风机齿轮箱太阳轮花键失效分析研究

Failure Analysis of Sun Gear Splines in Fan Gearboxes

针对风机齿轮箱太阳轮花键失效问题,通过对失效花键进行化学成分、显微组织、微观断口以及力学性能的试验分析,查明花键键齿发生磨损的原因。结果表明,中间轴(Inter Mediate Shaft,IMS)太阳轮电机侧花键金相组织中存在较多杆状和不等轴块状或岛状未溶铁素体,降低了材料的耐磨性;IMS太阳轮花键失效主要是齿面硬度低,同时受疲劳磨损、化学腐蚀、磨粒磨损等几种磨损机制的综合作用,齿面出现严重磨损,导致IMS太阳轮电机侧花键承载力下降,力的传递不平稳,运行中振动加剧,致使齿轮箱失效。试验结果可为风电齿轮箱故障检测与诊断提供一定的理论指导。

In view of the failure problem of sun gear splines in fan gearboxes,through the analysis of the chemical composition,microstructure,microfracture and mechanical properties of the failure spline,the cause of the spline wear is found out.The results show that there are more rods,unequal axes or islands of the undissolved ferrite in the metallographic structure of inter mediate shaft(IMS) sun gear motor side splines,which reduces the wear resistance of the material.The failure of sun gear splines is mainly caused by low tooth surface hardness.At the same time,due to the comprehensive action of fatigue wear,chemical corrosion,abrasive wear and other wear mechanisms,serious tooth surface wear occurs,resulting in a decrease of the bearing capacity of IMS sun gear motor side splines.The force transmission is not smooth,and the vibration is aggravated during operation,resulting in the failure of the gearbox.The test results can provide some theoretical guidance for the fault detection and diagnosis of wind power gearboxes.