FSH锥齿轮传动啮合特性的理论与实验研究
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摘要
主减速器锥齿轮是汽车机械传动系统的重要组成部分,其传动质量及可靠性直接影响整车质量。目前,我国商用重型载货汽车主减速器锥齿轮,在恶劣工况下的传动齿轮副存在使用寿命短、不能满足使用要求的问题。本文基于FSH锥齿轮(分阶式双圆弧弧齿锥齿轮)的接触强度高于现在广泛应用的弧齿锥齿轮,提出将其应用于我国商用重型载货汽车驱动桥以解决目前寿命短的问题。
FSH锥齿轮是将圆弧齿廓应用于弧齿锥齿轮的一种新型传动形式,其承载能力与啮合特性紧密相关,接触点初始位置的确定以及之后由点接触向区域接触的发展是影响承载能力的关键,机床调整参数实现对初始接触点的控制,齿形设计与跑合决定了齿面接触由点到面的发展,本文的研究目的是通过对虚拟制造核心技术LTCA(齿面承载接触分析)开展研究,实现合理机床调整参数快速获取,探索针对FSH锥齿轮的跑合方法。
论文围绕FSH锥齿轮啮合特性开展相关工作,在虚拟设计制造系统、跑合、动态特性等方面进行研究,论文的主要内容及结论如下：
(1)应用微分几何与齿轮啮合原理等理论,针对FSH锥齿轮齿形参数灵活设计的特点,提出基于跑合特性的齿形参数设计方法,从理论上推导了FSH锥齿轮的圆弧齿廓合理曲率半径计算公式,根据FSH锥齿轮的圆弧齿廓特点提出合理曲率半径的确定方法。
(2)根据FSH锥齿轮加工原理,推导大、小轮的啮合方程和齿面方程；并对适合分析跑合的啮合方程进行推导,分析其诱导法曲率和啮合过程,确立了跑合速率与齿面磨损率的数学关系。
(3)以空间啮合原理和TCA分析(轮齿接触分析)为基础,对FSH锥齿轮进行LTCA分析(加载轮齿接触分析)；根据TCA原理和LTCA原理,分析FSH锥齿轮的啮合特性,明确了影响齿面接触区的具体因素,完善了FSH锥齿轮的虚拟仿真加工方法,提出了考虑齿面加工特征的齿面接触应力有限元计算方法,完成了FSH锥齿轮的LTCA(加载轮齿接触分析)。
(4)进行FSH锥齿轮的跑合理论研究,对影响跑合的因素进行分析,建立FSH锥齿轮跑合数学模型,探索针对FSH锥齿轮的跑合方法,提出了SLH(乏油、低速、重载)跑合方法。
(5)设计了锥齿轮动态特性测试实验台,对FSH锥齿轮与Gleason弧齿锥齿轮的动态特性进行测试,对比FSH锥齿轮跑合前后的振动与噪声特征信号,并将FSH锥齿轮跑合后的噪声振动信号与Gleason弧齿锥齿轮进行对比。
本文的研究得到了国家自然科学基金项目“超高速大能流密度非稳态润滑空间曲面啮合特征实验提取方法”(批准号：50875009)的资助。
As important part of automotive mechanical transmission, the transmission quality and reliability of spiral bevel gear of the main reducer will determine the quality of vehicle. At present, the service life of bevel gears in heavy truck main reducer working in the complex and harsh condition is too short, which because of low contact strength and can not meet the requirement, therefore, FSH bevel gear, which is also called double circular arc spiral bevel gear, comparing with the spherical involutes bevel gear, has the advantages of high load capacity, long service life, high contact strength and bending strength. On the base of these, it is suggested that the FSH bevel can be applied to the main reducer of heavy truck.
The FSH bevel gear is a new technology which applied double arc tooth to the spiral bevel gear and its load capacity is closely related the meshing characteristics. In the gear transmission, the initial location of contact area and the development of contact area may influence the gear meshing characteristics and drive quality. The initial location of contact is determined by the machine tool adjustment parameters, and the development of contact area is determined by the tooth profile design and running-in method. The purpose of this thesis is to put forward the LTCA(Load Tooth Contact Analysis), which is the core technology of the virtual manufacturing, with which reasonable machine tool adjustment parameters can be obtained at the least try-cut, and the method of running-in can be explored quickly and efficiently.
The focus of this thesis is on the meshing characteristics of the FSH bevel. Some progress and accomplishment have been made on the key issues such as virtual design and manufacturing system, running-in, strength test and dynamic characteristics. The major works of this thesis are listed as follows:
1) According to the differential geometry and meshing principle, the tooth profile design method, which is based on the running-in characteristics, is proposed, and in accordance with circular arc profile feature of FSH bevel gear, the proper method to find curvature radius is proposed.
2) According to the conjugate gear tooth surface forming principle, gear processing principle and running-in principle, meshing equation that fitted running-in is deduced. In addition, the induced normal curvature and meshing process are analyzed. The meshing equation and the tooth surface equation of pinion and large wheel are deduced based on FSH bevel gear processing principle. The mathematical relation of running-in rate and tooth surface wear rate are determined.
3) On the basis of the spatial engagement principle and TCA principle, the loading contact analysis is made. Based on the TCA and LTCA principle, the meshing characteristic of FSH bevel gear is analyzed, and the method of virtual simulation of machining is proposed. The tooth contact stress FEA is completed base on the machining of digitized gear-tooth surface. The LTCA of FSH bevel gear is completed.
4) The running-in theory and test are carried on the meshing gear pairs, the factors that influenced running are analyzed, then, the mathematical model of running-in is established, and the running-in method for FSH bevel gear is proposed. The SLH(Starved-oil Low-speed Hard-load) running-in method is proposed.
5) Dynamic testing tap of the bevel gear is designed and constructed to obtain the dynamic characteristic of the FSH and Gleason bevel gear system, and the vibration and noise of running-in pre and post are compared. What is more, the vibration and noise of FSH and Gleason bevel gear are compared.
This thesis was supported by National Natural Science Foundation of China"Extraction method of maximum and average densities Unsteady Lubrication space surface meshing characteristics"(No.50875009).
FSH锥齿轮是将圆弧齿廓应用于弧齿锥齿轮的一种新型传动形式,其承载能力与啮合特性紧密相关,接触点初始位置的确定以及之后由点接触向区域接触的发展是影响承载能力的关键,机床调整参数实现对初始接触点的控制,齿形设计与跑合决定了齿面接触由点到面的发展,本文的研究目的是通过对虚拟制造核心技术LTCA(齿面承载接触分析)开展研究,实现合理机床调整参数快速获取,探索针对FSH锥齿轮的跑合方法。
论文围绕FSH锥齿轮啮合特性开展相关工作,在虚拟设计制造系统、跑合、动态特性等方面进行研究,论文的主要内容及结论如下：
(1)应用微分几何与齿轮啮合原理等理论,针对FSH锥齿轮齿形参数灵活设计的特点,提出基于跑合特性的齿形参数设计方法,从理论上推导了FSH锥齿轮的圆弧齿廓合理曲率半径计算公式,根据FSH锥齿轮的圆弧齿廓特点提出合理曲率半径的确定方法。
(2)根据FSH锥齿轮加工原理,推导大、小轮的啮合方程和齿面方程；并对适合分析跑合的啮合方程进行推导,分析其诱导法曲率和啮合过程,确立了跑合速率与齿面磨损率的数学关系。
(3)以空间啮合原理和TCA分析(轮齿接触分析)为基础,对FSH锥齿轮进行LTCA分析(加载轮齿接触分析)；根据TCA原理和LTCA原理,分析FSH锥齿轮的啮合特性,明确了影响齿面接触区的具体因素,完善了FSH锥齿轮的虚拟仿真加工方法,提出了考虑齿面加工特征的齿面接触应力有限元计算方法,完成了FSH锥齿轮的LTCA(加载轮齿接触分析)。
(4)进行FSH锥齿轮的跑合理论研究,对影响跑合的因素进行分析,建立FSH锥齿轮跑合数学模型,探索针对FSH锥齿轮的跑合方法,提出了SLH(乏油、低速、重载)跑合方法。
(5)设计了锥齿轮动态特性测试实验台,对FSH锥齿轮与Gleason弧齿锥齿轮的动态特性进行测试,对比FSH锥齿轮跑合前后的振动与噪声特征信号,并将FSH锥齿轮跑合后的噪声振动信号与Gleason弧齿锥齿轮进行对比。
本文的研究得到了国家自然科学基金项目“超高速大能流密度非稳态润滑空间曲面啮合特征实验提取方法”(批准号：50875009)的资助。
As important part of automotive mechanical transmission, the transmission quality and reliability of spiral bevel gear of the main reducer will determine the quality of vehicle. At present, the service life of bevel gears in heavy truck main reducer working in the complex and harsh condition is too short, which because of low contact strength and can not meet the requirement, therefore, FSH bevel gear, which is also called double circular arc spiral bevel gear, comparing with the spherical involutes bevel gear, has the advantages of high load capacity, long service life, high contact strength and bending strength. On the base of these, it is suggested that the FSH bevel can be applied to the main reducer of heavy truck.
The FSH bevel gear is a new technology which applied double arc tooth to the spiral bevel gear and its load capacity is closely related the meshing characteristics. In the gear transmission, the initial location of contact area and the development of contact area may influence the gear meshing characteristics and drive quality. The initial location of contact is determined by the machine tool adjustment parameters, and the development of contact area is determined by the tooth profile design and running-in method. The purpose of this thesis is to put forward the LTCA(Load Tooth Contact Analysis), which is the core technology of the virtual manufacturing, with which reasonable machine tool adjustment parameters can be obtained at the least try-cut, and the method of running-in can be explored quickly and efficiently.
The focus of this thesis is on the meshing characteristics of the FSH bevel. Some progress and accomplishment have been made on the key issues such as virtual design and manufacturing system, running-in, strength test and dynamic characteristics. The major works of this thesis are listed as follows:
1) According to the differential geometry and meshing principle, the tooth profile design method, which is based on the running-in characteristics, is proposed, and in accordance with circular arc profile feature of FSH bevel gear, the proper method to find curvature radius is proposed.
2) According to the conjugate gear tooth surface forming principle, gear processing principle and running-in principle, meshing equation that fitted running-in is deduced. In addition, the induced normal curvature and meshing process are analyzed. The meshing equation and the tooth surface equation of pinion and large wheel are deduced based on FSH bevel gear processing principle. The mathematical relation of running-in rate and tooth surface wear rate are determined.
3) On the basis of the spatial engagement principle and TCA principle, the loading contact analysis is made. Based on the TCA and LTCA principle, the meshing characteristic of FSH bevel gear is analyzed, and the method of virtual simulation of machining is proposed. The tooth contact stress FEA is completed base on the machining of digitized gear-tooth surface. The LTCA of FSH bevel gear is completed.
4) The running-in theory and test are carried on the meshing gear pairs, the factors that influenced running are analyzed, then, the mathematical model of running-in is established, and the running-in method for FSH bevel gear is proposed. The SLH(Starved-oil Low-speed Hard-load) running-in method is proposed.
5) Dynamic testing tap of the bevel gear is designed and constructed to obtain the dynamic characteristic of the FSH and Gleason bevel gear system, and the vibration and noise of running-in pre and post are compared. What is more, the vibration and noise of FSH and Gleason bevel gear are compared.
This thesis was supported by National Natural Science Foundation of China"Extraction method of maximum and average densities Unsteady Lubrication space surface meshing characteristics"(No.50875009).
引文
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