直齿圆柱齿轮耐磨性和疲劳寿命的仿生研究

发布时间：2018-09-07 08:28

【摘要】：齿轮产业是装备制造业的基础性产业，具有产业关联度高、吸纳就业强、技术资金密集的特点，是我国从制造大国走向制造强国的标志性产业。国内骨干齿轮企业已达200多家，但很多高性能、长寿命齿轮只能依靠进口，因此只有重视自主研发与自主创新才能扭转这种被动的局面。目前有很多方法和措施都能提高齿轮的使用性能和服役寿命，但这些方法并不能完美地解决所有问题，都存在这样或那样的不足有待改进。仿生研究发现，很多具有耐磨和抗疲劳特性的生物（如穿山甲和贝类）体表面往往是非光滑的、软硬相间的。所以本文就从仿生学的角度出发，基于仿生非光滑表面理论，借鉴吉林大学工程仿生教育部重点实验室已有的研究成果，结合激光淬火处理技术设计了9种与贝类等生物体体表相似的、软硬相间的、具有不同微小宽度和深度的（宽度为160-260μm，深度为3μm左右）并规则排列的条纹状仿生表面形态，并把优选后的仿生表面形态制备到轮齿表面上获得仿生齿轮。齿轮啮合传动试验的结果表明仿生齿轮具有较好的抗疲劳特性和耐磨特性，这不仅扩展了仿生学的应用范围，而且为工程仿生技术在齿轮传动上的实际应用打下了良好的基础。论文的主要研究工作如下：首先，在全面考虑了贝类等生物体体表的非光滑表面形态、齿轮传动的特点、齿轮和圆柱滚子试件的尺寸、齿轮的疲劳失效原因以及现有设备的加工精度等级后，精心设计了9种不同参数的、软硬相间的仿生表面形态。为了节约成本、简化试验并提高效率，根据齿轮传动过程中既有滚动又有滑动的特点，将齿轮的传动简化成了圆柱滚子试件的对滚，从而通过圆柱滚子试件的对滚试验选出最优仿生表面形态，进而制备仿生齿轮。其次，用激光淬火设备把上述9种不同参数的仿生表面形态制备到9个圆柱滚子试件的外圆面上得到仿生圆柱滚子试件，分别观测了试件表面形态的2D、3D形貌，分析了试件的断面形态、金相组织以及显微硬度。然后用磨损试验机分别进行了仿生圆柱滚子试件、普通圆柱滚子试件（外圆面光滑）和激光淬火圆柱滚子试件（外圆面全部淬火）的模拟齿轮啮合传动过程的对滚试验，试验结果表明仿生圆柱滚子试件的耐磨性要明显好于普通圆柱滚子试件和激光淬火圆柱滚子试件，其中2号仿生圆柱滚子试件（条纹宽度为185μm，激光扫描速度为120mm/s，条纹的周向中心距为457μm）的耐磨性能最好，磨损率为0.0279%，比普通圆柱滚子试件和激光淬火圆柱滚子试件的耐磨性有了很大程度的提高。第三，为了进一步探究仿生表面形态对齿轮综合性能的影响，把上述最优仿生表面形态制备到齿轮轮齿表面上得到仿生齿轮，并用齿轮试验机分别进行了普通齿轮和仿生齿轮的啮合传动试验，所用设备为CL-100A齿轮试验机。通过对比试验前后二者齿廓总偏差和螺旋线总偏差的变化量对齿轮的耐磨性进行了评定；通过对比试验后二者的单齿点蚀面积率对齿轮的疲劳寿命进行了评定。试验结果表明普通大齿轮与普通小齿轮在啮合试验前后的齿廓总偏差变化量分别为25.750μm、9.175μm，，螺旋线总偏差变化量分别为3.500μm、3.750μm；而仿生大齿轮与仿生小齿轮在啮合试验前后的齿廓总偏差变化量分别为3.825μm、6.500μm，螺旋线总偏差变化量分别为2.450μm、3.625μm。普通大齿轮与普通小齿轮的平均单齿点蚀面积率分别为1.26%、1.55%；而仿生大齿轮与仿生小齿轮的平均单齿点蚀面积率分别为0.58%、1.04%。由此可见仿生齿轮的耐磨性和疲劳寿命均要好于普通齿轮；论文最后还对仿生齿轮的耐磨与抗疲劳机理做了探讨性分析。
[Abstract]:Gear industry is the basic industry of equipment manufacturing industry, which has the characteristics of high industrial correlation, strong employment absorption, and intensive technology and capital. It is a symbolic industry of China from a big manufacturing country to a strong manufacturing country. Only with independent innovation can we reverse this passive situation.
At present, there are many methods and measures to improve the performance and service life of gears, but these methods can not solve all the problems perfectly. There are some shortcomings to be improved. From the point of view of bionics, based on the theory of bionic non-smooth surface and the existing research results of Key Laboratory of Engineering bionic education of Jilin University, nine kinds of surface similar to shellfish and other organisms with different micro-width and depth were designed by using laser quenching technology. The results of gear meshing transmission test show that the bionic gear has better fatigue resistance and wear resistance, which not only extends the application of bionics. The main research work of this paper is as follows:1.
Firstly, after considering the non-smooth surface morphology of shellfish and other organisms, the characteristics of gear transmission, the sizes of gear and cylindrical roller specimens, the fatigue failure causes of gears and the machining accuracy levels of existing equipment, nine bionic surface morphologies with different parameters, soft and hard, were designed carefully. According to the characteristics of both rolling and sliding in the process of gear transmission, the transmission of the gear is simplified as the counter-rolling of the cylindrical roller specimen, and the optimal bionic surface shape is selected through the counter-rolling test of the cylindrical roller specimen, and then the bionic gear is prepared.
Secondly, the bionic cylindrical roller specimens with 9 different parameters were fabricated on the outer surface of 9 cylindrical roller specimens by laser quenching equipment. The surface morphologies of the specimens were observed in 2D and 3D. The fracture morphology, metallographic structure and microhardness of the specimens were analyzed. The counter-rolling test of the meshing transmission process of the simulated gears of the bionic cylindrical roller specimen, the ordinary cylindrical roller specimen (smooth outer cylindrical surface) and the laser quenched cylindrical roller specimen (all quenched outer cylindrical surface) was carried out. The results show that the wear resistance of the bionic cylindrical roller specimen is obviously better than that of the ordinary cylindrical roller specimen and the laser quenched cylindrical roller specimen. Among the specimens, the wear resistance of the bionic cylindrical roller specimen No. 2 (stripe width 185 micron, laser scanning speed 120 mm/s, stripe circumferential center distance 457 micron) is the best, and the wear rate is 0.0279%, which is much higher than that of the common cylindrical roller specimens and laser quenched cylindrical roller specimens.
Thirdly, in order to further explore the influence of bionic surface morphology on the comprehensive performance of gears, the above-mentioned optimal bionic surface morphology was prepared on the surface of gear teeth to get bionic gears, and the meshing transmission tests of common gears and bionic gears were carried out by gear testing machine, using CL-100A gear testing machine. The wear resistance of the gears was evaluated by the variation of the total tooth profile deviation and the total helix deviation before and after testing, and the fatigue life of the gears was evaluated by comparing the pitting area ratio of the two teeth.
The test results show that the total deviation of the tooth profile of the ordinary big gear and the ordinary small gear before and after the meshing test are 25.750 micron, 9.175 micron, 3.500 micron and 3.750 micron respectively, while that of the bionic big gear and the bionic small gear before and after the meshing test is 3.825 micron, 6.500 micron and screw respectively. The average pitting area ratio of single tooth of the ordinary big gear and the ordinary small gear is 1.26% and 1.55% respectively, while the average pitting area ratio of the bionic big gear and the bionic small gear is 0.58% and 1.04% respectively. Finally, the mechanism of wear resistance and fatigue resistance of bionic gears is discussed.
【学位授予单位】：吉林大学
【学位级别】：硕士
【学位授予年份】：2012
【分类号】：TH132.417

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