电动汽车变速器用复合材料齿轮设计与研究

Design and Research of Composite Gear for Electric Vehicle Transmission

为了降低汽车变速器的重量、噪声和振动,对复合材料齿轮进行了研究,提出了一种新型的钢与芳纶/苯酚复合变速器齿轮,并给出了其优化设计。该方法将聚合复合材料沿齿轮的径向放置在钢齿和中心轮毂区域之间,以便降低从齿到轮毂的振动传递以及齿轮系的重量。为了最小化复合齿轮的重量,通过考虑钢和复合材料的疲劳强度,计算出了齿轮径向复合区的最佳尺寸。采用有限元方法和边界元法,对纯钢齿轮和复合齿轮进行了振动、噪声和优化分析。研究结果表明,相比于纯钢齿轮,优化和未优化复合齿轮的平均声压级分别降低了7.2%(53.2 dB)和4.6%(54.7 dB),平均加速度分别降低了15.3%(62.7 dB)和12.0%(65.2 dB),验证了聚合复合材料区域和优化设计的有效性。

In order to reduce the weight,noise and vibration of automobile transmission,the composite gear was studied,a new type of steel and aramid/phenol composite transmission gear was put forward,and its optimal design was given. In this method,the polymer composite was placed between the steel tooth and the central hub area along the radial direction of the gear,so as to reduce the vibration transmission rate from the tooth to the hub and the weight of the gear train. In order to minimize the weight of the composite gear,the optimum size of the radial composite zone of the gear was calculated by considering the fatigue strength of steel and composite materials. The vibration,noise and optimization design of pure steel gear and composite gear were analyzed by finite element method and boundary element method. The results show that,compared with pure steel gears,the average sound pressure levels of optimized and un-optimized composite gears are reduced by 7.2%(53.2dB) and 4.6%(54.7dB),respectively,and the average acceleration is reduced by 15.3%(62.7dB) and 12.0%(65.2dB),respectively,which verified the effectiveness of the polymer composite area and optimized design.