渐开线齿轮传动疲劳寿命分析
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摘要
渐开线齿轮在传递运动和动力时,其承载能力及使用寿命是工程上非常关注的内容,因此,开展渐开线齿轮强度及其寿命分析研究具有重要的意义。传统的分析方法无法形象地得到齿轮传动中的应力和疲劳寿命分布状况,本文以齿轮疲劳强度试验为依托,应用有限元和疲劳分析软件对试验齿轮进行分析,为齿轮传动机构设计提供有力支持。
考虑齿轮实际加工情况以及进行精确建模,本文创建了相对精确的齿根过渡曲线,并解决了齿轮渐开线与齿根过渡曲线不连续问题,同时基于齿轮啮合原理,实现齿轮无干涉装配。
对齿轮几何模型进行结构简化和边界简化,在试验齿轮静态弯曲疲劳强度有限元分析计算中,采用映射方法对齿轮端面进行网格划分,应用扫掠方法生成六面体单元,并采用MPC刚体控制法对主动轮施加转矩,利用非线性分析软件MSC.Marc进行应力分析,最后结合齿轮特点分析了应力结果。
对某材料渐开线齿轮进行接触疲劳强度试验和弯曲疲劳试验,确定了试验齿轮接触和弯曲的疲劳特性曲线及疲劳极限应力,为该材料渐开线齿轮接触和弯曲的疲劳强度计算提供了有试验基础的参考数据。
本文以接触疲劳试验中疲劳断齿齿轮为依据,利用有限元应力分析结果以及试验得到的弯曲疲劳寿命曲线,应用MSC.Fatigue软件,采用Goodman应力修正方法,调整影响疲劳寿命的应力集中系数、载荷放大系数等相应参数,使之预测寿命与接触疲劳试验中疲劳断齿齿轮的寿命比较接近,通过以上工作,能够对该材料齿轮的疲劳寿命进行较好的预测。
Carrying capacity and service life of the involute gears are paid much attention when they transmit movement and power. It is of great significance to carry out the analysis on the strength and life of involute gears. It is hard to get the stress and life distribution during gear transmission through traditional analytical methods. Based on the test of gear fatigue life, this paper applies the software FEM to analyze the test gear, providing strong support for gear transmission design.
Considering the actral gear processing and setting up precise model, this paper has set up relatively precise dedendum transition curve and solved the problem of incontinuity between the gear involute and tooth root transition curve. At the same time, it carries out non-interference assembly based on the principle of gear meshing. This paper applies FEM method to analyze gear contact and bending stress.
Structure and borderline of gear Geometric model were simplified, in the finite element analysis calculation of the test gear static bending fatigue strength , mapping methods were used to conduct gear face mesh, sweeping method was applied to generate hexahedral element, MPC rigid control method was used to impose torque on the driving wheel, MSC.Marc software was used to make analysis of non-linear stress ,finally stress result was analysed combined with the characteristics of gear.
The contact fatigue tests and bending fatigue tests of involute gear were carried on, fatigue characteristic curve and fatigue limit stress of the gear contacting and bending were determined, this can provide reference data for the caculation of the involute gear contacting and bending fatigue strength.
Based on the broken gear teeth in contact fatigue test, bending fatigue life curve was got by applying finite element stress analysis results, MSC.Fatigue software was applied ,Goodman stress correction method was used, the corresponding parameters that affected fatigue life such as load magnification factors ,stress concentration factor were adjusted, in order to assure predicting fatigue life is closer to the broken gear life in contact fatigue test.Through the above work, fatigue life prediction of the gear can be made better.
考虑齿轮实际加工情况以及进行精确建模,本文创建了相对精确的齿根过渡曲线,并解决了齿轮渐开线与齿根过渡曲线不连续问题,同时基于齿轮啮合原理,实现齿轮无干涉装配。
对齿轮几何模型进行结构简化和边界简化,在试验齿轮静态弯曲疲劳强度有限元分析计算中,采用映射方法对齿轮端面进行网格划分,应用扫掠方法生成六面体单元,并采用MPC刚体控制法对主动轮施加转矩,利用非线性分析软件MSC.Marc进行应力分析,最后结合齿轮特点分析了应力结果。
对某材料渐开线齿轮进行接触疲劳强度试验和弯曲疲劳试验,确定了试验齿轮接触和弯曲的疲劳特性曲线及疲劳极限应力,为该材料渐开线齿轮接触和弯曲的疲劳强度计算提供了有试验基础的参考数据。
本文以接触疲劳试验中疲劳断齿齿轮为依据,利用有限元应力分析结果以及试验得到的弯曲疲劳寿命曲线,应用MSC.Fatigue软件,采用Goodman应力修正方法,调整影响疲劳寿命的应力集中系数、载荷放大系数等相应参数,使之预测寿命与接触疲劳试验中疲劳断齿齿轮的寿命比较接近,通过以上工作,能够对该材料齿轮的疲劳寿命进行较好的预测。
Carrying capacity and service life of the involute gears are paid much attention when they transmit movement and power. It is of great significance to carry out the analysis on the strength and life of involute gears. It is hard to get the stress and life distribution during gear transmission through traditional analytical methods. Based on the test of gear fatigue life, this paper applies the software FEM to analyze the test gear, providing strong support for gear transmission design.
Considering the actral gear processing and setting up precise model, this paper has set up relatively precise dedendum transition curve and solved the problem of incontinuity between the gear involute and tooth root transition curve. At the same time, it carries out non-interference assembly based on the principle of gear meshing. This paper applies FEM method to analyze gear contact and bending stress.
Structure and borderline of gear Geometric model were simplified, in the finite element analysis calculation of the test gear static bending fatigue strength , mapping methods were used to conduct gear face mesh, sweeping method was applied to generate hexahedral element, MPC rigid control method was used to impose torque on the driving wheel, MSC.Marc software was used to make analysis of non-linear stress ,finally stress result was analysed combined with the characteristics of gear.
The contact fatigue tests and bending fatigue tests of involute gear were carried on, fatigue characteristic curve and fatigue limit stress of the gear contacting and bending were determined, this can provide reference data for the caculation of the involute gear contacting and bending fatigue strength.
Based on the broken gear teeth in contact fatigue test, bending fatigue life curve was got by applying finite element stress analysis results, MSC.Fatigue software was applied ,Goodman stress correction method was used, the corresponding parameters that affected fatigue life such as load magnification factors ,stress concentration factor were adjusted, in order to assure predicting fatigue life is closer to the broken gear life in contact fatigue test.Through the above work, fatigue life prediction of the gear can be made better.
引文
[1]王小宝.齿轮失效的原因与对策[J].矿冶,1998,7(2):63-67
[2]王国军.典型传动零件多轴疲劳设计理论与方法研究[D].北京:北京理工大学,2006
[3]李玉萍.基于Pro/E的减速器大齿轮三维建模及参数化设计[D].四川:西南科技大学,2007
[4]王晓勇.基于UG的章动齿轮减速器建模和仿真研究[D].云南:昆明理工大学,2006
[5]王国军,闫清东.齿轮弯曲疲劳寿命有限元计算方法研究[J].农业装备与车辆工程2006,(1):40-42
[6]扬汾爱,张志强,龙小乐等.基于精确模型的斜齿轮接触应力有限元分析[J].机械科学与技术,2003,22(3):34-36
[7] S.Glodez,M.Srarnl,J.Kramberger.A computational model for determination of service life of gears[J].International Journal of Fatigue,2002,24(10)
[8] J.Kramberger,M.Sraml,I.Potrc.Numerical calculation of bending fatigue life of thin-rim spur gears[J].Engineering Fracture Mechanics,2004,71
[9] M.Guagliano, E.Riva, M. Guidetti.Contact fatigue failure analysis of shot peened gears[J].Engineering Failure Analysis, 2002,9(2):147-158
[10] E. Akata, M. T. Altinbalik, Y. Can.Three point load application in single tooth bending fatigue test for evaluation of gear blank manufacturing methods[J].International Journal of Fatigue, 2004, 26
[11]蒋轩,张军,郑慕侨.用断裂力学理论预估负重轮疲劳寿命[J].兵工学报,2000,21(增):35-37
[12]减廷杰.车辆传动系统随机载荷谱和疲劳设计研究[D].北京:北京理工大学,1999
[13]高连华,郭金茂.车辆悬挂系统扭杆弹簧疲劳寿命的统计分析[J].装甲兵工程学院学报,1994, 8(1):31-35
[14]李永东,张丙喜,贾斌.某型主战坦克扭力轴的疲劳断裂分析与寿命计算[J].机械强度,2004, 26(4),443-446
[15]吴继泽,王统编著.齿根过渡曲线与齿根应力[M].北京:国防工业出版社,1989:6-11.
[16]吴序堂.齿轮啮合原理[M].北京:机械工业出版社,1979:60-62
[17]陈火红,杨剑.Marc有限元实例教程[M].北京:机械工业出版社2007:107-109
[18]范晓珂.基于Pro/E的渐开线圆柱齿轮参数化实体设计[J].煤炭地质与勘测,2006,34(5):78-80
[19]袁菲.某火炮传动系统随机载荷下齿轮疲劳寿命预测方法研究[D],陕西:西北工业大学,2006
[20]陈德民.圆柱斜齿轮动态强度与疲劳损伤仿真[J].计算机辅助工程,2006.15(增):294-296
[21]郑元宝.应用Pro/E软件精确绘制斜齿圆柱齿轮的方法[J].汽车齿轮,2006.(4):43-46
[22]傅志红,张凯.齿面接触疲劳点蚀原因分析[J].株洲工学院学报,1995,9(3):57-60
[23]姚英姿,邓召义,莫云辉.齿轮的精确建模及基接触应力有限元分析[J].现代机械,2004,(6):16-17
[24] GB/T14230-1993,齿轮接触疲劳强度试验方法[S].北京:中国标准出版社,1993
[25]武宝林,邵家辉.GB12759-91型双圆弧齿轮调质钢接触疲劳强度的可靠性试验与分析[J].机械传动,1992,16(3):42-47
[26]易秉钺,陈键,周建梁.20CrMnMo渗碳淬火齿轮的接触疲劳强度[J].北京科技大学学报,1992,14(5):530-536
[27]傅群.齿面接触疲劳寿命试验载荷的确定[J].航天工艺,1997(3):20-21
[28]朱孝录.齿轮材料的接触疲劳强度[J].机械传动,1994,18(3):34-36
[29]张晗亮.渗碳淬火齿轮接触疲劳强度可靠性试验[J].石油机械,1995,23(5):25-33
[30] GB/T19406-2002,渐开线圆柱齿轮承载能力计算方法[S].北京:机械工业出版社,2002
[31] GB/T14230-1993,齿轮弯曲疲劳强度试验方法[S].北京:中国标准出版社,1993
[32]朱孝录等主编.齿轮的试验技术与设备[M].北京:机械工业出版社,1988
[33]姚卫星著.结构疲劳寿命分析[M].北京:国防工业出版社,2003
[34]马爱军,周传月,王旭编著.Patran和Nastran有限元分析专业教程[M].北京:清华大学出版社,2005
[35]清源计算机工作室编著.Matlab基础及其应用[M].北京:机械工业出版社,2000
[36]包研科,李娜编著.数理统计与matlab数据处理[M].辽宁:东北大学出版社,2008
[37]林晓斌译.基于有限元的疲劳设计分析系统NSC/FATIGUE[J].中国机械工程,1998,9(11):12-16
[38]吕海波.结构疲劳可靠性分析方法研究[D].南京:南京航空航天大学,2000
[39]陈德民.变速箱加速寿命试验与等损伤设计研究[D].北京:北京理工大学,2006
[40]许洪斌,祖世华.随机载荷条件下齿轮弯曲疲劳强度[J].重庆工学院学报,2007.21(11):49-51
[41]孙桓,陈作模.机械原理[M].北京:高等教育出版社,1996
[42]王玉新等.渐开线直齿圆柱齿轮齿根应力的有限元分析[J].机械设计,2001,(8):49-52
[43]白云飞.斜齿圆柱齿轮和面齿轮啮合传动的几何和静力学仿真[D].陕西:西北工业大学2006
[44]章文强,盛云,于莉.燃料电池轿车变速器齿轮接触应力分析及疲劳寿命计算[J].计算机辅助工程,2007,16(4):36-39
[45] v.Ramamurti,M.Ananda Rao.Dynamic analysis of spur gear teeth[J].Computers and Structures,1988,29(5):832-843
[46] Q.JYang.Fatigue test and reliability design of gears[J].International Journal of Fatigue,1996,18(3):171-177
[47]刘兵山,黄聪等编著.Patran从入门到精通[M].北京:中国水力水电出版社,2003
[48] M.A.Seireg Arikan,Bilgin Kaftanoglu.Dynamic load and root stress analysis of spur gear[J].Annals of the CIRP,1989,38(1):171-174
[49] MinerMA.Cumulative damage in fatigue[J].Journal of Applide Mechics,1945,(12) 159-164
[50] D.Barlam,E.Zahavi.The reliability of solutions in contact problems[J]. Computer and Structures,1999,70:35-45
[51] G.D.Bibel.Contact Stress Analysis of Spiral Bevel Gears Using Finite Element Analysis[J].ASME Journal of Mechanical Design,1995,117:235-240
[2]王国军.典型传动零件多轴疲劳设计理论与方法研究[D].北京:北京理工大学,2006
[3]李玉萍.基于Pro/E的减速器大齿轮三维建模及参数化设计[D].四川:西南科技大学,2007
[4]王晓勇.基于UG的章动齿轮减速器建模和仿真研究[D].云南:昆明理工大学,2006
[5]王国军,闫清东.齿轮弯曲疲劳寿命有限元计算方法研究[J].农业装备与车辆工程2006,(1):40-42
[6]扬汾爱,张志强,龙小乐等.基于精确模型的斜齿轮接触应力有限元分析[J].机械科学与技术,2003,22(3):34-36
[7] S.Glodez,M.Srarnl,J.Kramberger.A computational model for determination of service life of gears[J].International Journal of Fatigue,2002,24(10)
[8] J.Kramberger,M.Sraml,I.Potrc.Numerical calculation of bending fatigue life of thin-rim spur gears[J].Engineering Fracture Mechanics,2004,71
[9] M.Guagliano, E.Riva, M. Guidetti.Contact fatigue failure analysis of shot peened gears[J].Engineering Failure Analysis, 2002,9(2):147-158
[10] E. Akata, M. T. Altinbalik, Y. Can.Three point load application in single tooth bending fatigue test for evaluation of gear blank manufacturing methods[J].International Journal of Fatigue, 2004, 26
[11]蒋轩,张军,郑慕侨.用断裂力学理论预估负重轮疲劳寿命[J].兵工学报,2000,21(增):35-37
[12]减廷杰.车辆传动系统随机载荷谱和疲劳设计研究[D].北京:北京理工大学,1999
[13]高连华,郭金茂.车辆悬挂系统扭杆弹簧疲劳寿命的统计分析[J].装甲兵工程学院学报,1994, 8(1):31-35
[14]李永东,张丙喜,贾斌.某型主战坦克扭力轴的疲劳断裂分析与寿命计算[J].机械强度,2004, 26(4),443-446
[15]吴继泽,王统编著.齿根过渡曲线与齿根应力[M].北京:国防工业出版社,1989:6-11.
[16]吴序堂.齿轮啮合原理[M].北京:机械工业出版社,1979:60-62
[17]陈火红,杨剑.Marc有限元实例教程[M].北京:机械工业出版社2007:107-109
[18]范晓珂.基于Pro/E的渐开线圆柱齿轮参数化实体设计[J].煤炭地质与勘测,2006,34(5):78-80
[19]袁菲.某火炮传动系统随机载荷下齿轮疲劳寿命预测方法研究[D],陕西:西北工业大学,2006
[20]陈德民.圆柱斜齿轮动态强度与疲劳损伤仿真[J].计算机辅助工程,2006.15(增):294-296
[21]郑元宝.应用Pro/E软件精确绘制斜齿圆柱齿轮的方法[J].汽车齿轮,2006.(4):43-46
[22]傅志红,张凯.齿面接触疲劳点蚀原因分析[J].株洲工学院学报,1995,9(3):57-60
[23]姚英姿,邓召义,莫云辉.齿轮的精确建模及基接触应力有限元分析[J].现代机械,2004,(6):16-17
[24] GB/T14230-1993,齿轮接触疲劳强度试验方法[S].北京:中国标准出版社,1993
[25]武宝林,邵家辉.GB12759-91型双圆弧齿轮调质钢接触疲劳强度的可靠性试验与分析[J].机械传动,1992,16(3):42-47
[26]易秉钺,陈键,周建梁.20CrMnMo渗碳淬火齿轮的接触疲劳强度[J].北京科技大学学报,1992,14(5):530-536
[27]傅群.齿面接触疲劳寿命试验载荷的确定[J].航天工艺,1997(3):20-21
[28]朱孝录.齿轮材料的接触疲劳强度[J].机械传动,1994,18(3):34-36
[29]张晗亮.渗碳淬火齿轮接触疲劳强度可靠性试验[J].石油机械,1995,23(5):25-33
[30] GB/T19406-2002,渐开线圆柱齿轮承载能力计算方法[S].北京:机械工业出版社,2002
[31] GB/T14230-1993,齿轮弯曲疲劳强度试验方法[S].北京:中国标准出版社,1993
[32]朱孝录等主编.齿轮的试验技术与设备[M].北京:机械工业出版社,1988
[33]姚卫星著.结构疲劳寿命分析[M].北京:国防工业出版社,2003
[34]马爱军,周传月,王旭编著.Patran和Nastran有限元分析专业教程[M].北京:清华大学出版社,2005
[35]清源计算机工作室编著.Matlab基础及其应用[M].北京:机械工业出版社,2000
[36]包研科,李娜编著.数理统计与matlab数据处理[M].辽宁:东北大学出版社,2008
[37]林晓斌译.基于有限元的疲劳设计分析系统NSC/FATIGUE[J].中国机械工程,1998,9(11):12-16
[38]吕海波.结构疲劳可靠性分析方法研究[D].南京:南京航空航天大学,2000
[39]陈德民.变速箱加速寿命试验与等损伤设计研究[D].北京:北京理工大学,2006
[40]许洪斌,祖世华.随机载荷条件下齿轮弯曲疲劳强度[J].重庆工学院学报,2007.21(11):49-51
[41]孙桓,陈作模.机械原理[M].北京:高等教育出版社,1996
[42]王玉新等.渐开线直齿圆柱齿轮齿根应力的有限元分析[J].机械设计,2001,(8):49-52
[43]白云飞.斜齿圆柱齿轮和面齿轮啮合传动的几何和静力学仿真[D].陕西:西北工业大学2006
[44]章文强,盛云,于莉.燃料电池轿车变速器齿轮接触应力分析及疲劳寿命计算[J].计算机辅助工程,2007,16(4):36-39
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[46] Q.JYang.Fatigue test and reliability design of gears[J].International Journal of Fatigue,1996,18(3):171-177
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