基于误差规律的汽车主驱动FH准双曲面齿轮齿面再设计方法研究

To improve the strength and dynamic performance of face-hobbed(FH) hypoid gears that in the main reducer of automotive drive axle and cannot be ground, a redesign methodology is proposed to solve the problem of lower bearing capacity, vibration and noise caused by machining error and heat treatment deformation. The real tooth surface model that can reveal the deviation role will be built based on statistical analysis of measurement data and surface fitting and smoothing, the generating method of conjugate tooth surface will be studied as well; Meanwhile, the internal relations of tooth contact pattern and transmission error will be explored through tooth contact analysis and loaded tooth contact analysis, and the synthesized optimization design method of them will be studied; Then the optimal ease-off that meet the functional requirements will be developed based on conjugate tooth surface and key parameters of tooth contact pattern and transmission error, by which the change law of tooth surface geometry under different functional requirements will be estimated and the optimal tooth surface as well as the adjustments of machining parameters will be obtained; Finally, we will carry out the gear cutting, tooth surface measuring and meshing experiments. We mainly focus on seeking a way to achieve the predetermined meshing performances via only one modification while the tooth surface error occur and there is no finishing modification after heat treatment, so as to provide the theory and application basis for independent design and high-efficiency-low-coat manufacture of high-performance face-hobbed hypoid gears in automotive drive axle.

为解决机加工误差和热处理变形引起的汽车主驱动FH准双曲面齿轮承载能力降低及振动噪声问题，以提高其强度和动态性能为目标，围绕提高FH准双曲面齿轮啮合性能的齿面再设计方法展开研究。通过齿面测量数据统计分析、曲面拟合及光顺处理，建立可反映实际齿面误差一般规律的高精度数字化真实齿面模型，研究真实齿面的共轭齿面展成方法，同时采用空间齿面几何接触分析和承载接触分析，揭示齿面接触印痕和传动误差曲线的内在联系，研究其综合优化设计方法。进而结合优化获得的接触印痕及传动误差曲线的关键参数，基于共轭齿面构建最优配对齿面ease-off，探明不同功能需求下齿面几何拓扑的变化规律，并反求齿面及加工参数，开展切齿、齿面测量和啮合传动试验研究。获得大、小轮齿面均存在误差且无热后精加工修形条件下，通过一次修正实现预期啮合性能的有效途径，为自主设计高性能驱动桥FH准双曲面齿轮并实现其高效低成本制造提供理论与应用基础。

汽车驱动桥FH准双曲面齿轮的滚齿加热后研齿工艺，因其所需设备少、生产效率高，特别适用于大批量生产的汽车工业。但不可避免的机加工误差、热处理变形，以及研磨不具备齿面修形能力，致使齿面误差无法消除，引起偏载、振动噪声和承载能力降低等一系列问题，这严重阻碍了这一具有潜在优势的驱动桥齿轮的性能提升及其向高端应用领域的发展。因此，本项目提出基于误差规律的汽车主驱动FH准双曲面齿轮齿面再设计方法研究。首先，充分利用已有齿面测量数据库，探索同一产品在相同冷热加工条件下的齿面误差规律，拟合获得可反映实际齿面误差规律的高精度数字化真实齿面模型，并提出一种基于实测齿面数据的驱动桥FH准双曲面齿轮数字化滚检技术，探讨了这一技术在齿轮闭环制造乃至智能制造中的应用前景；其次，基于共轭啮合原理展成小轮共轭齿面，并在这一基准齿面上进行了配对齿面ease-off的主动优化设计，通过预置接触印痕及传动误差以兼顾齿轮传动的强度和动态性能要求；第三步，建立了双面法加工齿轮的双侧齿面误差最小优化模型，并在齿面误差敏感性分析的基础上，进行了最优配对齿面的加工参数反求；最后，进行了切齿、齿面测量以及啮合传动等实验研究。实验结果表明本项目所提出理论方法可行且具有一定精度。本项目提出的这种在目前机加工误差和热处理变形条件下、能够在热前有效控制并提高驱动桥FH准双曲面齿轮啮合性能的预修正方法，仅需进行一次修正便可综合考虑大、小轮实际齿面误差，有利于缩短生产周期，减少刀具成本，解决了实际齿面误差存在条件下、满足功能需求的不磨齿齿轮的再设计和制造问题，为高性能驱动桥准双曲面齿轮的高效低成本制造提供了理论与应用基础。