航发主轴轴承全参量控形控性防打滑异形外滚道设计方法

As a key component of aircraft engine spindle, angular contact ball bearing becomes more prone to skidding in high speed and light load condition. Bearing failure caused by skidding can reach 34.46%. Therefore, how to prevent skidding effectively becomes an urgent technical problem in the field of aircraft engine bearing. In this project, the angular contact ball bearing outer raceway of aircraft engine spindle will be taken as object, for controlling performance (anti-skidding) by controlling shape (raceway surface). The fully parametric drived mathematical model of the raceway is constructed with Fourier series to characterize any possible raceway surface for analyzing the relationship between parameters of mathematical model of outer raceway and structural parameters of bearing. A time varying contact characteristics of roller and irregular raceway will be analyzed for exploring the influence of the time varying contact characteristics on thickness distribution of oil film. Considering effect of gyroscopic effect, nonlinear contact between roller and cage and working condition parameters, a skidding model of angular contact ball bearing will be built based on thickness distribution of oil film, and the influence rule of raceway shape on skidding characteristics will be revealed. Aiming at the non-skidding and minimum heating up, a inverse design model of the irregular raceway will be established, based on the model, a theoretical optimal raceway surface with minimum temperature and anti-skid performance will be obtained, and then a complete design method for anti-skid of aircraft engine spindle will be formed. The results of this project provide a theoretical basis for the design of anti-skid aircraft engine spindle bearing.

角接触球轴承作为航发主轴关键部件，在高速轻载工况下，极易发生打滑，打滑造成的轴承失效可达到34.46%，因此，如何有效地防止打滑，成为航发主轴轴承技术领域亟待解决的问题。本项目以航发主轴角接触球轴承外滚道为研究对象，以实现控形(滚道曲面)控性(防打滑)为目标，采用傅里叶级数建立异形外滚道全参量广义泛函数学模型，以表征任意可能滚道曲面形状，分析异形外滚道数学模型参数与轴承结构参数之间的映射关系；建立滚动体与异形外滚道和内滚道时变接触特性分析模型，探索滚动体与内外滚道时变接触关系对油膜厚度分布的影响规律；结合油膜厚度分布，计及陀螺效应、滚动体与保持架非线性接触和工况参数建立轴承打滑分析模型，揭示异形外滚道曲面形状对打滑特性的影响规律；以不发生打滑和温升最小为目标，建立异形外滚道反设计模型，获得兼具温升最小和防打滑性能的理论最优滚道曲面，形成完整的设计方法，为航发主轴轴承防打滑设计提供理论依据。

在高速轻载工况下，航发主轴轴承极易发生打滑，打滑造成的轴承失效可达到34.46%，因此，如何有效地防止打滑，成为航发主轴轴承技术领域亟待解决的问题，这是本项目的初衷。随着研究的深入，高速轻载打滑是航发主轴轴承动态性能一个重要方面，单纯的降低打滑率可能会导致轴承寿命受到影响，因此，本项目以航发主轴轴承综合动态性能提升为终极目标开展以下研究：. 1. 针对航发主轴轴承（角接触球轴承和圆柱滚子轴承），结合空间解析几何理论、弹流润滑理论、弹性接触理论等，基于Gupta理论框架，建立了角接触球轴承和圆柱滚子轴承全参量动力学模型，采用四阶变步长龙格库塔法进行求解，搭建了高速轴承保持架运动状态试验机，验证了模型的有效性；. 2. 基于全参量动力学模型，系统分析了轴承结构全部重要参量：滚道形面、滚动体数量、轴/径向游隙、保持架兜孔间隙、引导间隙等轴承结构参数对轴承接触应力、打滑、最大冲击力、保持架涡动偏差比、功率损失（温升）等动态性能参数的影响规律，研究结果表明，角接触球轴承的打滑问题可以通过调整预紧力加以抑制，而圆柱滚子轴承打滑的抑制较为复杂，它受轴承结构参数的影响极为显著；. 3. 以影响轴承综合动态性能最为显著的三个指标：最大冲击力、涡动偏差比（衡量打滑）和功率损失（衡量温升）为目标，以轴承结构参数为自变量，开展了基于动力学分析的轴承多目标优化方法研究，首先采用响应面法建立了三个性能指标的回归模型，而后对航发主轴轴承进行了多目标优化，实现控形控性。在典型工况下，经过优化的轴承各项动态性能指标均优于现有产品的性能，相关成果已在某型号发动机上得到应用。