面向跨尺度自润滑齿轮的齿面构型设计及接触承载特性研究

For the sake of solving the problems such as easy peeling of coating and low life of existing self-lubricating gears, a novel configuration about cross-scale tooth surface is proposed in order to achieve the goal of designing and manufacturing the self-lubricating gear with the characteristics of good tribological properties and high transmission reliability. After investigating the configuration of cross-scale tooth surface, the macro-micro configuration parameters of cross- scale tooth surface are determined. Through analyzing tribological properties of self-lubricating tooth surface, the mechanism that configuration parameters influence the friction reduction properties of self-lubricating tooth surface is clarified, the rule of antifriction and wear resistance of self-lubricating gear is discovered. The fractal model of the contact stress calculation for the self-lubricating tooth surface with anisotropic characteristics is constructed, which is used to analyze the effect of the configuration parameters on the contact strength. By employing the theory of Blok flash temperature, the numerical solution for calculating contact temperature of self-lubricating tooth surface is explored, thereby the association between the configuration parameters and scuffing load capacity is obtained. The optimization strategy of configuration parameters considering multi objectives is worked out to achieve the overall excellent performance for self-lubricating tooth surface in terms of friction reduction and contact bearing characteristics. Finally, the methodology of configuration design and theory of contact bearing analysis for self-lubricating gear with cross scale are set up. The research is expected to effectually expend structure system of self-lubricating gear, which lays a theoretical foundation for its application in the condition of oil-free, lack of oil, high vacuum and strong radiation.

为了解决现有自润滑齿轮涂层易脱落、寿命低等问题，本项目提出一种全新的跨尺度自润滑齿面构型设计方案，以期实现摩擦学特性好、传动可靠性高的自润滑齿轮设计制造目标。拟进行自润滑齿面构型方案设计，确定齿面宏、微跨尺度构型参数；分析自润滑齿面的摩擦学特性，厘清构型参数对齿面减摩特性的影响机制，揭示跨尺度自润滑齿面的减摩、耐磨规律；构建具有各向异性特征的自润滑齿面接触应力计算分形模型，用于其接触疲劳强度分析；基于Blok闪温理论，探讨自润滑齿面接触温度的数值求解方法，得出构型参数与胶合承载能力之间的关联；制定考虑多目标的构型参数优化策略，达到自润滑齿面在减摩和接触承载特性方面综合最优；最终建立跨尺度自润滑齿轮构型设计方法与接触承载分析理论。该研究可有效扩充自润滑齿轮结构体系，为其在无油或乏油、高真空、强辐射等环境下的应用奠定理论基础。

本项目以跨尺度自润滑齿轮为对象，研究齿面构型参数对其摩擦学性能以及接触承载特性的影响机理。主要完成工作如下：设计跨尺度自润滑齿面构型，通过摩擦磨损试验台测试不同自润滑材料的摩擦学性能，确定自润滑材料最佳成分配比；根据流体动压润滑理论，建立表面交叉网状沟槽润滑的数学模型，获得跨尺度构型参数对微沟槽表面减摩特性的影响规律；建立齿面微观形貌影响下的跨尺度自润滑齿面接触应力计算模型，获得齿面粗糙度和分形维数等齿面微观因素与齿轮接触力学特性之间的关联规律；结合传统齿轮扭转动力学模型，建立齿面微观形貌影响下的齿轮非线性动力学模型，实现解析法分析齿面微观参数对齿轮系统动力学的影响。采用电化学法与激光加工方法制作跨尺度自润滑齿轮，搭建齿轮传动性能动态检测平台，开展跨尺度自润滑齿轮动力学性能验证试验，检测跨尺度自润滑齿轮的自润滑效果及传动性能，结果表明：在干摩擦条件下，自润滑齿轮的平均啮合噪声声压级比普通无织构齿轮低6.4dB；在边界润滑条件下，自润滑齿轮的平均啮合噪声声压级比普通无织构齿轮低7.5dB，且传动效率也比普通无织构齿轮高1.1%。本项目的研究成果为齿轮在无油/乏油、高（低）温、高真空、高负荷和强辐射等极限工况下的应用奠定理论基础，对于改善齿面啮合噪声以及提高军事武器和航空航天装备可靠性有着积极促进的作用。