动力总成轴瓦磨损和齿轮噪声分析
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摘要
汽车动力总成是汽车的动力源,主要由发动机和变速器两大部分组成,在新车的研发过程中,发动机和变速器的研发属于非常重要的部分。作者所在的汽车公司在开发一种自主品牌新车的过程中,发现该新车的动力总成在耐久试验和与汽车匹配过程中出现了轴瓦磨损和变速器在加减速时噪声大两个问题。本文通过试验和研究,找出新车开发过程中动力总成产生这两个问题的根本原因,并有针对性地采取措施对其进行改善,解决了动力总成开发问题点,同时制订出解决动力总成相关问题的分析参考方法。
针对动力总成轴瓦磨损的故障问题,通过对零件装配情况、零件尺寸、材料化学成份和磨损表面形态进行分析,确诊此轴瓦磨损类型为黏着磨损;并对黏着磨损的可能原因(摩擦副材料、载荷、表面温度和润滑条件等)进行分析排查,找到轴瓦磨损的根本原因是加工不当导致轴瓦机油泄漏和润滑不良,从而引起轴瓦异常磨损;通过工艺变更和刀具改造防止轴瓦机油泄漏最终解决了问题。针对加减速时变速器齿轮噪声大的故障问题,通过采集变速箱行驶过程噪声和转速波动数据进行分析,找出变速器齿轮噪声大的原因离合器是刚度和阻尼选取不当,调整离合器刚度和阻尼后最终有效地减小了车辆加减速时发生的噪声。
本文内容为典型的汽车动力故障分析,通过理论分析和试验指导零件规格变更与零件工艺变更,不仅解决了两个车辆动力总成开发过程的故障问题,而且形成了比较清晰的分析思路,为汽车的新车开发研究提供借鉴,具有较大的工程实用价值。
As the power source of automobile, automotive powertrain consisting of contains engine and transmission mainly. In the process of new cars’research and development, engine and transmission are the important parts of it. When the the company, which the author works in, develops a car as self owned brand one, and in this process, two problems are exposed that the bearing pad wears seriously in in durability test and the transmission generating loud noise when the engine speed up and speed down in car matching for the new car’s powertrain. In this paper, the main causes and the solutions of the two problems above mentions are found and given. The paper not only resolves the powertrain problems, but also works out a relative analysis method for related issures of powertrain.
Aiming at the wears seriously problem of bearing pad of powertrain, several steps are carried out. First, by analysing the components’assembling effect, dimensions, material chemical composition and the form of worn out surface are, the wear type of the bearing pad that is adhesive wear, are obtained. Secondly, the possible causes of adhesive wear, including the material of rubbing pair, load, surface temperature, lubrication condition and so on, are checked and analyzed. Then, the primary cause of bearing pad’abnormal wear is found that is unsuitable process leading to the leak of lubricating oil for bearing pad and poor lubrication. Finally, by improving processing technic and cutter to decrease the leak of lubricating oil for bearing pad, the bearing pad wearing problem is solved. Aiming at the fault problem of transmission generating loud noise when revolving speed changes, the noisy signals and the data of revolving speed’fluctuation collected from the transmission are analyzed, and the cause of loud noise of transmission is found that is improper rigidity and damping for clutch. The noise of transmission is decreased obviously by adjusting the rigidity and damping for clutch.
The content of this paper is a typical automobile power fault analysis, the modifications of components’dimensions and processing technic is guided by means of theoretical analysis and test. The paper not only solves the fault problems in the process of the development of new car’s powertrain, but also obtains a relatively distinct analysis idea, which provides a reference for new car’development and engineering application.
针对动力总成轴瓦磨损的故障问题,通过对零件装配情况、零件尺寸、材料化学成份和磨损表面形态进行分析,确诊此轴瓦磨损类型为黏着磨损;并对黏着磨损的可能原因(摩擦副材料、载荷、表面温度和润滑条件等)进行分析排查,找到轴瓦磨损的根本原因是加工不当导致轴瓦机油泄漏和润滑不良,从而引起轴瓦异常磨损;通过工艺变更和刀具改造防止轴瓦机油泄漏最终解决了问题。针对加减速时变速器齿轮噪声大的故障问题,通过采集变速箱行驶过程噪声和转速波动数据进行分析,找出变速器齿轮噪声大的原因离合器是刚度和阻尼选取不当,调整离合器刚度和阻尼后最终有效地减小了车辆加减速时发生的噪声。
本文内容为典型的汽车动力故障分析,通过理论分析和试验指导零件规格变更与零件工艺变更,不仅解决了两个车辆动力总成开发过程的故障问题,而且形成了比较清晰的分析思路,为汽车的新车开发研究提供借鉴,具有较大的工程实用价值。
As the power source of automobile, automotive powertrain consisting of contains engine and transmission mainly. In the process of new cars’research and development, engine and transmission are the important parts of it. When the the company, which the author works in, develops a car as self owned brand one, and in this process, two problems are exposed that the bearing pad wears seriously in in durability test and the transmission generating loud noise when the engine speed up and speed down in car matching for the new car’s powertrain. In this paper, the main causes and the solutions of the two problems above mentions are found and given. The paper not only resolves the powertrain problems, but also works out a relative analysis method for related issures of powertrain.
Aiming at the wears seriously problem of bearing pad of powertrain, several steps are carried out. First, by analysing the components’assembling effect, dimensions, material chemical composition and the form of worn out surface are, the wear type of the bearing pad that is adhesive wear, are obtained. Secondly, the possible causes of adhesive wear, including the material of rubbing pair, load, surface temperature, lubrication condition and so on, are checked and analyzed. Then, the primary cause of bearing pad’abnormal wear is found that is unsuitable process leading to the leak of lubricating oil for bearing pad and poor lubrication. Finally, by improving processing technic and cutter to decrease the leak of lubricating oil for bearing pad, the bearing pad wearing problem is solved. Aiming at the fault problem of transmission generating loud noise when revolving speed changes, the noisy signals and the data of revolving speed’fluctuation collected from the transmission are analyzed, and the cause of loud noise of transmission is found that is improper rigidity and damping for clutch. The noise of transmission is decreased obviously by adjusting the rigidity and damping for clutch.
The content of this paper is a typical automobile power fault analysis, the modifications of components’dimensions and processing technic is guided by means of theoretical analysis and test. The paper not only solves the fault problems in the process of the development of new car’s powertrain, but also obtains a relatively distinct analysis idea, which provides a reference for new car’development and engineering application.
引文
[1]张宝义.内燃机轴瓦的损坏形式及其机理[J].内燃机配件,2005,(3):11 14
[2]朱玲玉.发动机轴瓦的损坏机理与预防措施[J].内燃机配件,2009,(1):11 14
[3]吉建平.发动机曲轴轴颈与轴瓦磨损及预防措施[J].内燃机,2004,(4):45 47
[4]朱华.发动机轴承损坏的原因分析[J].润滑与密封,2006,(3):189,191
[5]帅志宏.内燃机滑动轴承失效的全分析[J].润滑与密封,2007,32(2):189 190,195
[6] G.H.Jiang, D.J.Chang. Analysis of a hydrodynamic herringbone grooved journal bearing using Mobility method[J]. Wear, 1996,93(2):155 162
[7] C.M.Taylor. Fluid film lubrication in the internal combustion engine: an invited review [C]. Conference paper, J.Phs, D: appl, 25(1992)
[8]裘祖干,张青松.动载径向粗糙轴承分析[J].内燃机学报,1993,11(2):159 164
[9] Yutaka Okamoto. A study for wear and fatigue of engine bearing on rig test by using elastohydro dynamic lubrication analysis [J]. SAE 1999 01 0287
[10] Kenshi Ushijima. A study on engine bearing wear and fatigue using EHL analysis and experimental analysis [J]. SAE 1990 01 1514
[11]王晓力,朱克勤.基于应力偶流体模型的动载荷轴承润滑研究[J].清华大学学报,2001,41(8):60 63
[12]杨建军,安琦,杨剑,等.滑动轴承弹性变形的耦合算法研究[J].机械科学与技术, 2004,23(9):1044 1046,1134
[13]孙军,王震华,桂长林.计入曲轴受载变形的粗糙表面曲轴轴承弹性流体动力润滑分析[J].机械工程学报,2009,45(1):135 140
[14]杨光兴,杨懿,叶盛焱,等.内燃机轴承轴心轨迹的测试与研究[J].武汉工学院学报,1992,14(3):17 27
[15]程鹏,高印寒,韩永强,等.单缸机主轴承轴心轨迹的测量[J].内燃机工程,2003,24(1):66 69
[16]富彦丽,朱均,马希直.径向轴承启动过程瞬态热效应的研究[J].摩擦学学报,2003,23(2):136 140
[17] I. Spyros, Tseregounis. Determination of Bearing Oil Film Thickness(BOFT) for Various Engine Oils in an Automotive Gasoline Engine Using Capacitance Measurements and Analytical Predictions[J] SAE 982661
[18] W. Ducai. Correlation of Measured and Predicted Oil Flow for a Big End Bearing[J].SAE 2000 01 2919
[19]李宝志.试论汽车变速器总成的噪音源及降噪措施[J].汽车齿轮.2006,(2):9 14
[20]施飞.汽车变速器总成的噪声源及降噪措施[J].机械管理开发,2009,24(5): 96 97,99
[21]冯振东,史广奎,邬惠乐,等.东风牌EQ2D140柴油车变速器怠速噪声的研究[J].汽车工程,1989,(2):63 66,39
[22]沈玉娣,万年红,屈梁生.汽车变速器的噪声源识别及缺陷诊断[J].汽车工程,1990,(1):30 36
[23]马怀琳.变速器的异常噪声与控制[J].汽车技术,1995,(3):25 31,35
[24]陈文枢,王文达,赵璇. BC131变速器阻尼降噪结构设计[J].汽车工程,1993, (4):238 241,225
[25]徐向农,蓝伟坤,聂启莉,等汽车变速器高档齿轮的降噪设计[J].中国机械工程, 1995,(6):54 56
[26]彭生辉,李志远.汽车变速器齿轮噪声产生机理及影响因素分析[J].拖拉机与农用运输车. 2005,(4):37 39
[27]王文平,项昌乐,刘辉.基于FEM/BEM变速器箱体辐射噪声的研究[J].噪声与振动控制,2007,(5):107 111
[28]葛如海,姜旭义,杨文涛.齿面微观修形在汽车变速器降噪中的应用研究[J].汽车工程,2009,31(6):557 560
[29]郭栋,邓斌,石晓辉,等.国产轿车变速器啸叫噪声源的识别与控制[J].中国机械工程,2011,22(18):2264 2267
[30] M. F. Jacobson, R. Singh. Acoustic radiation efficiency models of a simple gearbox. Seventh International Power Transmission and Gearing Conferece[C]. October 6 9, 1996
[31] M.Y.Wang, R.Manoj, W.Zhao.汽车手动变速箱的齿轮敲击模拟和分析[J].传动技术,2002,(4):27 42
[32] E. Tanaka, H. Houjoh, D. Mutoh, et al. Vibration and sound radiation analysis for designing a low noise gearbox with a multi stage helical gear system[J]. JSME International Journal, 2003,46(3):1178 1185
[33] M. Hajzman, V. Zeman. Modeling of gearbox vibration and noise[J]. PAMM. Proc. Appl. Math. Mech. 5, 93 94(2005)/DOI 10.1002
[34] R.Rrancati, E.Rocca, R.Russo.计算啮合齿轮轮齿间油膜挤压的齿轮敲击振动模型[J].传动技术,2006,20(3):15 21,48
[35]崔朝英,张琴,黄晓荣.汽轮机轴瓦磨损的主要因素及预防措施[J].汽轮机技术, 2008,50(5):395 396,370
[36]张直明.滑动轴承的流体动力润滑理论[M].北京:高等教育出版社,1984
[2]朱玲玉.发动机轴瓦的损坏机理与预防措施[J].内燃机配件,2009,(1):11 14
[3]吉建平.发动机曲轴轴颈与轴瓦磨损及预防措施[J].内燃机,2004,(4):45 47
[4]朱华.发动机轴承损坏的原因分析[J].润滑与密封,2006,(3):189,191
[5]帅志宏.内燃机滑动轴承失效的全分析[J].润滑与密封,2007,32(2):189 190,195
[6] G.H.Jiang, D.J.Chang. Analysis of a hydrodynamic herringbone grooved journal bearing using Mobility method[J]. Wear, 1996,93(2):155 162
[7] C.M.Taylor. Fluid film lubrication in the internal combustion engine: an invited review [C]. Conference paper, J.Phs, D: appl, 25(1992)
[8]裘祖干,张青松.动载径向粗糙轴承分析[J].内燃机学报,1993,11(2):159 164
[9] Yutaka Okamoto. A study for wear and fatigue of engine bearing on rig test by using elastohydro dynamic lubrication analysis [J]. SAE 1999 01 0287
[10] Kenshi Ushijima. A study on engine bearing wear and fatigue using EHL analysis and experimental analysis [J]. SAE 1990 01 1514
[11]王晓力,朱克勤.基于应力偶流体模型的动载荷轴承润滑研究[J].清华大学学报,2001,41(8):60 63
[12]杨建军,安琦,杨剑,等.滑动轴承弹性变形的耦合算法研究[J].机械科学与技术, 2004,23(9):1044 1046,1134
[13]孙军,王震华,桂长林.计入曲轴受载变形的粗糙表面曲轴轴承弹性流体动力润滑分析[J].机械工程学报,2009,45(1):135 140
[14]杨光兴,杨懿,叶盛焱,等.内燃机轴承轴心轨迹的测试与研究[J].武汉工学院学报,1992,14(3):17 27
[15]程鹏,高印寒,韩永强,等.单缸机主轴承轴心轨迹的测量[J].内燃机工程,2003,24(1):66 69
[16]富彦丽,朱均,马希直.径向轴承启动过程瞬态热效应的研究[J].摩擦学学报,2003,23(2):136 140
[17] I. Spyros, Tseregounis. Determination of Bearing Oil Film Thickness(BOFT) for Various Engine Oils in an Automotive Gasoline Engine Using Capacitance Measurements and Analytical Predictions[J] SAE 982661
[18] W. Ducai. Correlation of Measured and Predicted Oil Flow for a Big End Bearing[J].SAE 2000 01 2919
[19]李宝志.试论汽车变速器总成的噪音源及降噪措施[J].汽车齿轮.2006,(2):9 14
[20]施飞.汽车变速器总成的噪声源及降噪措施[J].机械管理开发,2009,24(5): 96 97,99
[21]冯振东,史广奎,邬惠乐,等.东风牌EQ2D140柴油车变速器怠速噪声的研究[J].汽车工程,1989,(2):63 66,39
[22]沈玉娣,万年红,屈梁生.汽车变速器的噪声源识别及缺陷诊断[J].汽车工程,1990,(1):30 36
[23]马怀琳.变速器的异常噪声与控制[J].汽车技术,1995,(3):25 31,35
[24]陈文枢,王文达,赵璇. BC131变速器阻尼降噪结构设计[J].汽车工程,1993, (4):238 241,225
[25]徐向农,蓝伟坤,聂启莉,等汽车变速器高档齿轮的降噪设计[J].中国机械工程, 1995,(6):54 56
[26]彭生辉,李志远.汽车变速器齿轮噪声产生机理及影响因素分析[J].拖拉机与农用运输车. 2005,(4):37 39
[27]王文平,项昌乐,刘辉.基于FEM/BEM变速器箱体辐射噪声的研究[J].噪声与振动控制,2007,(5):107 111
[28]葛如海,姜旭义,杨文涛.齿面微观修形在汽车变速器降噪中的应用研究[J].汽车工程,2009,31(6):557 560
[29]郭栋,邓斌,石晓辉,等.国产轿车变速器啸叫噪声源的识别与控制[J].中国机械工程,2011,22(18):2264 2267
[30] M. F. Jacobson, R. Singh. Acoustic radiation efficiency models of a simple gearbox. Seventh International Power Transmission and Gearing Conferece[C]. October 6 9, 1996
[31] M.Y.Wang, R.Manoj, W.Zhao.汽车手动变速箱的齿轮敲击模拟和分析[J].传动技术,2002,(4):27 42
[32] E. Tanaka, H. Houjoh, D. Mutoh, et al. Vibration and sound radiation analysis for designing a low noise gearbox with a multi stage helical gear system[J]. JSME International Journal, 2003,46(3):1178 1185
[33] M. Hajzman, V. Zeman. Modeling of gearbox vibration and noise[J]. PAMM. Proc. Appl. Math. Mech. 5, 93 94(2005)/DOI 10.1002
[34] R.Rrancati, E.Rocca, R.Russo.计算啮合齿轮轮齿间油膜挤压的齿轮敲击振动模型[J].传动技术,2006,20(3):15 21,48
[35]崔朝英,张琴,黄晓荣.汽轮机轴瓦磨损的主要因素及预防措施[J].汽轮机技术, 2008,50(5):395 396,370
[36]张直明.滑动轴承的流体动力润滑理论[M].北京:高等教育出版社,1984