初始齿面点缺陷斜齿轮磨损模式演变与状态评估

为了探究如大型风电齿轮初始缺陷存在下的摩擦磨损机制与演变历程，避免齿轮发生开放式磨损和重大故障，对初始齿面点缺陷下的斜齿轮磨损特征与演变过程进行研究。实验采用控制变量法，在自制齿轮磨损实验台上分别进行了3组不同工况条件下的磨损实验，分别设置了正常齿轮与缺陷齿轮、低载工况与重载工况条件的对比实验。采用振动监测和油液检测技术，对齿轮箱振动情况以及齿轮产生的磨粒进行统计分析，结合轮齿表面的微观形貌分析，对重载工况下缺陷齿轮磨损衰退过程进行准确评估。结果表明：初始缺陷将导致齿轮表面应力集中且数值高达数倍，而初始圆坑缺陷附近却无异常磨损特征；初始圆坑缺陷会缩短齿轮稳定磨损期，削减齿轮使用寿命，磨损后期导致磨损加剧、振幅增加数倍且伴随较大冲击载荷。

Wear Pattern Evolution and Condition Evaluation of Helical Gears with Initial Tooth Surface Point Defects

In order to explore the friction and wear mechanism and evolution process of large wind power gears with initial defects and to avoid open wear and major faults of gears, the wear characteristics and evolution process of helical gears with initial tooth surface point defects were studied. Using the control variable method, three groups of wear experiments under different working conditions were carried out on the self-made gear wear test-bed, and the comparative experiments of normal gear and defective gear, low load condition and heavy load condition were set up respectively. The vibration monitoring and oil detection technology were used to statistically analyze the vibration of the gearbox and the wear particles produced by the gear. Combined with the micro morphology analysis of the gear surface, the wear decline process of the defective gear under heavy load conditions was accurately evaluated. The results show that the initial defect will lead to the stress concentration on the gear surface, and the value is several times as high, while there is no abnormal wear feature near the initial pit defect; the initial pit defect will shorten the stable wear period of the gear and reduce the service life of the gear; in the later stage of wear, it will aggravate the wear, increase the amplitude several times and be accompanied with large impact load.