线形初始缺陷下斜齿轮磨损特征演变研究

Research on Wear Characteristics of Helical Gear with Linear Initial Defects

为揭示用于风电、水利轮船等大型齿轮在存在初始缺陷下的摩擦磨损特征,避免早期灾难性故障的发生,对线形初始缺陷下斜齿轮磨损特征与演变过程进行实验研究。采用控制变量法,通过电火花线切割的方式沿齿宽方向加工出线形初始缺陷。为加速实验进程,实验齿轮的齿宽为标准齿轮的1/3。实验过程中采用功率闭流式加载方式施加高扭矩恒定载荷,使用颗粒计数器和分析式铁谱仪分析油样磨粒,并利用扫描电镜观测并分析齿面磨痕形貌。结果表明:线形初始缺陷会加速齿轮齿面磨损,导致齿轮提前进入疲劳磨损阶段,并引起齿面发生严重损伤,产生的磨粒尺寸较大;齿轮啮合产生的油泥污染物会加剧缺陷处的磨损,从而导致齿轮断裂失效。

In order to reveal the friction and wear characteristics of large gears used for wind power and hydraulic ship and avoid the occurrence of early catastrophic failures, the wear characteristics and evolution process of helical gears under linear initial defect were studied experimentally. The control variable method was adopted to process the linear initial defect along the tooth width direction by means of EDM cutting.In order to speed up the experimental process, the tooth width of the experimental gear was 1/3 of that of the standard gear. In the experiment process, the power closed current loading method was used to apply a constant load of high torque, particle counter and analytical iron spectrometer were used to analyze the abrasive particles in the oil sample, and the wear condition of tooth surface was observed and analyzed by using scanning electron microscope. The results show that the linear initial defect can accelerate gear wear, lead to the gear entering the fatigue wear stage in advance, and cause serious damage to the tooth surface, resulting in large size of abrasive particles;the oil sludge produced by gear meshing aggravates the flaw and generates to the failure of the gear.