高速数滚机床齿轮箱轮齿失效分析

针对数滚机床齿轮箱渐开线齿轮疲劳和磨损严重的问题,通过二次元影像测仪、齿轮检测仪、表面粗糙度仪和硬度计分别对齿轮的齿面微观形貌、轮廓和齿面硬度、粗糙度进行研究。结果发现,从动轮表面出现明显的划痕损伤,表面粗糙度达到了1.340,从动齿轮疲劳磨损后齿廓总偏差Fα为0.89μm,主动轮的磨损量是其2.5倍;主动轮表面有明显的微观切削形貌,表面粗糙度Ra为0.6μm,显微硬度明显大于从动轮的齿面硬度。造成齿轮严重疲劳和磨损的主要原因是:主齿轮和从动齿轮的表面粗糙度和硬度参数不匹配。齿轮的根部有一个深切削槽,齿根处局部应力集中,产生裂纹源,使主动轮磨损恶化。

Dynamic characteristics of gear system under different micro-topographies with the same roughness on tooth surface

The topography of gear meshing interfaces is one of the key factors affecting the dynamic characteristics of the gear transmission system.In order to obtain the contact characteristics of meshing gear pair with different surface micro-topographies,an interface feature model and a tribo-dynamics coupling model for the gear system are proposed in this paper.The effects of the gear tooth surface micro-topography on the oil film distribution,contact damping and friction are considered.The time-varying meshing stiffness and the static transmission error are included in the abovementioned models.An exemplary gear pair is analyzed using the proposed models to investigate the influence of the surface micro-topography on the dynamic characteristics of gear system under different micro-topographies and input torque conditions.Simulation results show that the effects of gear tooth micro-topography on the gear dynamic responses(including the friction and the vicious damping at the gear meshing interface and the vibration in the direction of offline of action)are highly dependent on the regularity of tooth surface.The vibration and noise can be significantly controlled by manufacturing a regular gear tooth profiles instead of random profiles.

某减速器圆柱齿轮磨损失效分析

针对某型减速器圆柱齿轮磨损严重的问题,通过激光共聚焦显微镜、白光干涉仪和硬度计分别对齿轮的齿面微观形貌和表面硬度进行检测,检测结果发现经磷化渗氮后的从动轮表面有明显的不规则纹理,并且表面粗糙度R_a达到0.87μm,显微硬度大于经渗碳后喷丸处理的主动轮;主动轮表面有明显的凹坑形貌,表面粗糙度较低,R_a在0.50μm左右,根据检测结果分析认为主动轮磨损严重的主要原因为:主、从动轮齿表面粗糙度与硬度不匹配;从动轮微观表面的抗磨损Abbott曲线优于主动齿轮。