齿轮表面摩擦学设计与表面织构化研究进展

State of Art in Tribological Design and Surface Texturing of Gear Surfaces

我国国防事业的飞速发展对航空高速齿轮提出了更高要求,而有关齿轮副表面摩擦学设计仍是薄弱环节。表面织构技术已成为摩擦学领域的研究热点,在减摩抗磨、减振、抗粘附和抗蠕爬等多个领域展示出良好的应用潜力。有关齿面织构化设计研究尚处于起步阶段,还远未能形成规范成熟的设计理念和方法。对当前在齿轮表面摩擦学设计及表面织构化方面的研究工作进行全面综述。首先从齿轮表面摩擦学设计基本要求展开介绍,指出表面粗糙度和表面纹理是齿轮副表面摩擦学设计的关键,而大量研究已经证实,不管是滚动还是滑动摩擦,并非表面越光滑摩擦学性能越优异,在齿轮副表面织构化设计方面的研究工作已经展开。随后对现有齿轮副表面织构化的研究工作进行梳理,总结齿面织构化处理后带来的性能增益,主要包括减摩抗磨效应、表面强化效应、减振和降温效应。接着,介绍齿轮弹流润滑数值计算方面的研究进展,总结在表面纹理、表面织构对齿轮副的弹流润滑特性影响机制方面的研究。随后,对齿轮副表面织构加工技术进行对比分析,主要包括织构激光刻蚀、织构掩膜电解和织构微磨料射流等特种加工技术的优劣。对现有研究不足和潜在研究方向进行展望,从织构设计和加工等方面对齿轮表面织构化设计提供指导,研究结果可为未来航空高速齿轮副表面织构化设计提供科学指导和数据支撑,填补该领域研究空白并扩大表面织构应用领域。

The rapid advancement in national defense technology has escalated the demands on aviation equipment.The importance and prominence of gears,being fundamental components,has been steadily increasing.Nonetheless,the development of surface tribological properties for gear pairs remains a challenge.Focusing on the tribology and texture design of gear pair surfaces holds the promise of significantly enhancing their service performance and advancing the design of high-reliability and long-life aerospace gears.This study begins with an overview of the basic meshing characteristics of gear pairs and delves into how surface roughness impacts their performance.It has been discovered that diminishing surface roughness effectively contributes to wear resistance.For decades,the tribological design of gear surfaces has evolved toward achieving higher precision and smoother finishes,grounded in conventional mechanical design and tribology principles.Despite advancements in polishing techniques,the average roughness of aviation gear teeth surfaces has been capped at approximately 0.4μm.Given the considerations for processing cost-effectiveness,endlessly minimizing surface roughness is impractical.Recent research has demonstrated that under conditions of either rolling or sliding friction,a smoother surface does not necessarily equate to superior wear resistance and friction reduction outcomes.Then,the influences of surface texture on the tribological performance of gear pairs are discussed.Over the past few decades,researchers from both domestic and international spheres have conducted extensive studies on the surface texturing design of gear pairs.The formation of surface textures through various processes is presented,along with a detailed review of the current research on gear surface texture design,covering both experimental investigations and theoretical simulations.According to the literature available,the benefits of surface texturing on performance are outlined,primarily encompassing friction reduction,wear resistance,surface strengthening,vibration damping,and temperature mitigation effects.Subsequently,advancements in the numerical calculation of gear elastic-fluid lubrication are introduced,summarizing the effects of surface texture and texturing on the elastic-fluid lubrication characteristics of gear pairs.The prevailing numerical simulation efforts related to gear pairs mainly address two factors:surface roughness and texture.Historically,simulations of elastic-fluid lubrication for gear pairs predominantly utilized the infinite-length wire contact model.However,recent research has gradually shifted from this non-linear-length wire contact model to finite-length models that more accurately reflect the real contact length under actual surface conditions and mixed lubrication conditions,acknowledging the limitations of real wire contact length.Surface texture represents the three-dimensional morphology on the tooth surface,making the two-dimensional infinite-length model inadequate for current research needs.Investigating how to extend the application of three-dimensional wire contact models to numerically simulate surface texture,considering surface roughness,is of significant interest.Following this,a comparative analysis of various surface texturing processing technologies for gear surfaces is conducted.This includes examining the advantages and disadvantages of specialized processing techniques such as laser etching,mask electrolysis,and micro abrasive jet texturing.Finally,a summary and outlook of the surface texture design of gear surfaces are proposed,including the existing research gaps and future research directions.Current design approaches for the surface texturing of gear pairs involve theoretical simulation and experimental optimization.Although surface textures present clear benefits and potential for application,it is important to recognize the challenges in designing surface textures for high-speed aviation gears,which remain areas for further exploration.The efficacy of surface textures on tooth surfaces is intrinsically linked to their operational conditions.The primary challenges are twofold:the design of gear surface textures and advancement of gear manufacturing technologies.Surface textures are believed to significantly enhance tribological performance,offering innovative solutions for the design of high-reliability and long-life aviation gears.This approach is anticipated to bridge the research gap in this domain and broaden the future application of surface texturing.