长寿命重型变速器齿轮断裂分析与研究

The fracture analysis on the long lifetime heavy duty transmission gear

针对正在开发中的某商用车长寿命重型变速器副箱低挡齿轮台架试验断裂问题,从齿轮材料、金相组织及热处理、机械加工、齿轮强度仿真计算分析、齿轮润滑系统和喷丸工艺等多个方面进行了详细分析和研究,讨论齿轮断裂的原因,最终提出了通过调整齿轮喷丸工艺和参数,即增大齿轮齿面和齿根残余压应力大小的改进措施,改进后的台架通过了试验验证,通过总结该变速器的齿轮开发经验,可为满足高可靠性、长寿命重型变速器齿轮开发提供设计参考。

Aiming at gears fracture at bench test for a long lifetime heavy duty transmission of commercial vehicle,it analyzes the reason of fracture in details such as the gear material,metallographic structure and heat treatment,mechanical machining,gear strength simulation,gear lubrication system and shot peening process. It discusses the possible reason of fracture,proposes that the regulation of the shot peening technique and parameters can increase the compressive residual stress of the gear flank and gear root. The test validates the analysis. It summarizes the development experience of transmission gears,supplies the design reference of the reliability and long lifetime heavy duty transmission gears.