大型轨梁轧机主传动人字齿轮损坏机理及防治措施的研究
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摘要
大型轨梁轧机主传动人字齿轮是轧机主传动系统的关键设备，该人字齿轮是大模数宽齿轮，承受载荷较大，易对齿面造成损伤。攀钢轨梁厂950/850/800轨梁轧机主传动人字齿轮运行二十年来，已有多套人字齿轮的齿面发生了点蚀、剥落、塑性变形等损伤。对设备安全运行带来了隐患。能否继续正常使用及能否进行修复，本文根据攀钢轨梁厂实际生产过程中轧机主传动齿轮的传动啮合情况，利用现有的商用有限元分析软件对齿轮传动过程中出现的损伤情况进行了详细地分析，并与无损伤状态下的接触应力和VonMises应力相比较，对出现由于损伤而导致应力值增大有一个正确的认识。从齿轮损伤后的计算结果得出:齿轮损伤处的接触应力最大值有明显的跃迁，跃迁值大约是未损伤的1.5倍,但齿轮的弯曲应力没有多大变化。根据计算结果和现有的修复手段对齿轮出现的损伤提出一个可行性修复建议。对于在齿轮中部，出现由孔径3-10mm不等、深约2mm的连续小坑组成的长约50mm的损伤带，可以运用手工电弧焊。对于小坑类损伤，也可以采用火焰焊或电阻钎焊，对于槽状缺陷运用溶解扩散焊。
Main lambdoidal transmission gear of the great girder rolling mill is the key machine of this system.. It's belongs to big modulus wide gear enduring heavy loads so it's surface is easy to be hurt. In the last 2 decades drop corroding, desquamating and distortion had happened in a few sets of 950/850/800 main lambdodial transmission gear located in rolling mill plant of PanZhihua steel&iron factory. That's a hidden trouble for the safe running of machine. The thesis bases on the practical situation of transmission mesh of main transmission gear at the same time uses the business finity element software to detail analyze the damnification degree. Then compares with contact stress and VonMises stress in a normal state. At last correctly recognize the accretion of stress which is induced by damnification. It deduces from the results of calculation that the maximal contact stress have a obvious accretion at the hurt spot, the quantity is maybe 1.5 times than the normal state. But the bend stress almost the same. Bases on the result and maintenance means proposing a suggestion about the feasibility of maintenance. Using manual arc welding to deal with the damnification belt about 50mm long result from continuous spot which looks like a circle with 2mm deep. The spot's diameter is from 3mm to10mm. About spot face hurt using blaze welding or resistance welding. Using melting diffuse welding to deal slot disfigurement.
Main lambdoidal transmission gear of the great girder rolling mill is the key machine of this system.. It's belongs to big modulus wide gear enduring heavy loads so it's surface is easy to be hurt. In the last 2 decades drop corroding, desquamating and distortion had happened in a few sets of 950/850/800 main lambdodial transmission gear located in rolling mill plant of PanZhihua steel&iron factory. That's a hidden trouble for the safe running of machine. The thesis bases on the practical situation of transmission mesh of main transmission gear at the same time uses the business finity element software to detail analyze the damnification degree. Then compares with contact stress and VonMises stress in a normal state. At last correctly recognize the accretion of stress which is induced by damnification. It deduces from the results of calculation that the maximal contact stress have a obvious accretion at the hurt spot, the quantity is maybe 1.5 times than the normal state. But the bend stress almost the same. Bases on the result and maintenance means proposing a suggestion about the feasibility of maintenance. Using manual arc welding to deal with the damnification belt about 50mm long result from continuous spot which looks like a circle with 2mm deep. The spot's diameter is from 3mm to10mm. About spot face hurt using blaze welding or resistance welding. Using melting diffuse welding to deal slot disfigurement.
引文
[1] 邹家祥等.《轧钢机现代设计理论》.北京：冶金工业出版社，1991
[2] 黄清华.《轧钢机械》.冶金工业出版社，1983
[3] 郑兆昌.《机械振动》.上册，北京：机械工业出版社，1980
[4] K.J巴特，E.L威尔逊.《有限元的数值方法》.北京：科学出版社，1985
[5] Charles W.Thomas,《Torque Amplification and Tensional models and Large Reversing Mill Drives》.Iron and Steel Eng.1969 No.5: 55-73
[6] Guy Monacs,《Dynamics of rolling mills-mathematical models and experimental results》. Iron and Steel Eng.1977 No.2
[7] Albert J.Molnar,《Torque amplification factor(TAF)analyses and tests on two bar mill stands》. Iron and Steel Eng.1981 No.1
[8] Alexm.Kashsy,《J&L-AISE Torque Amplification and Vibration Investigation Project》. Iron and Steel Eng.1973 No.7
[9] 臧勇.《实用有限元法》.北京科技大学，1993
[10] 关治，罗景良.《数值计算方法》.北京：清华大学出版社，1990
[11] RANDLL.R.B.,LUO DEYANG,《Hilbert Transform Techniques for Tensional Vibration Analysis》.The institution of Engineers Australia, Vibration and Noise conference, Melboume 18-20 sept 1990
[12] R.B.RANDALL,《Hilbert Transform Techniques In Machine Diagnosticate》.Gruel Kjaer Australia Pty Ltd
[13] MCFADDEN P.O.《Detecting Fatigue Cracks in Gears by Amplitude and phase Demodulation of the Meshing Vibration》.J.Vib.Acoust. Stress Rel.Des,108/165,April 1986
[14] 欧恒安，李润芳.《三维冲击-动力接触问题的有限元混合算法》.重庆大学学报，1993
[15] 佟维，吴昌华《SS7 型电力机车牵引齿轮系统的有限元三维接触分析》.机车电传动,1999
[16] 陈兵奎，李润芳.《连续运转齿轮静动力接触有限元前处理技术》.机械传动，1994
[17] 林腾蛟等《斜齿轮的齿面载荷及啮合刚度数值分析》.机械工艺师，2000
[18] 李润芳，刘鹤然.《分阶式双圆弧齿轮有限元应力计算》.机械科学与技术，1994
[19] 李润方等《宽斜齿轮啮合过程三维接触有限元分析》. 机械科学与技术，1997
[20] 陈作炳等.《磨机减速机齿轮传动系统动态特性计算机仿真》.中国建材装备，1994
[21] 李润芳等.《运转中啮合轮齿的三维应力应变数值分析及实验研究》.机械工程学报，1994
[22] Cook,R.D.《有限元的概念和应用》.北京：科学出版社，1989
[23] 郭成壁，陈全福.《有限元法及其在动力机械中的应用》.北京：国防出版社，1984
[24] 蒋孝煜.《有限元法基础》.北京：清华大学出版社，1984
[25] 姜尚礼，庞之恒.《有限元法及其理论基础》.北京：人民教育出版社，1979
[26] 孙菊芳，荣王伍.《有限元法及其应用》.北京：北京航空航天大学出版社，1990
[27] 王革，陈大宏.《受转矩作用零部件有限元法分析加载及约束方式的研究》.冶金设备，1995.2
[28] 康贵信，周家祥.《有限元法及其在冶金机械中的应用》.冶金工业出版社，1991
[29] 刘鸿文.《材料力学》.高等教育出版社，1982
[30] 黄迪山等.《振动与动态测试》.1988（2）：8-71
[31] 吴宗岱，陶宝祺.《应变电测原理及技术》.国防工业出版社，1982
[32] 胡宗武.《工程振动分析基础》.上海交通大学出版社，1985
[33] 陈锦荣.《动态参数测试技术》.国防工业出版社，1985
[34] 张如一，陆耀桢.《实验应力分析》.机械工业出版社，1981
[35] 陈大宏《CAD技术在有限元分析前处理中的应用》.北京科技大学学报，1994.11
[2] 黄清华.《轧钢机械》.冶金工业出版社，1983
[3] 郑兆昌.《机械振动》.上册，北京：机械工业出版社，1980
[4] K.J巴特，E.L威尔逊.《有限元的数值方法》.北京：科学出版社，1985
[5] Charles W.Thomas,《Torque Amplification and Tensional models and Large Reversing Mill Drives》.Iron and Steel Eng.1969 No.5: 55-73
[6] Guy Monacs,《Dynamics of rolling mills-mathematical models and experimental results》. Iron and Steel Eng.1977 No.2
[7] Albert J.Molnar,《Torque amplification factor(TAF)analyses and tests on two bar mill stands》. Iron and Steel Eng.1981 No.1
[8] Alexm.Kashsy,《J&L-AISE Torque Amplification and Vibration Investigation Project》. Iron and Steel Eng.1973 No.7
[9] 臧勇.《实用有限元法》.北京科技大学，1993
[10] 关治，罗景良.《数值计算方法》.北京：清华大学出版社，1990
[11] RANDLL.R.B.,LUO DEYANG,《Hilbert Transform Techniques for Tensional Vibration Analysis》.The institution of Engineers Australia, Vibration and Noise conference, Melboume 18-20 sept 1990
[12] R.B.RANDALL,《Hilbert Transform Techniques In Machine Diagnosticate》.Gruel Kjaer Australia Pty Ltd
[13] MCFADDEN P.O.《Detecting Fatigue Cracks in Gears by Amplitude and phase Demodulation of the Meshing Vibration》.J.Vib.Acoust. Stress Rel.Des,108/165,April 1986
[14] 欧恒安，李润芳.《三维冲击-动力接触问题的有限元混合算法》.重庆大学学报，1993
[15] 佟维，吴昌华《SS7 型电力机车牵引齿轮系统的有限元三维接触分析》.机车电传动,1999
[16] 陈兵奎，李润芳.《连续运转齿轮静动力接触有限元前处理技术》.机械传动，1994
[17] 林腾蛟等《斜齿轮的齿面载荷及啮合刚度数值分析》.机械工艺师，2000
[18] 李润芳，刘鹤然.《分阶式双圆弧齿轮有限元应力计算》.机械科学与技术，1994
[19] 李润方等《宽斜齿轮啮合过程三维接触有限元分析》. 机械科学与技术，1997
[20] 陈作炳等.《磨机减速机齿轮传动系统动态特性计算机仿真》.中国建材装备，1994
[21] 李润芳等.《运转中啮合轮齿的三维应力应变数值分析及实验研究》.机械工程学报，1994
[22] Cook,R.D.《有限元的概念和应用》.北京：科学出版社，1989
[23] 郭成壁，陈全福.《有限元法及其在动力机械中的应用》.北京：国防出版社，1984
[24] 蒋孝煜.《有限元法基础》.北京：清华大学出版社，1984
[25] 姜尚礼，庞之恒.《有限元法及其理论基础》.北京：人民教育出版社，1979
[26] 孙菊芳，荣王伍.《有限元法及其应用》.北京：北京航空航天大学出版社，1990
[27] 王革，陈大宏.《受转矩作用零部件有限元法分析加载及约束方式的研究》.冶金设备，1995.2
[28] 康贵信，周家祥.《有限元法及其在冶金机械中的应用》.冶金工业出版社，1991
[29] 刘鸿文.《材料力学》.高等教育出版社，1982
[30] 黄迪山等.《振动与动态测试》.1988（2）：8-71
[31] 吴宗岱，陶宝祺.《应变电测原理及技术》.国防工业出版社，1982
[32] 胡宗武.《工程振动分析基础》.上海交通大学出版社，1985
[33] 陈锦荣.《动态参数测试技术》.国防工业出版社，1985
[34] 张如一，陆耀桢.《实验应力分析》.机械工业出版社，1981
[35] 陈大宏《CAD技术在有限元分析前处理中的应用》.北京科技大学学报，1994.11