泡沫铝填充结构大型齿轮优化设计及其性能分析

Optimal design and properties analysis of large gear filled of foam aluminum

为探讨大型齿轮传动装置轻量化及减振降噪新途径,以某矿用减速器大型齿轮为研究原型,初步设计了泡沫铝填充结构齿轮.以扭转刚度满足使用要求为约束条件,以降低齿轮的质量并提高其动态特性为优化目标,对泡沫铝填充结构齿轮进行优化.对三种齿轮的前5阶模态进行仿真分析,对其降噪性进行实验研究.结果表明,与原型齿轮相比,优化后和初始设计的泡沫铝填充结构齿轮的前5阶振型固有频率均有所提高,最大提高量分别为16.1%和1.9%;而振幅均有所降低,最大降低量分别为10.0%和5.4%;相同转速情况下前两种齿轮的传动噪声均较后一种齿轮的传动噪声有所降低,最大降低量分别为11.1%和5.5%.前两种齿轮的质量分别较后一种齿轮减轻10.92%和15.93%.证明了泡沫铝填充结构齿轮在提高大型齿轮轻量化和减振降噪特性方面的有效性.

In order to explore the new way to reduce weight, vibration and noise of large gear, this paper studies on optimal design and its properties of gear with aluminum foam by taking a large gear in mineral decelerator for an example. The first type, the gear with aluminum foam is designed by original gear. The second type, the gear is optimal designed by taking torsion stiffness as constraint condition, taking maximum mass aluminum foam filled as object function. The third type, the modals of the three types of gear are analyzed by ANSYS, and their reduction noise is studied by test. It is shown that optimal designed and original gears filled aluminum foam are superior to original gear in dynamic properties and noise reduction. The first two types of gears are greater than original gear in the natural frequencies of the first 5 modes, the maximum increase is 16.1 and 1.9 percent respectively. In the same rotation speed, the first two types of gears are less than original gear in the amplitude of the first 5 modes, the maximum reduction is 10.0 and 5.4 percent respectively. The first two types of gears are lighter 10.92 and 15.93 percent than original gear, respectively. So gear filled aluminum foam is effective in improving light natural, vibration and noise reduction of large gear.