高载荷下人字齿轮传动点接触混合润滑机理与粘着磨损计算方法研究

Lubrication failure and adhesive wear are the most outstanding problems for double helical gear, which is the core component of the main drive system in a large-scale or complete equipment. However, the solving problems are mainly determined by a breakthrough in the basic theory and key technology on gear lubrication and wear. So this project focuses on a heavy-loaded double helical gear with the consideration of its error, modification and deformation. Hence, the key researches of the project comprise the mechanism and model of mixed transient thermo-elastohydrodynamic lubrication in point contact, and the adhesive wear model and the wear-reduced method as the effects of high temperature rise and dynamic friction considered. Furthermore, the main researches on the point-contact mixed lubrication (PCML) of the double helical gear include: PCML mechanism under heavy load, the rheological model of a high shear rate film, PCML calculation model and the elastic-plastic asperities contact model with fiction, and the optimization method for lubrication performance. Meanwhile, the main researches on the adhesive wear of the point-contact profile include: the calculation method of slide path and distance, the multi-nest algorithm of wear height and profile recalculation in the group of contact ellipses, the calculation methods of temperature coefficient, adhesive friction coefficient and the wear coefficient with the consideration of elastic-plastic asperity, and the methods for parameter analysis and wear reduction. According to the research results of this project, the part theoretical basis is provided for the high-performance double helical gear design with reducing friction and wear, and the capacity of independence innovation on a high-end gear and its equipment is partly increased as well.

作为大型装备或成套设备主传动系统的核心元件，高载荷人字齿轮传动的润滑失效与粘着磨损已成为最突出的问题，解决该问题的根本在于齿轮润滑与磨损基础理论和关键技术的突破。本项目以高载荷下含误差、修形和变形的人字齿轮传动为研究对象，重点研究瞬态热弹流的点接触混合润滑机理与计算模型，和考虑高温升和动摩擦的齿面粘着磨损模型与减磨设计。点接触混合润滑研究的主要内容：高载荷下点接触混合润滑机理；高切应变率油膜的流变模型；点接触混合润滑计算模型与粗糙表面多微凸体弹塑性侧接触模型；润滑性能优化方法。点接触齿面粘着磨损研究的主要内容：滑移路径与滑移距离的计算方法；接触椭圆族磨损高度与齿形重算的多重嵌套算法；温度修正系数、粘着摩擦系数与考虑微凸体塑性的磨损系数的计算方法；参数分析与减磨设计方法。本项目的完成将为高性能人字齿轮的减摩耐磨设计提供一定的理论依据，一定程度上提升我国高端齿轮产品及其装备的自主研发能力。

本项目以高载荷下含误差、修形和变形的人字齿轮传动系统为对象，结合理论模型、数值方法与测试技术研究了其点接触瞬态热弹流混合润滑机理与计算模型，和考虑温升和粗糙表面接触的齿面粘着磨损模型与减磨设计。根据点接触润滑理论，建立了鼓形修形人字齿轮非牛顿准稳态及瞬态热弹流混合润滑数值计算模型，并研究了恒加速启动过程中的时变混合润滑特性。基于提出的标准与修形齿轮非牛顿弹流动压润滑的油膜刚度与阻尼模型，对高速重载齿轮的瞬态微弹流力热特性以及含油膜刚度-阻尼的齿轮动力学效应进行了研究。考虑高速弹性轴和转子的陀螺效应以及基于反求计算的润滑齿面摩擦系数，建立了齿轮-转子-轴承系统的弹性摩擦动力学模型。基于Archard磨损计算通式，提出了一种标准斜齿轮和含滚齿加工误差的直齿轮齿面粘着磨损的计算方法。结合提出的通用滑动距离计算模型，计算了标准和鼓形修形人字齿轮的齿面磨损深度。基于随机统计学理论，对磨损后2-D和3-D粗糙齿面进行了重构，基于累和的思想计算了齿面的压缩量与实际接触载荷和面积。基于真实粗糙齿面和弹性理论，采用分段线性插值计算粗糙齿面接触压力，并应用于齿面磨损计算。根据扩展的Archard磨损模型，计算了混合润滑下直齿轮和斜齿轮的齿面磨损量。结合点接触非牛顿瞬态热弹流混合润滑模型，对不同材料配副在混合润滑下的磨损率与磨损量进行了分析。上述研究对高性能人字齿轮润滑与减摩耐磨设计具有一定的指导意义，对高端齿轮产品的设计制造具有一定的工程意义。