重载齿轮性能分析及结构优化技术研究
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摘要
重载齿轮在大型工程机械中得到广泛应用。为满足大型工程的重载需求,减速器的齿轮需要在保持原有渐开线齿轮传动平稳、振动小等优点的同时,进一步提高其承载能力,减小在复杂工况中承受的冲击。这需要在了解齿轮重载传动性能的基础上,对轮齿进行优化设计。目前,诸多学者的研究偏向于齿轮的瞬态冲击或稳态的接触,这对于了解全齿面的动态接触性能是不全面的。
本文以轮边减速器的齿轮为研究对象,以提高齿轮承载能力和齿轮传动运动平稳性为目的,在已进行的课题组动力学分析基础上,进一步深入研究重载齿轮副接触分析技术和基于接触的热固耦合分析技术,对太阳轮进行了齿向和齿廓的修形,并验证了修形方法的可行性。因此,本文的主要工作归纳如下：
1、建立了圆柱齿轮接触的数学模型和物理模型。主要是应用齿轮空间啮合的数学理论,建立直角坐标系下的齿轮接触模型；将经典接触力学中圆柱面接触的基础理论扩展到齿轮接触分析中。
2、在有限元分析软件ABAQUS的支持下,研究研究重载齿轮对的接触分析技术和基于接触的热固耦合分析技术。包括：离散齿轮实体模型：然后,对离散后的实体模型按照有限元的思路不断判断接触的状态；最后,在求解接触状态平衡方程的同时,应用接触力学的方法,求解接触应力和位移。而基于接触的热固耦合分析,在前述计算的同时,还要不断的求解温度场。另外,本文在保证边界和载荷不变的前提下,采用加密网格多次计算的方式,来验证有限元计算的准确性。
3、提取了有限元计算结果的变形量、全齿面接触线应力曲线图,以了解全齿面在整个接触过程中的应力分布情况,确定修形的主要区域。并以单双齿交替啮合时的最大变形量为主要参数,确定最大修形量。
4、总结已有的修形方案,结合有限元计算的结果,对太阳轮进行齿向和齿廓修形。最后给出了一组针对重载工况的修形参数,创建了修形后的太阳轮实体模型。
本文应用有限元的方法进行了全齿面的接触分析和基于接触的热固耦合分析：依据AGMA标准确定了用于反映全齿面接触应力情况的五条接触线；以性能分析为基础指导了重载齿轮的修形,并给出了针对该模型使用的一组修形参数。
Heavy-duty gear is widely used in various engineering machinery. In order to meet the demand of heavy load in large-scale projects, the original advantages of involute gear need to be maintained, carrying capacity need to be further improved, and dynamic load and impact in the complex condition is minimized. On the basis of understanding the heavy load gear transmission performance, optimizing the gear structure is suggested. At present, many scholars tend to study transient impact or steady-state gear contact. It is not comprehensive to understand the whole tooth surface dynamic contact performance.
In this paper, by taking hub reducer gear in a certain type of excavator as the research object, in order to improve gear carrying capacity and transmission stability, combined with the result of dynamic analysis, contact analysis and thermal-structure coupled analysis, profile modification and longitudinal correction is done. Then operating the thermal contact analysis again is used to verify the feasibility of the modification. Thus, the main work of this paper is summarized as follows.
1. The mathematical model and physical model of cylindrical gear contact are established. The gear space mesh mathematical theory is applied, and obtaining the gear contact model in rectangular coordinate system. Furthermore the basic theory of contact mechanics is used in gear contact.
2. Based on the finite element analysis software ABAQUS, the technology of contact analysis and thermal-structure coupled analysis are implemented. First of all, to discrete the gear model; then, to judge the contact state constantly on the discrete entity model according to FEM; finally, to solve the contact state equation, the contact stress and displacement. In addition to this, thermal-structure coupled analysis need to solve temperature field. And then, in the same boundary and load, using the way of refined grids and calculation, the accuracy of finite element calculation is verified.
3. The amount of deformation and tooth contact line stress curves are extracted from the finite element calculation results. That is used to understand the contact stress distribution of the whole tooth surface in the process of contact. And the main areas of modification are determined. Using the maximum amount of deformation in odd teeth alternately engaging as the main parameters, the maximum amount of modification is determined.
4. Summarizing the existing modification programs, combining with the results of the finite element calculation, profile modification and longitudinal correction is applied to the sun gear tooth. Finally, a set of modification parameters for heavy load working conditions are proposed. And the modification sun gear model is created.
In this paper, the whole tooth surface contact analysis and thermal-structural coupled analysis based on contact are practiced by FEM. Five contact lines are determined according to the AGMA standard, which are used to reflect the whole tooth surface contact stress distribution. The results of performance analysis give directions to heavy duty gear modification. And a set of modification parameters used for the very model are proposed.
本文以轮边减速器的齿轮为研究对象,以提高齿轮承载能力和齿轮传动运动平稳性为目的,在已进行的课题组动力学分析基础上,进一步深入研究重载齿轮副接触分析技术和基于接触的热固耦合分析技术,对太阳轮进行了齿向和齿廓的修形,并验证了修形方法的可行性。因此,本文的主要工作归纳如下：
1、建立了圆柱齿轮接触的数学模型和物理模型。主要是应用齿轮空间啮合的数学理论,建立直角坐标系下的齿轮接触模型；将经典接触力学中圆柱面接触的基础理论扩展到齿轮接触分析中。
2、在有限元分析软件ABAQUS的支持下,研究研究重载齿轮对的接触分析技术和基于接触的热固耦合分析技术。包括：离散齿轮实体模型：然后,对离散后的实体模型按照有限元的思路不断判断接触的状态；最后,在求解接触状态平衡方程的同时,应用接触力学的方法,求解接触应力和位移。而基于接触的热固耦合分析,在前述计算的同时,还要不断的求解温度场。另外,本文在保证边界和载荷不变的前提下,采用加密网格多次计算的方式,来验证有限元计算的准确性。
3、提取了有限元计算结果的变形量、全齿面接触线应力曲线图,以了解全齿面在整个接触过程中的应力分布情况,确定修形的主要区域。并以单双齿交替啮合时的最大变形量为主要参数,确定最大修形量。
4、总结已有的修形方案,结合有限元计算的结果,对太阳轮进行齿向和齿廓修形。最后给出了一组针对重载工况的修形参数,创建了修形后的太阳轮实体模型。
本文应用有限元的方法进行了全齿面的接触分析和基于接触的热固耦合分析：依据AGMA标准确定了用于反映全齿面接触应力情况的五条接触线；以性能分析为基础指导了重载齿轮的修形,并给出了针对该模型使用的一组修形参数。
Heavy-duty gear is widely used in various engineering machinery. In order to meet the demand of heavy load in large-scale projects, the original advantages of involute gear need to be maintained, carrying capacity need to be further improved, and dynamic load and impact in the complex condition is minimized. On the basis of understanding the heavy load gear transmission performance, optimizing the gear structure is suggested. At present, many scholars tend to study transient impact or steady-state gear contact. It is not comprehensive to understand the whole tooth surface dynamic contact performance.
In this paper, by taking hub reducer gear in a certain type of excavator as the research object, in order to improve gear carrying capacity and transmission stability, combined with the result of dynamic analysis, contact analysis and thermal-structure coupled analysis, profile modification and longitudinal correction is done. Then operating the thermal contact analysis again is used to verify the feasibility of the modification. Thus, the main work of this paper is summarized as follows.
1. The mathematical model and physical model of cylindrical gear contact are established. The gear space mesh mathematical theory is applied, and obtaining the gear contact model in rectangular coordinate system. Furthermore the basic theory of contact mechanics is used in gear contact.
2. Based on the finite element analysis software ABAQUS, the technology of contact analysis and thermal-structure coupled analysis are implemented. First of all, to discrete the gear model; then, to judge the contact state constantly on the discrete entity model according to FEM; finally, to solve the contact state equation, the contact stress and displacement. In addition to this, thermal-structure coupled analysis need to solve temperature field. And then, in the same boundary and load, using the way of refined grids and calculation, the accuracy of finite element calculation is verified.
3. The amount of deformation and tooth contact line stress curves are extracted from the finite element calculation results. That is used to understand the contact stress distribution of the whole tooth surface in the process of contact. And the main areas of modification are determined. Using the maximum amount of deformation in odd teeth alternately engaging as the main parameters, the maximum amount of modification is determined.
4. Summarizing the existing modification programs, combining with the results of the finite element calculation, profile modification and longitudinal correction is applied to the sun gear tooth. Finally, a set of modification parameters for heavy load working conditions are proposed. And the modification sun gear model is created.
In this paper, the whole tooth surface contact analysis and thermal-structural coupled analysis based on contact are practiced by FEM. Five contact lines are determined according to the AGMA standard, which are used to reflect the whole tooth surface contact stress distribution. The results of performance analysis give directions to heavy duty gear modification. And a set of modification parameters used for the very model are proposed.
引文
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[2]宋乐民.齿形与齿轮强度[M].国防工业出版社,1987,7：1-4,105-149,331-341.
[3]K.L.Johnson(著),徐秉业,罗学富,刘信声,宋国华,孙学伟(译).Contact mechanics[M].北京：高等教育出版社,1992,5：1,12-23,32-35,103-122,425-450.
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