齿轮传动中磨损问题的研究及修复方法

齿轮传动是机器传递运动和动力的一种主要形式.如何减少齿轮工作中的磨损、延长其使用寿命是工业生产中至关重要的问题.重点总结了齿轮磨损问题的基本类型、研究历程、研究方法以及对失效齿轮的常用修复方法等.     

大模数磨损齿轮齿条静力学分析

针对磨损故障形式下的齿轮齿条起升机构,通过分析计算相同载荷下1/12磨损、1/6磨损、1/4磨损下的齿轮齿条基本参数变化情况,利用将齿轮齿条磨损问题量化为ISO相关基本参数改变的方法,对正常和不同磨损故障形势下的弯曲强度进行理论计算,得到其弯曲应力理论计算值.再通过有限元方法对正常和1/12磨损、1/6磨损、1/4磨损下的大模数齿轮齿条起升机构进行静力学分析,研究不同磨损状况下齿轮齿条的弯曲应力和接触应力应变分布规律,并将静力学分析得出的弯曲应力分析结果与利用ISO公式计算的弯曲强度计算结果进行对比分析,验证了将齿轮齿条磨损问题转化为相关基本参数改变问题的可行性,并通过对大模数故障齿轮齿条起升机构的静力学分析,得到其故障形式下的静力学特性,为大模数齿轮齿条起升机构的故障诊断和运行健康评估提供必要的理论基础.     

齿轮磨损故障动态响应特征与诊断指标研究

齿轮磨损属于典型的早期故障,为监测齿轮磨损状态,开展齿轮磨损故障机理与诊断指标研究.采用解析建模的方法,定量研究了齿轮磨损对时变啮合刚度和无负载静态传递误差动力学参数的影响规律:采用Archard磨损模型计算齿轮齿面磨损深度,获得沿齿廓方向的非均匀磨损分布;采用势能法计算齿轮啮合刚度,揭示了齿轮磨损对啮合刚度幅值影响的定量规律;将齿轮磨损等效为轮齿齿廓偏差,揭示了齿轮磨损对无负载静态传递误差影响的定量规律.采用集中参数法建立齿轮传动的动力学模型,通过两级直齿轮疲劳寿命试验对比验证了齿轮磨损动态响应特征.结果 表明,齿轮磨损主要影响齿轮啮合频率及其谐波成分,同时啮合频率及其谐波的边频带以转频为主,且随磨损增加出现明显变化.基于获得的磨损动态响应特征,构造了四个基于振动信号啮合频率边带的诊断指标,该指标对磨损状态变化敏感,通过仿真和试验验证了指标的有效性和鲁棒性.     

等相对曲率齿轮磨损性能研究*

为探讨新型等相对曲率(CRC)齿轮的磨损性能,建立CRC齿轮的数学模型,分别基于克拉盖尔斯基的疲劳磨损计算方法及Archard磨损计算方法对CRC齿轮的磨损性能进行理论分析。2种方法的计算结果具有相同的趋势,且计算得到的最大磨损深度值相当接近,可以认为计算结果是可信的。与相同设计参数的渐开线齿轮的磨损情况对比,发现CRC齿轮的磨损趋势与渐开线齿轮相一致,表现为齿根处磨损大于齿顶处,主动轮磨损大于从动轮;相同啮合位置处相对曲率越大磨损会越严重,因CRC齿轮相对曲率保持不变且为一较小值,其与渐开线齿轮相比在主动轮齿根处及从动轮齿顶处磨损有较大的改善。研究表明,CRC齿轮的磨损性能较渐开线齿轮有着较大的提升。     

复杂工况条件下齿轮传动过程中磨损量预测研究

磨损是齿轮传动过程中的主要失效形式,磨损加剧会使齿轮齿侧间隙非线性增大、传动精度下降及齿面冲击力增大,进而导致齿轮传动系统振动加剧,对齿轮传动性能及设备的稳定运行造成重大影响。为了解决上述问题,提出了复杂工况条件下齿轮传动过程中磨损量预测方法。基于形式磨损指数识别并判定齿轮磨损状态,通过深入分析齿轮磨损机制并以此为基础,绘制典型齿轮磨损过程曲线,计算齿轮传动摩擦力矩数值,构建了齿轮磨损量数学模型;再将已知齿轮状态数值输入至所构建模型中,即可得出齿轮预测磨损量,实现齿轮磨损量的预测。试验结果表明,在3种复杂工况条件下,提出的预测模拟数据更接近于实际参数,验证了磨损量预测的精度。     

计入轴线偏差的斜齿轮副齿面磨损分析

针对齿轮轴线偏差会加剧齿面磨损的问题,提出了一种综合了数值仿真和有限元的方法,对齿面磨损进行了仿真分析。以单对斜齿轮副为研究对象,基于Archard磨损公式,建立了计入轴线偏差的齿面磨损深度解析模型;在此基础上,分析了轮齿螺旋角修形、渐开线鼓形修形对齿面最大磨损深度的影响,并据此制定了减缓齿面磨损的轮齿综合修形策略。研究结果表明:同一工况下,斜齿轮垂直平面轴线偏差比水平轴线偏差对齿面磨损的影响更为显著;采用渐开线鼓形修形与螺旋角修形的综合修形方式可降低齿轮轴线偏差对齿面磨损的影响;该研究结果可为减缓齿面磨损过程制定出合适的修形策略。     

齿轮全寿命过程轮齿形貌变化的试验研究

针对于齿轮全寿命过程中轮齿形貌变化的问题,用8个齿轮模拟磨损试验来模拟齿轮全寿命过程,然后用Taylor CL100形貌仪得到正常齿轮在模拟试验中形成的三维形貌,并计算它们的分形维数和三维粗糙度,最后对形貌参数进行分析得出齿轮全寿命过程中形貌的变化情况.结果表明:齿轮全寿命过程,齿轮轮齿表面三维粗糙度呈现比较明显的增长趋势;齿轮轮齿分形维数从正常磨损到轻微磨损过程增加比较明显,但从中度磨损到严重磨损增加不明显.     

应用Hilbert-Huang变换的齿轮磨损故障诊断研究

提出了一种基于H ilbert-Huang变换的齿轮磨损故障诊断的新方法。H ilbert-Huang变换是先把时间序列信号,用经验模态分解方法分解成不同特征时间尺度的固有模态函数,然后经过H ilbert变换获得频谱的信号处理新方法。介绍了该方法的基本原理,并将H ilbert-Huang变换应用于齿轮箱中齿轮磨损故障诊断的研究,通过选取表征齿轮磨损故障的IM F分量进行边际谱和能量谱分析,就可提取齿轮故障振动信号的特征。齿轮故障实验信号的研究结果表明,H ilbert-Huang变换时频分析方法,能有效地诊断齿轮的磨损故障。     

重型柴油载货汽车差速器的设计与改进

针对重型汽车差速器的十字轴和行星齿轮之间磨损严重,机械损失较大的缺点,在结构上对重型汽车的差速器进行改进设计.对差速器的行星半轴齿轮、半轴花键联接进行设计计算,重点是改变十字轴与行星齿轮转动接合面之间的滑动摩擦为滚动摩擦,方法是在十字轴与行星齿轮接触面之间加入滚针轴承,大大改善了十字轴和行星齿轮之间的磨损情况,减少机械损失,延长差速器使用寿命.     

利用时序模型参数指标的齿轮故障诊断研究

对齿轮故障诊断方法进行研究,针对齿轮箱早期故障特征不明显,研究一种时序模型参数指标的诊断方法.利用齿轮故障模拟实验台采集了齿轮正常、早期裂纹与磨损的振动信号,应用时序AR模型将参数指标作为判据,实现了此三种故障模式的分类和诊断.结果表明,时序模型参数指标诊断法,对于故障的分类和检测是一种有效的诊断方法.     

Mesh relationship modeling and dynamic characteristic analysis of external spur gears with gear wear

Gear wear is one of the most common gear failures, which changes the mesh relationship of normal gear. A new mesh relationship caused by gear wear affects meshing excitations, such as mesh stiffness and transmission error, and further increases vibration and noise level. This paper aims to establish the model of mesh relationship and reveal the vibration characteristics of external spur gears with gear wear. A geometric model for a new mesh relationship with gear wear is proposed, which is utilized to evaluate the influence of gear wear on mesh stiffness and unloaded static transmission error (USTE). Based on the mesh stiffness and USTE considering gear wear, a gear dynamic model is established, and the vibration characteristics of gear wear are numerically studied. Comparison with the experimental results verifies the proposed dynamic model based on the new mesh relationship. The numerical and experimental results indicate that gear wear does not change the structure of the spectrum, but it alters the amplitude of the meshing frequencies and their sidebands. Several condition indicators, such as root-mean-square, kurtosis, and first-order meshing frequency amplitude, can be regarded as important bases for judging gear wear state.     

齿轮点蚀破坏中磨损与振动关系的试验研究

利用铁谱分析技术和振动分析技术中的时频分析方法研究了模拟点蚀故障齿轮磨损与振动的关系。分析结果表明点蚀齿轮磨损和4个时域特征值从一面一点、一面三点到多面多点依次变大,多面多点蚀齿轮磨损严重,磨粒数量最多;点蚀齿轮出现以输入输出端的啮合频率为中心,以转频为调制频率的边频带。齿轮磨损与振动相互关联,磨损量的变化率与振动方差变化率在3种点蚀齿轮中表现明显;但磨损量的增长率不仅与齿面点蚀的程度有关,还与点蚀的齿数有关;而齿轮的振动强度与齿轮齿面点蚀的程度最相关,即齿面点蚀破坏越厉害,振动越剧烈。     

斜齿轮渐进性磨损对齿轮振动特性的影响分析

目前,研究磨损对齿轮动力学特性的影响大多采用传统的Archard磨损模型,并未考虑齿轮的润滑特性,且主要研究对象多为直齿轮。为了弥补斜齿轮研究方面的不足,数值模拟了混合弹流润滑状态下斜齿轮的磨损过程,建立了一个8自由度斜齿轮动力学模型,研究齿面磨损对斜齿轮动态特性的影响。在斜齿轮试验台上进行了齿轮疲劳试验,对数值仿真结果进行验证。结果表明,齿面磨损主要发生在靠近齿根和齿顶部分,且由于齿根处较高的滑滚比导致其磨损更加严重。根据齿轮啮合频率及其谐波幅值的变化可知,磨损导致齿轮的振动增加。试验分析与数值仿真有较好的一致性,说明该研究可以为斜齿轮磨损的预测和故障诊断提供可靠的理论依据。     

The Slow-Speed Wear Behavior of Case-Carburized Gears Lubricated with NLGI 00 Grease under Boundary Lubrication Conditions

NLGI 00 greases are often used to lubricate gears running at low pitch line velocities, such as, for example, in large open gear drives. At low pitch line velocities, sliding wear, which under these operating conditions is referred to as slow speed wear, is often the limiting factor to gear lifetime. A thorough knowledge of the effect of different grease components on the wear behavior is therefore important when selecting a grease to effectively reduce gear wear in a given gear drive. In order to systematically investigate and analyze the influence of different grease components on the slow-speed wear behavior of case-carburized gears, systematic gear tests using the Gear Research Center's (FZG) back-to-back gear test rig were conducted. Primarily, the focus of the experimental investigations is on the influence of the base oil viscosity and type, the additive type, and also the type of soap thickener on the gear wear behavior at low pitch line velocities. To experimentally determine the influence of these different grease components on the wear behavior of case-carburized gears, a modified, more stringent wear test, based on the standard DGMK slow-speed wear test for gear oils, was developed. Different NLGI 00 greases with base oil viscosities between ν₄₀ = 70 and 1,200 mm²/s were investigated.

Base oil type and base oil viscosity were shown to have only a minor effect on the wear behavior under boundary lubrication conditions. On the other hand, the thickener type and especially the additive type play an important role in determining the wear behavior.     

高分子复合材料齿轮磨损模型及磨损测试研究

基于Archard磨损模型,建立高分子复合材料齿轮磨损量模型;分析黏弹性体高分子复合材料齿轮的啮合特性,探讨高分子复合材料齿轮磨损量测量原理。设计了一种高分子复合材料齿轮磨损量测量系统,该系统的测试原理是,通过单铰链支撑的悬臂梁和枢轴箱对齿轮动态加载,使齿轮轮齿表面发生磨损从而导致枢轴箱发生旋转,通过位移传感器测量枢轴箱的偏转角,然后由建立的偏转角与齿轮磨损量之间的关系模型计算得到磨损量。在设计的测试系统上对尼龙66齿轮进行疲劳磨损实验,实验结果和理论模型计算结果基本吻合,既验证了理论模型的正确性,也为高分子复合材料齿轮磨损测试提供了一种新方法。     

Polymer gear surface thermal wear and its performance prediction

This paper will concentrate on acetal gear wear behaviour and its performance prediction based on the extensive investigations on the gear thermal mechanical contact both experimentally and numerically. It has been found from the tests that acetal gear wear rate will be increased dramatically when the load reaches a critical value for a specific geometry and running speed. The gear surface will wear slowly with a low specific wear rate if the gear is loaded below the critical one. The possible reason of the sudden increase in wear rate is due to the gear operating temperature reaching the material melting point under the critical load condition. Gear surface temperature has been then investigated in details through three components: ambient, bulk and flash temperatures. Through extensive experimental investigations and modelling on gear surface temperature variations, a general relation has been built up between gear surface temperature and gear load capacity. An approach for acetal gear transition torque prediction has been proposed and this method is based on the link between polymer gear wear rate and its surface temperature. The method has been related to test results under different operating speeds and gear geometries. Good agreements have been achieved between the proposed method predictions and experimental test results.     

A surface wear model for hypoid gear pairs

In this paper, a methodology was proposed for simulation of surface wear of face-milled or face-hobbed hypoid gear pairs. The methodology combines Archard's wear model with a finite-element based hypoid gear contact model. The wear model requires the sliding distances and contact pressures to be computed along the contact zones at each rotational gear position. Formulations were proposed for computation of sliding distance along the tooth contact zones based on hypoid gear kinematics and geometry of the tooth surfaces, and the contact model was used to predict the normal contact pressure distributions. An example hypoid gear pair was analyzed for its wear behavior. Influences of gear position errors on wear patterns were demonstrated. An approximate method that is computationally more efficient was also proposed at the end.     

齿面磨损对齿轮系统动态特性的影响

为研究齿面磨损对齿轮系统动态特性的影响,综合考虑齿轮齿侧间隙、传输误差、齿面磨损,采用集中参数法建立齿轮平移-扭转非线性动力学模型,分析齿轮的转速、运行次数对含有齿面磨损的齿轮传动系统动态特性的影响。结果表明:在啮合区域内,齿根处的齿面磨损量呈减小趋势,在节点处理论磨损量为零,齿顶处的齿面磨损呈增加趋势,齿面磨损量减小趋势大于增加趋势,整个过程中齿面磨损会造成啮合刚度的减小;存在齿面磨损时,过大或过小的转速都会使齿轮系统的振幅波动变大,幅值减小;当转速一定时,含有齿面磨损的系统随着运行次数的增加,振幅幅值会逐渐减小,传动的波动会加剧。     

在线铁谱数据分析方法的研究

在线铁谱仪已成功地用于机械设备的磨损状态监测,如何根据铁谱数据来分析机器磨损状态和磨损规律一直被人们所重视。本文利用自组织特征映射神经网络对齿轮整个磨损过程的铁谱数据进行分类,提出了齿轮不同磨损状态下磨粒的分布规律,根据这种规律可以识别齿轮的不同磨损状态。这对监测机械设备运行状态具有十分重要的意义。     

带式啮合介质齿轮传动的磨损仿真分析

带式啮合介质齿轮传动中,齿轮副的接触由高模量的齿轮对接触转化为高模量齿轮与低模量介质带的接触,磨损主要发生在柔性介质带上。应用Archard黏着磨损理论,建立带式啮合介质齿轮传动磨损数学模型,用Solid Works三维建模软件建立带式啮合介质齿轮的实体模型,并对其结构静力学进行分析;根据磨损数学模型和接触应力的分布情况,模拟计算出介质带的磨损量。结果表明:带式啮合介质齿轮传动最大接触应力发生在啮合节点处,弹性应变主要发生在介质带上,啮合节点处应变值最大;介质带的磨损量随载荷和滑动距离的增加而增加,最大磨损量发生在啮合节点处,在齿轮啮合线上不同节点处磨损量略有差距,边缘处磨损量最大。