method could track the wear evolution process and capture the wear redistribution in the end region of the cylinder bore under the investigated operating conditions.

基于磨损图的轴向柱塞泵/马达柱塞副磨损预测方法

作者：吕飞^1,2，沈旭栋¹，Felix SCHLEGEL²，张小龙¹，宋良宇¹，张军辉¹，Katharina SCHMITZ²，徐兵¹
机构：¹浙江大学，流体动力与机电系统全国重点实验室，中国杭州，310058；²亚琛工业大学，流体驱动与系统研究所，德国亚琛，52074
目的：预测柱塞副的磨损行为对于提高轴向柱塞泵-马达的可靠性和服役寿命至关重要。本文旨在通过柱塞副磨损图来改进现有方法在柱塞副复合承载润滑状态下磨损率计算不够准确的问题，从而实现更加全面和可靠的柱塞副磨损进程预测。
创新点：提出了基于实测磨损图的磨损预测方法，以替代现有的简化硬切换磨损计算模型，从而获得柱塞副复合磨损机制下，界面全域接触状态与磨损率的映射关系。
方法：1.使用柱塞副混合润滑模型描述摩擦副界面的全域接触状态，并将其作为工况矩阵输入盘-盘摩擦磨损试验台，以获得柱塞副全域接触状态的磨损图，从而建立接触状态与磨损率的映射关系；2.通过观测柱塞副全域接触状态下磨损特征的复合性，阐明磨损图的必要性；3.将磨损图嵌入到柱塞副磨损进程预测模型中，并分析磨损图对磨损分布和演化进程的影响，且通过整泵磨损进行验证。
结论：1.柱塞副局部磨损率随接触应力非线性增加，并且在所研究的接触工况内的中应力水平下，对滑动速度的敏感性较明显。2.从磨损轮廓来看，磨损主要出现在缸孔轴向两端，而且基于磨损图的方法和传统的基于Archard模型的方法都能够识别主要磨损区域。3.从磨损演化进程来看，0.5 h内缸孔顶端迅速出现磨损，然后顶端磨损增长缓慢；在缸孔底端，磨损从3h起迅速增加，到15 h达到比顶端更高的水平。传统的基于Archard模型的方法未重现底端磨损量的反超，然而基于磨损图的方法更一致地捕获了这种缸孔两端磨损量随着时间重新分布的情况。

关键词组：磨损图；磨损演化；混合润滑；柱塞副；轴向柱塞泵/马达

Darkslateblue:Affiliate; Royal Blue:Author; Turquoise:Article

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