船用大型齿轮接触与应力分布数值分析
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摘要
船用齿轮减速器是船舶上应用非常广泛的一类机械,在调速轴系,柴油机喷油系统,绞锚机中都有它的身影。因此,齿轮的失效将会给船舶的正常工作带来不可估量的影响,船用齿轮的失效形式主要有点蚀,胶合,磨损,极少情况下会发生折断,此外,减小振动和噪声也成为目前人们所追求的目标。为了增加齿轮的使用寿命,改善其工作性能,就不能不对齿轮工作中的接触与应力分布问题进行研究,其中研究接触问题就必须研究齿轮的润滑状态,研究应力分布必须研究齿轮的强度分析,本文就是从这两个角度进行展开的。
本文以某单级内河船用直齿轮为研究对象,引入弹流润滑理论,对该齿轮的接触润滑参数进行了计算,应用强度理论,分析了齿轮的接触应力,以指导齿轮的润滑接触不当而出现的故障,论文的主要内容可概括如下：
综述船用齿轮的应用与失效,对失效影响因素进行分析,指出润滑接触不良是引起失效的主要根源；建立运动与受力模型,应用弹流润滑理论对齿轮的润滑参数进行了计算,应用弹性力学与数学算法相结合,对齿轮齿面强度进行分析,并应用三维建模软件建立齿轮简图,导入ANSYS有限元分析软件中去,进行分析计算,得到齿轮的三维受力简明的结果。
数值计算结果表明：随着计算区域节点的增加,计算速度减慢；油膜压力有明显的二次压力峰出现,可以形成稳定的油膜；啮合线上的双单交替啮合点附近受力最差,采用润滑结果对强度进行分析比用Hertz接触所得结果更小；采用仿真软件进行计算所得结果与数值计算结果相符。
Marine gear reducer is a class of machinery widely used on the ship, There is its presence in the governor shaft, diesel fuel injection system and the anchor machine. Therefore, the failure of gear will bring immeasurable impact to the ship work, the failure of the main form of marine gear contain pitting, bonding, wear, when break occurs in rare cases, in addition, reducing vibration and noise also become the goal by the people. In order to increase the service life of gears and improve its performance, it will have on the work gear contact and stress distribution in the study the issue, including issues of access you have to study gear lubrication, gear of stress intensity distribution must be studied, this paper is carried out from the two perspectives.
Taking marine a single-stage spur gear for the study, the paper introduce the EHL theory, calculate the contact of the gear lubricant parameters, analysis the contact stress of gears using the strength theory, to guide the emergence of improper contact with failure in gear lubrication, the main contents of the paper can be summarized as follows:
This paper summarizes the application and failure of marine gear failure, analyses the failure factors and figures out that the main causes of the failure is poor contact of lubrication.Motion model and force model are established. Then, the lubrication parameter of marine gear is calculated by using the elastic-hydrodynamic lubrication theory and tooth surface strength is analyzed by elasticity combining with mathematical algorithms.At last, finite element analysis software ANSYS input the gear diagram which is created by three-dimensional modeling software to obtain concise results of three-dimensional stress.
The results of numerical computation show:when the calculation region node is increased, the calculation speed will slow down; oil film pressure appears obvious secondary pressure peak; stable oil film mesh can format in mesh point; the double single alternate mesh point force is worst in line of action; the strength from lubrication results is smaller than from Hertz contact; and the simulation calculation results consistent with the numerical computation results.
本文以某单级内河船用直齿轮为研究对象,引入弹流润滑理论,对该齿轮的接触润滑参数进行了计算,应用强度理论,分析了齿轮的接触应力,以指导齿轮的润滑接触不当而出现的故障,论文的主要内容可概括如下：
综述船用齿轮的应用与失效,对失效影响因素进行分析,指出润滑接触不良是引起失效的主要根源；建立运动与受力模型,应用弹流润滑理论对齿轮的润滑参数进行了计算,应用弹性力学与数学算法相结合,对齿轮齿面强度进行分析,并应用三维建模软件建立齿轮简图,导入ANSYS有限元分析软件中去,进行分析计算,得到齿轮的三维受力简明的结果。
数值计算结果表明：随着计算区域节点的增加,计算速度减慢；油膜压力有明显的二次压力峰出现,可以形成稳定的油膜；啮合线上的双单交替啮合点附近受力最差,采用润滑结果对强度进行分析比用Hertz接触所得结果更小；采用仿真软件进行计算所得结果与数值计算结果相符。
Marine gear reducer is a class of machinery widely used on the ship, There is its presence in the governor shaft, diesel fuel injection system and the anchor machine. Therefore, the failure of gear will bring immeasurable impact to the ship work, the failure of the main form of marine gear contain pitting, bonding, wear, when break occurs in rare cases, in addition, reducing vibration and noise also become the goal by the people. In order to increase the service life of gears and improve its performance, it will have on the work gear contact and stress distribution in the study the issue, including issues of access you have to study gear lubrication, gear of stress intensity distribution must be studied, this paper is carried out from the two perspectives.
Taking marine a single-stage spur gear for the study, the paper introduce the EHL theory, calculate the contact of the gear lubricant parameters, analysis the contact stress of gears using the strength theory, to guide the emergence of improper contact with failure in gear lubrication, the main contents of the paper can be summarized as follows:
This paper summarizes the application and failure of marine gear failure, analyses the failure factors and figures out that the main causes of the failure is poor contact of lubrication.Motion model and force model are established. Then, the lubrication parameter of marine gear is calculated by using the elastic-hydrodynamic lubrication theory and tooth surface strength is analyzed by elasticity combining with mathematical algorithms.At last, finite element analysis software ANSYS input the gear diagram which is created by three-dimensional modeling software to obtain concise results of three-dimensional stress.
The results of numerical computation show:when the calculation region node is increased, the calculation speed will slow down; oil film pressure appears obvious secondary pressure peak; stable oil film mesh can format in mesh point; the double single alternate mesh point force is worst in line of action; the strength from lubrication results is smaller than from Hertz contact; and the simulation calculation results consistent with the numerical computation results.
引文
[1]籍国宝.摩擦磨损原理[M].北京：农业出版社,1992
[2]张天勇.船用齿轮齿面润滑与接触数值分析[D].武汉：武汉理工大学,2009
[3]刘维民,夏延秋,付兴国.齿轮传动润滑材料[M].北京：化学工业出版社,2005
[4]余放,王明为.舰船减速齿轮装置的加工与设计[M].北京：国防工业出版社,2009
[5]于瑞侠.核动力汽轮机[M].哈尔滨：哈尔滨工程大学出版社,2000
[6]濮良贵,纪名刚.机械设计[M].北京：高等教育出版社.2004
[7]LinhongXu, Leiming Li, Yin Liu.Stress Analysis and Optimization of Gear teeth[C]. International Conference on Measuring Technology and Mechatronics Automation,2009:895-898
[8]张延化,王优强.润滑油膜压力作用下齿轮应力有限元分析[J].机械设计与制造,2010,444-45
[9]戴明城,刘正林,吴铸新,周建辉.船用重载斜齿轮啮合过程接触有限元仿真分析[J].船海工程,2009,38(4)：128-135
[10]尹刚.高重合度齿轮应力场有限元分析[J].重庆大学学报,2010,33(7)：53-56
[11]温诗铸.摩擦学原理[M].北京：清华大学出版社,1990
[12]王发挥.基于理想模型的齿轮弹流动力润滑研究[D].南昌：南昌大学,2008
[13]温诗铸.润滑理论研究的进展与思考[J].摩擦学报,2007,27(6)：487-503
[14]Martin.H.M.Lubrication of gearteeth.Engineering,1916,102:199-204
[15]Dowson D.Higginson G.R.Elasto-Hydrodynamic Lubrication [M].Pergamon:Pergamon Press, 1977
[16]YP Koo. Transient EHL analysis on spur gear teeth with consideration of gear kinematics. KSME International Journal,2004,18(8):1319-1326
[17]S Akbarzadeh, MM Khonsari. Performance of Spur Gears Considering Surface Roughness and Shear Thinning LubricantJournal of Tribology,2008,130:1-8
[18]S Akbarzadeh, MM Khonsari. Thermoelastohydrodynamic Analysis of Spur Gears with Consideration of Surface. Tribol Lett,2008,32:129-141
[19]S Akbarzadeh, MM Khonsari. Prediction of Steady State Adhesive Wear in Spur Gears Using the EHL Load Sharing. Journal of Tribology,2009,131:1-5
[20]Sheng li. Lubrication And Contact Fatigue Models For Roller And Gear. Presented in Partial Fulfillment of the Requirements for The Degree of Doctor of Philosophy in the Graduate School of The Ohio State University 2009:1-266
[21]S. Li. A.Kahraman. A Transient Mixed Elastohydrodynamic Lubrication Model for Spur Gear Pairs Journal of Tribology.2010.1.132:1-9
[22]孙桓.齿轮传动的主摩擦学设计[D].太原理工大学.2007
[23]卢洪,杨沛然.用多重网格法准确计算弹流润滑膜厚的方法[J].润滑与密封.2010.4.(4)：5-9
[24]吕琦,沈雪瑾.有限长热弹流温度影响因素的研究[J].润滑与密封.2010.4.(4)：33-38
[25]王顺,王文中,胡元中等.点接触润滑粗糙表面滑动摩擦力的预测研究[J].摩擦学学报,2007,27(2)：152-155
[26]黄立,胡元中,王文中.斜齿轮非稳态等温弹流润滑数值分析[J].润滑与密封,2009,34(7)：23-27
[27]孙文龙,马丽然,李刚等.弹流润滑点接触Hertz区温度分布及其变化规律的实验研究[J].润滑与密封,2009,34(3)：16-19
[28]CK Gaol, XM Qi, RW Snidle, et al. Effect of film thickness ratio on gearing contact fatigue life。In:Symposium on Elastohydrodynamics and Micro-elastohydrodynamics, RW Snidle and HP Evans (eds), Cardiff, UK,2006,134:423-434
[29]高创宽.渐开线齿轮传动的混合弹流润滑研究[D].太原：太原理工大学,2005
[30]张增强,高创宽,尹晓亮.润滑油粘度对齿轮接触疲劳寿命影响的研究[J].机械工程与自动化,2008,6：79-81
[31]CirinoM.FriedrichK.Pipes RB. The effect of fiberorien-tation on the abrasivewear behavior of Poylmer composite materials [J]. Wear. V121,1988.127-136
[32]CirinoM.FriedrichK.PipesRB.Evaluation of Poylmer composites for sliding and.abrasivewear applications [J]. Composites.1988. V5. No.19.383-392
[33]Andras Z, Szeri. Fluid film lubrication:theory and design. Cambridge University Press, 2005:289-291
[34]孙桓,陈作模,葛文杰.机械原理(第七版)[M].北京：高等教育出版社,2006
[35]V Bakola, A Mihailidis. Analysis of rough line contacts operating under mixed elastohydrodynamic lubrication conditions. Lubrication Science,2004,16:50-55
[36]徐芝纶.弹性力学(第3版,上册).北京：高等教育出版社,2004
[37]王德俊,何雪浤.现代机械强度理论及应用[M].北京：科学出版社,2003
[38]杨沛然.流体润滑数值分析[M].北京：国防工业出版社,1998
[39]哈克布思.多重网格方法[M].科学出版社,1988,189-204
[40]王家序,余江波,田凡等.水润滑塑料合金轴承数控值分析的多重网格法[J].润滑与密封.2005(5)：62-65
[41]张鹏顺,陆思聪.弹性流体动力润滑及其应用[M].北京：高等教育出版社.1995
[42]翟玉生,李安,张金中.应用摩擦学[M].石油大学出版社.1996
[43]张洪信.有限元基础理论与ANSYS应用[M].北京：机械工业出版社.2006
[44]段进,倪栋,王国业ANSYS10.0结构分析从入门到精通[M].北京：兵器工业出版社,2006
[45]康渊,陈信吉Ansys入门[M].北京：中国电力出版社.2007
[46]孟庆恩.人工关节弹流润滑问题多重网格问题及结果分析[D].青岛：青岛理工大学,2006
[47]李朵朵.齿轮传动动态弹流润滑的数值计算模型研究[D].太原：太原理工大学,2006
[48]冯桂萍.基于齿面粗糙度的齿轮传动热弹流润滑研究[D].太原：太原理工大学,2005
[2]张天勇.船用齿轮齿面润滑与接触数值分析[D].武汉：武汉理工大学,2009
[3]刘维民,夏延秋,付兴国.齿轮传动润滑材料[M].北京：化学工业出版社,2005
[4]余放,王明为.舰船减速齿轮装置的加工与设计[M].北京：国防工业出版社,2009
[5]于瑞侠.核动力汽轮机[M].哈尔滨：哈尔滨工程大学出版社,2000
[6]濮良贵,纪名刚.机械设计[M].北京：高等教育出版社.2004
[7]LinhongXu, Leiming Li, Yin Liu.Stress Analysis and Optimization of Gear teeth[C]. International Conference on Measuring Technology and Mechatronics Automation,2009:895-898
[8]张延化,王优强.润滑油膜压力作用下齿轮应力有限元分析[J].机械设计与制造,2010,444-45
[9]戴明城,刘正林,吴铸新,周建辉.船用重载斜齿轮啮合过程接触有限元仿真分析[J].船海工程,2009,38(4)：128-135
[10]尹刚.高重合度齿轮应力场有限元分析[J].重庆大学学报,2010,33(7)：53-56
[11]温诗铸.摩擦学原理[M].北京：清华大学出版社,1990
[12]王发挥.基于理想模型的齿轮弹流动力润滑研究[D].南昌：南昌大学,2008
[13]温诗铸.润滑理论研究的进展与思考[J].摩擦学报,2007,27(6)：487-503
[14]Martin.H.M.Lubrication of gearteeth.Engineering,1916,102:199-204
[15]Dowson D.Higginson G.R.Elasto-Hydrodynamic Lubrication [M].Pergamon:Pergamon Press, 1977
[16]YP Koo. Transient EHL analysis on spur gear teeth with consideration of gear kinematics. KSME International Journal,2004,18(8):1319-1326
[17]S Akbarzadeh, MM Khonsari. Performance of Spur Gears Considering Surface Roughness and Shear Thinning LubricantJournal of Tribology,2008,130:1-8
[18]S Akbarzadeh, MM Khonsari. Thermoelastohydrodynamic Analysis of Spur Gears with Consideration of Surface. Tribol Lett,2008,32:129-141
[19]S Akbarzadeh, MM Khonsari. Prediction of Steady State Adhesive Wear in Spur Gears Using the EHL Load Sharing. Journal of Tribology,2009,131:1-5
[20]Sheng li. Lubrication And Contact Fatigue Models For Roller And Gear. Presented in Partial Fulfillment of the Requirements for The Degree of Doctor of Philosophy in the Graduate School of The Ohio State University 2009:1-266
[21]S. Li. A.Kahraman. A Transient Mixed Elastohydrodynamic Lubrication Model for Spur Gear Pairs Journal of Tribology.2010.1.132:1-9
[22]孙桓.齿轮传动的主摩擦学设计[D].太原理工大学.2007
[23]卢洪,杨沛然.用多重网格法准确计算弹流润滑膜厚的方法[J].润滑与密封.2010.4.(4)：5-9
[24]吕琦,沈雪瑾.有限长热弹流温度影响因素的研究[J].润滑与密封.2010.4.(4)：33-38
[25]王顺,王文中,胡元中等.点接触润滑粗糙表面滑动摩擦力的预测研究[J].摩擦学学报,2007,27(2)：152-155
[26]黄立,胡元中,王文中.斜齿轮非稳态等温弹流润滑数值分析[J].润滑与密封,2009,34(7)：23-27
[27]孙文龙,马丽然,李刚等.弹流润滑点接触Hertz区温度分布及其变化规律的实验研究[J].润滑与密封,2009,34(3)：16-19
[28]CK Gaol, XM Qi, RW Snidle, et al. Effect of film thickness ratio on gearing contact fatigue life。In:Symposium on Elastohydrodynamics and Micro-elastohydrodynamics, RW Snidle and HP Evans (eds), Cardiff, UK,2006,134:423-434
[29]高创宽.渐开线齿轮传动的混合弹流润滑研究[D].太原：太原理工大学,2005
[30]张增强,高创宽,尹晓亮.润滑油粘度对齿轮接触疲劳寿命影响的研究[J].机械工程与自动化,2008,6：79-81
[31]CirinoM.FriedrichK.Pipes RB. The effect of fiberorien-tation on the abrasivewear behavior of Poylmer composite materials [J]. Wear. V121,1988.127-136
[32]CirinoM.FriedrichK.PipesRB.Evaluation of Poylmer composites for sliding and.abrasivewear applications [J]. Composites.1988. V5. No.19.383-392
[33]Andras Z, Szeri. Fluid film lubrication:theory and design. Cambridge University Press, 2005:289-291
[34]孙桓,陈作模,葛文杰.机械原理(第七版)[M].北京：高等教育出版社,2006
[35]V Bakola, A Mihailidis. Analysis of rough line contacts operating under mixed elastohydrodynamic lubrication conditions. Lubrication Science,2004,16:50-55
[36]徐芝纶.弹性力学(第3版,上册).北京：高等教育出版社,2004
[37]王德俊,何雪浤.现代机械强度理论及应用[M].北京：科学出版社,2003
[38]杨沛然.流体润滑数值分析[M].北京：国防工业出版社,1998
[39]哈克布思.多重网格方法[M].科学出版社,1988,189-204
[40]王家序,余江波,田凡等.水润滑塑料合金轴承数控值分析的多重网格法[J].润滑与密封.2005(5)：62-65
[41]张鹏顺,陆思聪.弹性流体动力润滑及其应用[M].北京：高等教育出版社.1995
[42]翟玉生,李安,张金中.应用摩擦学[M].石油大学出版社.1996
[43]张洪信.有限元基础理论与ANSYS应用[M].北京：机械工业出版社.2006
[44]段进,倪栋,王国业ANSYS10.0结构分析从入门到精通[M].北京：兵器工业出版社,2006
[45]康渊,陈信吉Ansys入门[M].北京：中国电力出版社.2007
[46]孟庆恩.人工关节弹流润滑问题多重网格问题及结果分析[D].青岛：青岛理工大学,2006
[47]李朵朵.齿轮传动动态弹流润滑的数值计算模型研究[D].太原：太原理工大学,2006
[48]冯桂萍.基于齿面粗糙度的齿轮传动热弹流润滑研究[D].太原：太原理工大学,2005