基于加载接触分析的NW行星轮系齿轮修形研究
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摘要
矿用电动轮自卸车是一种集机、电、液于一体的高科技产品,是目前1000万吨级以上的大型露天矿场开采运输矿藏的关键装备。自卸车电动轮轮缘减速器是整车中故障多发部位,而国内研制的产品与国外同类产品相比还存在不小的差距；因此,对自卸车电动轮轮缘减速器进行研究,提高自卸车轮缘减速器的质量具有重要意义。轮缘减速器是一个典型的NW行星轮系,相对单对啮合轮齿而言行星轮系的工作指标不但要考虑各齿轮的齿面接触应力与齿根弯曲应力,还需要考虑行星轮系中各行星轮之间的载荷分配情况。所以本文在研究过程中主要使用上述三项指标来反映安装误差和齿轮修形对行星轮系啮合性能的影响。本文主要的研究内容如下：
1.从刀具齿面方程出发运用齿轮啮合与包络原理推导得到了包含过渡曲线的齿轮齿面方程,以此方程为基础结合修形原理得到了修形齿轮的齿面方程。将修形齿轮齿面方程写入到PRO/E中,运用PRO/E的扫描模块得到了修形齿轮参数化的精确几何模型。
2.研究在Abaqus中进行加载接触分析的关键技术,给出在Abaqus中进行加载接触分析的步骤。
3.研究不同齿轮的安装误差对轮边减速器在额定载荷工作时各齿轮的齿面接触应力、齿根弯曲应力及各行星轮之间载荷分配的影响,并针对每种安装误差给出了相应的修形方法。
4.基于轮系的加载分析结果设计了轮缘减速器修形参数,对比了新修形参数与原参数下轮系啮合性能,结果表明新设计修形参数下轮缘减速器的各项性能指标都得到了提升。
Electric wheel dump trucks used in mine are high-tech products gathered mechanial,,electrical and hydraulic characteristics..They are the key transport equipments used in the large-scale and open mine field under more than 10 million tons.The wheel rim reducer is the fault-prone part of the electric wheel dump truck used in mine, a big gap still exists while comparing similar foreign products with our own products. Therefore, research on the wheel rim reducer to improve the quality is of great significance. The wheel rim reducer is a typical NW planetary gear train, comparing with the single meshing gear, not only gear surface contact stress and tooth root bending stress are considered for indicators of planetary gears,but also the load distribution among each planet wheel in planet gear system.In this paper, these three indicators are used to scale the influence of installation error and gear modification to planet gear meshing performance.
The paper is organized as follows.
(1) Gear geometry equation with flank and transition curve is deduced with gear meshing and envelop theory. Subsequently, a modified gear equation is obtained with certain modification strategy. With these geometry equations, a precise geometrical 3D model by scanning module is developed in Pro/E.
(2) The key technology of loading contact analysis is studied in ABAQUS, and the steps of Load Tooth Contact Analysis are listed in detail in ABAQUS.
(3) The impact of gear surface contact stress, tooth root bending stress and load distribution among each planet gear with different gear modification errors to wheel rim reducer are considered under designed load. moreover the corresponding modification parameters have been given for each case.
(4) The modification parameters of the wheel rim reducer has been designed based on the results of loading analysis of gear, the gear meshing performance of the original modification parameters and of the new modification parameters have been compared. The results show that the performance of wheel rim reducer has been improved under the new modification parameters.
1.从刀具齿面方程出发运用齿轮啮合与包络原理推导得到了包含过渡曲线的齿轮齿面方程,以此方程为基础结合修形原理得到了修形齿轮的齿面方程。将修形齿轮齿面方程写入到PRO/E中,运用PRO/E的扫描模块得到了修形齿轮参数化的精确几何模型。
2.研究在Abaqus中进行加载接触分析的关键技术,给出在Abaqus中进行加载接触分析的步骤。
3.研究不同齿轮的安装误差对轮边减速器在额定载荷工作时各齿轮的齿面接触应力、齿根弯曲应力及各行星轮之间载荷分配的影响,并针对每种安装误差给出了相应的修形方法。
4.基于轮系的加载分析结果设计了轮缘减速器修形参数,对比了新修形参数与原参数下轮系啮合性能,结果表明新设计修形参数下轮缘减速器的各项性能指标都得到了提升。
Electric wheel dump trucks used in mine are high-tech products gathered mechanial,,electrical and hydraulic characteristics..They are the key transport equipments used in the large-scale and open mine field under more than 10 million tons.The wheel rim reducer is the fault-prone part of the electric wheel dump truck used in mine, a big gap still exists while comparing similar foreign products with our own products. Therefore, research on the wheel rim reducer to improve the quality is of great significance. The wheel rim reducer is a typical NW planetary gear train, comparing with the single meshing gear, not only gear surface contact stress and tooth root bending stress are considered for indicators of planetary gears,but also the load distribution among each planet wheel in planet gear system.In this paper, these three indicators are used to scale the influence of installation error and gear modification to planet gear meshing performance.
The paper is organized as follows.
(1) Gear geometry equation with flank and transition curve is deduced with gear meshing and envelop theory. Subsequently, a modified gear equation is obtained with certain modification strategy. With these geometry equations, a precise geometrical 3D model by scanning module is developed in Pro/E.
(2) The key technology of loading contact analysis is studied in ABAQUS, and the steps of Load Tooth Contact Analysis are listed in detail in ABAQUS.
(3) The impact of gear surface contact stress, tooth root bending stress and load distribution among each planet gear with different gear modification errors to wheel rim reducer are considered under designed load. moreover the corresponding modification parameters have been given for each case.
(4) The modification parameters of the wheel rim reducer has been designed based on the results of loading analysis of gear, the gear meshing performance of the original modification parameters and of the new modification parameters have been compared. The results show that the performance of wheel rim reducer has been improved under the new modification parameters.
引文
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[2]Inalpolat, M., A. Kahraman. A dynamic model to predict modulation sidebands of a planetary gear set having manufacturing errors. Journal of Sound and Vibration,2010.329(4):371-393.
[3]Inalpolat, M., A. Kahraman. A theoretical and experimental investigation of modulation sidebands of planetary gear sets. Journal of Sound and Vibration,2009.323(3-5):677-696.
[4]Yuksel, C., A. Kahraman. Dynamic tooth loads of planetary gear sets having tooth profile wear. Mechanism and Machine Theory,2004.39(7): 695-715.
[5]Krantz, T. L. A Method to Analyze and Optimize the Load Sharing of Split Path Transmissions.1996, NATIONAL AERONAUTICS AND SPACE ADMINISTRATION CLEVELAND OH LEWIS RESEARCH CEN TER.
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[19]Lin, H. H., F. B. Oswald, D. P. Townsend. Dynamic loading of spur gears with linear or parabolic tooth profile modifications. Mechanism and Machine Theory,1994.29(8):1115-1129.
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[21]Li, S.Finite element analyses for contact strength and bending strength of a pair of spur gears with machining errors, assembly errors and tooth modifications. Mechanism and Machine Theory,2007. 42(1):88-114.
[22]Li, S. Effect of addendum on contact strength, bending strength and basic performance parameters of a pair of spur gears. Mechanism and Machine Theory,2008.43(12):1557-1584.
[23]Li, S.Experimental investigation and FEM analysis of resonance frequency behavior of three-dimensional, thin-walled spur gears with a power-circulating test rig. Mechanism and Machine Theory, 2008.43(8):934-963.
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[35]唐增宝,钟毅芳,陈久荣.修形参数对齿轮动态性能影响的分析研究.机械传动,1994.1.
[36]唐增宝,陈久荣.齿轮动态性能最佳的齿廓修形曲线和参数.华中理工大学学报,1995.23(011)：52-55.
[37]唐增宝,钟毅芳.修形齿轮的最佳修形量和修形长度的确定.华中理工大学学报,1995.23(002)：125-128.
[38]方宗德,张永才,蔺天存.斜齿轮的齿廓修形的实验研究.机械传动,1992.16(004)：27-30.
[39]刘国华,李亮玉.含间隙和时变啮合刚度的渐开线齿轮副齿廓修形研究.中国机械工程,2007.18(012)：1409-1413.
[40]孙月海,张策.减少齿轮传动误差波动的渐开线直齿轮齿廓修形研究.天津大学学报,2001.
[41]孙月海.直齿轮齿廓修形的实验研究.中国机械工程,2003.14(008)：634-636.
[42]孙月海,张策,葛楠.含误差的直齿轮的齿廓修形.机械工程学报,2003.39(012)：91-94.
[43]朱朝宽,曾晓松.圆柱齿轮的装配误差对齿轮工作性能的影响分析.机床与液压,2007.35(004)：5-7.
[44]朱传敏.齿轮修形的优化设计与试验研究.机械工程学报,1998.34(004)：63-68.
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[2]Inalpolat, M., A. Kahraman. A dynamic model to predict modulation sidebands of a planetary gear set having manufacturing errors. Journal of Sound and Vibration,2010.329(4):371-393.
[3]Inalpolat, M., A. Kahraman. A theoretical and experimental investigation of modulation sidebands of planetary gear sets. Journal of Sound and Vibration,2009.323(3-5):677-696.
[4]Yuksel, C., A. Kahraman. Dynamic tooth loads of planetary gear sets having tooth profile wear. Mechanism and Machine Theory,2004.39(7): 695-715.
[5]Krantz, T. L. A Method to Analyze and Optimize the Load Sharing of Split Path Transmissions.1996, NATIONAL AERONAUTICS AND SPACE ADMINISTRATION CLEVELAND OH LEWIS RESEARCH CEN TER.
[6]日高照晃,山本信行,石田武.行星齿轮装置均载机构中的各种误差和载荷分配的关系[A].1986.
[7]袁茹,纪名刚.航空行星减速器的振动特性分析.航空动力学报,1995.10(004)：395-398.
[8]张锁怀,梁治国.内齿行星齿轮传动受力分析.机械传动,1994.18(004)：32-35.
[9]陆俊华,李斌,朱如鹏.行星齿轮传动静力学均载分析.机械科学与技术(西安),2005.24(006)：702-704.
[10]肖铁英,陆卫杰.行星齿轮机构均载系数的计算方法.东北重型机械学院学报,1992.16(004)：290-295.
[11]贺渡.SF3102电动轮自卸车的研制.专用汽车,1988.4.
[12]唐新成,赖曾美.电动轮自卸车内齿轮光弹性应力分析.矿山机械,1996(001)：7-10.
[13]杨钟胜.GE788电动轮自卸车轮边减速器NW行星轮系减速机构的综合评述.汽车工艺与材料,2008(011)：52-56.
[14]杨钟胜.进口电动轮自卸车轮边减速器传动齿轮的研究与制造.汽车工艺与材料,2009(006)：54-56.
[15]杨钟胜.电动轮自卸车轮边减速器齿轮常见失效形式和预防措施.汽车工艺与材料,2009(001)：49-55.
[16]Reister, D. Einseitiges Breitentragen bei Stirnr dern:Verfahren zur Messung, Berechnung und Verringerung oder Ungleichf rmigkeit der Lastverteilung.1965.
[17]Imrek, H., H. Duzcuoglu. Relation between wear and tooth width modification in spur gears. Wear,2007.262(3-4):390-394.
[18]Lin, H. H., D. P. Townsend, F. B. Oswald. Profile modification to minimize spur gear dynamic loading. NTIS, SPRINGFIELD, VA(USA),1987, 22,1987.
[19]Lin, H. H., F. B. Oswald, D. P. Townsend. Dynamic loading of spur gears with linear or parabolic tooth profile modifications. Mechanism and Machine Theory,1994.29(8):1115-1129.
[20]Li, S.Effects of machining errors, assembly errors and tooth modifications on loading capacity, load-sharing ratio and transmission error of a pair of spur gears. Mechanism and Machine Theory,2007.42(6):698-726.
[21]Li, S.Finite element analyses for contact strength and bending strength of a pair of spur gears with machining errors, assembly errors and tooth modifications. Mechanism and Machine Theory,2007. 42(1):88-114.
[22]Li, S. Effect of addendum on contact strength, bending strength and basic performance parameters of a pair of spur gears. Mechanism and Machine Theory,2008.43(12):1557-1584.
[23]Li, S.Experimental investigation and FEM analysis of resonance frequency behavior of three-dimensional, thin-walled spur gears with a power-circulating test rig. Mechanism and Machine Theory, 2008.43(8):934-963.
[24]Litvin, F. Reduction of noise of loaded and unloaded misaligned gear drives. Computer methods in applied mechanics and engineering,2006. 195(41-43):5523-5536.
[25]Litvin, F. L. Spur Gears:Optimal Geometry, Methods for Generation and Tooth Contact Analysis (TCA) Program.1988, ILLINOIS UNIV AT CHICAGO CIRCLE DEPT OF MECHANICAL ENGINEERING.
[26]Simon, V. V. Influence of tooth errors and shaft misalignments on loaded tooth contact in cylindrical worm gears. Mechanism and Machine Theory,2006.41 (6):707-724.
[27]Tsai, M., Y. Tsai. A method for calculating static transmission errors of plastic spur gears using FEM evaluation. Finite Elements in Analysis & Design,1997.27(4):345-357.
[28]魏任之,张永忠,史兴虹.关于直齿圆柱齿轮轮齿受载变形量的计算.齿轮,1980.4(4)：1-8.
[29]毛军.渐开线齿形的修形及测定.宁夏工学院学报：自然科学版,1997.9(001)： 17-19.
[30]宋乐民.渐开线鼓形齿的鼓形量.机械传动,1981(02)：63-68.
[31]张永忠.关于修形齿轮的计算方法.1984.
[32]杨廷力.渐开线高速齿轮的齿高修形(一).齿轮,1978.10(6)：14-24.
[33]詹东安,唐树为.高速齿轮齿部修形技术研究.机械设计,2000.17(008)：8-10.
[34]Brauer, J. Transmission error in anti-backlash conical involute gear transmissions:a global-local FE approach. Finite Elements in Analysis & Design,2005.41(5):431-457.
[35]唐增宝,钟毅芳,陈久荣.修形参数对齿轮动态性能影响的分析研究.机械传动,1994.1.
[36]唐增宝,陈久荣.齿轮动态性能最佳的齿廓修形曲线和参数.华中理工大学学报,1995.23(011)：52-55.
[37]唐增宝,钟毅芳.修形齿轮的最佳修形量和修形长度的确定.华中理工大学学报,1995.23(002)：125-128.
[38]方宗德,张永才,蔺天存.斜齿轮的齿廓修形的实验研究.机械传动,1992.16(004)：27-30.
[39]刘国华,李亮玉.含间隙和时变啮合刚度的渐开线齿轮副齿廓修形研究.中国机械工程,2007.18(012)：1409-1413.
[40]孙月海,张策.减少齿轮传动误差波动的渐开线直齿轮齿廓修形研究.天津大学学报,2001.
[41]孙月海.直齿轮齿廓修形的实验研究.中国机械工程,2003.14(008)：634-636.
[42]孙月海,张策,葛楠.含误差的直齿轮的齿廓修形.机械工程学报,2003.39(012)：91-94.
[43]朱朝宽,曾晓松.圆柱齿轮的装配误差对齿轮工作性能的影响分析.机床与液压,2007.35(004)：5-7.
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