齿轮磨损计算与测试方法及抑制技术
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摘要
齿轮是航空航天器、大型舰船、先进轨道车辆、电动汽车、智能机器人、高效能源机械等重大装备传动系的核心元件,齿面磨损则是其最常见的失效形式.有必要从理论与试验两方面,研究齿面磨损量的确定方法及其抑制技术.基于黏着磨损、疲劳磨损和能量磨损理论及材料磨损率,对不同的齿面磨损模型及其计算方法进行分析.按等效试件、比例试件和实际试件分3类试验方法,分述其在齿轮磨损研究中的应用;并对磨损量的常用测量技术,即称重法、表面轮廓法、铁谱与光谱分析法进行探讨.研究结果显示,齿轮磨损量的预测需要根据摩擦配副材料-结构特性、使役条件及其对应的失效形式选用合适的磨损模型和测算方法,将理论分析、数值计算与测试技术密切结合.在改进传统的硬齿面和润滑技术的同时,固体润滑薄膜材料、耐磨减摩涂层和齿面复合强化等先进技术,将为高性能齿轮产品及其装备的抗磨损设计提供重要的助力.
As core elements,gears are widely applied in aircrafts,large warships,advanced railway vehicles,electric automobiles,intelligent robots and power equipment. Since surface wear is a main failure mode of gear drives,the prediction methods and suppression techniques for tooth wear loss should be performed by both theoretical analysis and measuring techniques. According to adhesive wear,fatigue wear,energy wear theories,and material wear rate,different wear models and calculation methods for tooth surfaces were investigated first. Then,three tests( as equivalent,scale or real specimen in use)applied in investigation of gear wear,and weighing method,surface profiler,ferrography and spectral analysis were discussed. Results show that an available wear model and prediction method should be chosen according to the materials-structural characteristics,working conditions,failure modes of a gear drive,while the theoretical analysis,numerical simulation are combined with measuring techniques for determining the tooth wear loss. As the traditional hardened gears and lubrication techniques are improved,solid-film lubrication,wear-resistance and friction-reduction coating,and compound surfacereinforcement are beneficial for the antiwear design of high-performance gears.
As core elements,gears are widely applied in aircrafts,large warships,advanced railway vehicles,electric automobiles,intelligent robots and power equipment. Since surface wear is a main failure mode of gear drives,the prediction methods and suppression techniques for tooth wear loss should be performed by both theoretical analysis and measuring techniques. According to adhesive wear,fatigue wear,energy wear theories,and material wear rate,different wear models and calculation methods for tooth surfaces were investigated first. Then,three tests( as equivalent,scale or real specimen in use)applied in investigation of gear wear,and weighing method,surface profiler,ferrography and spectral analysis were discussed. Results show that an available wear model and prediction method should be chosen according to the materials-structural characteristics,working conditions,failure modes of a gear drive,while the theoretical analysis,numerical simulation are combined with measuring techniques for determining the tooth wear loss. As the traditional hardened gears and lubrication techniques are improved,solid-film lubrication,wear-resistance and friction-reduction coating,and compound surfacereinforcement are beneficial for the antiwear design of high-performance gears.
引文
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