变速器输出轴花键磨损原因分析

Analysis on the Reasons for Spline Wear of Transmission Output Shaft

本文针对变速器输出轴与同步器齿毂花键过度磨损问题,校核了磨损花键的连接强度并进行了台架试验验证;同时分析了内外花键配合间隙、材料、表面硬度、表面粗糙度及传动轴当量夹角对输出轴的影响,判断传动轴当量夹角引起的输出轴微幅振动、花键间隙配合、花键润滑不足三方面原因共同导致的花键磨损;并通过传动轴带当量夹角的台架疲劳试验复现了磨损花键的故障表现,同时确认了传动轴当量夹角是导致花键磨损的主要原因。根据原因分析结果,将输出轴与齿毂花键齿侧的间隙配合调整过盈配合,同时对花键位置的润滑进行了加强,最终通过传动轴带当量夹角的台架疲劳试验验证了改进措施效果良好,为花键设计、故障处理提供了强有力的参考及指导意义。

In this paper,aiming at the excessive wear of the splines between the transmission output shaft and the synchronizer hub,checked the connection strength of the worn splines and verified by bench tests.And analysis the influence of internal and external splines fit clearance,material,surface hardness,surface roughness and equivalent angle of the transmission shaft on the output shaft.Judging the spline wear caused by the output shaft’s slight vibration caused by the equivalent angle of the transmission shaft,the spline clearance fit,and the lack of spline lubrication caused spline wear.And through the bench fatigue test of the equivalent angle of the transmission shaft,the failure of the worn splines is reproduced,and confirmed that the equivalent angle of the transmission shaft is the main cause of spline wear.According to the result of cause analysis,adjust the clearance fit of the spline tooth between the output shaft and the synchronizer hub to interference fit.And strengthen the lubrication of spline.Finally,through the bench fatigue test of the equivalent angle of the transmission shaft,verified that the improvement measures are effective,which provides a strong reference and guiding significance for spline design and fault handling.