Virtual Design And Simulation Analysis Of Friction And Wear Testing Machine

Roll wear is one of the factors that are difficult to be controlled accurately in the rolling process, and there is no suitable theoretical model can predict the calculation of roll wear till now. To study roll wear, domestic and international researchers designed a variety of friction and wear testing machines, but there are large differences between the working conditions and the rolling conditions, and the experimental data can not provide adequate reference for roll wear research. For simulating roll friction and wear behavior more realistically than other testing machines in the rolling process, and providing a powerful reference for roll wear research and practical application of roll materials, RollsFW240friction and wear testing machine was designed in this paper.For studying and analyzing system structure and work performance of RollsFW240friction and wear testing machine, firstly, according to the functions and main technical parameters of this testing machine, described the design process including general structural design, system composition and system modeling briefly. Secondly, structure static analysis and vibration analysis for the key parts of this testing machine were completed by FEM, and then the strength and stiffness properties of the relevant parts meeting the design requirements were verified. Thirdly, the rigid-flexible coupling model of transmission system was created by making use of the interface technology of UG, ADAMS and ANSYS, then its dynamic simulation and vibration analysis were preceded, thereby the stress and strain state of flexible shaft and the working state of transmission system under the actual conditions were obtained. Finally, electromagnetic-thermal coupling induction heating process of the test disk was simulated and analyzed by making use of ANSYS software’s physics environment method, the temperature distribution and its variation with time were obtained, and induction heating method meeting the design requirements of the test disk surface high-temperature heating was verified. In addition, the effect of induction heating including the variation of power frequency, current intensity on the test disk temperature control was analyzed, thereby the theoretical foundation for temperature control of the test disk and optimization design of the induction heating device were offered.The results of system modeling, finite element analysis and dynamic simulation were analyzed, thereby the experiment functions of this testing machine to simulate the strip rolling friction under the actual conditions were proved, and the design requirements of main technical parameters were satisfied, while the favorable theoretical guidance and technical support for system structure optimization design and technical parameters selection were provided. In addition, the virtual design and simulation analysis methods of this testing machine can provide certain reference for the same type of friction and wear testing machine design.