极端工况下航空弧齿锥齿啮合动态微观应力循环与疲劳胶合机制

This project mainly focuses on the key issues that the tooth surface is resulted in premature fatigue and scuffing under extreme condition, such as high speed, overload and acceleration etc. in spiral bevel gears of new generation helicopter and aero-engine. Based on the available research results, involving the mixed EHL with a number of testing technologies, this project is proposed to break through the traditional simplified design methods from macro/micro-scale by employing the theory of spatial meshing, interfacial mechanics, tribology and heat transfer. The objectives include investigating the 3D thermal mixed lubrication in spiral bevel gears, the mechanism of dynamic microscopic stress cycle and transient/steady temperature rise, contact fatigue & scuffing and multi-scale life optimization method, lubricating film and comprehensive performance test, etc. It is expected to reveal the failure mechanism of microscopic stress cycle and premature fatigue & scuffing in spiral bevel gears under extreme condition, and propose the prediction method of fatigue and scuffing life based on the multi-scale features of interface. Major breakthroughs and patents are expected in the fundamental researches of the application of spiral bevel gears, so that the theoretical basis can be applied for the active control of the fatigue life of some project conducted by the China Gas Turbine Establishment.

本项目针对我国新一代直升机、航空发动机等航空装备弧齿锥齿传动迫切需要解决高速重载、瞬间加速/制动等极端工况下啮合齿面远早于设计预期发生疲劳与胶合的科学难题，在取得混合润滑分析方法及多项测试技术等成果基础上，从宏/微多尺度出发，旨在突破传统简化设计方法，运用空间啮合原理、界面力学、摩擦学、传热学等多学科交叉理论和方法，开展航空弧齿锥齿全尺度三维热混合润滑分析、啮合瞬/稳态温升与动态微观应力循环、齿面疲劳胶合评价及多尺度延寿调控、界面润滑成膜与传动齿面疲劳胶合实验等创新研究，建立高速重载、瞬间加速/制动等极端工况下航空弧齿锥齿传动齿面动态微观应力循环表征方法，揭示疲劳与胶合寿命快速退化机理，提出基于界面多尺度特征的齿面疲劳胶合预测及延寿调控方法，力争在新一代航空装备弧齿锥齿传动研发手段方面有重要突破和创新，为我国航发涡轮院等单位有关国家型号工程实现弧齿锥齿疲劳胶合的主动控制提供设计与分析手段。

在国家自然科学基金委员会的大力支持下，通过本项目组全体成员的共同努力，围绕项目计划，揭示了弧齿锥齿轮传动接触区几何与轮齿设计参数的耦合关联机制；建立了弧齿锥齿轮瞬态混合润滑模型，实现了弧齿锥齿轮极端工况下的润滑特性模拟和分析；提出了考虑真实机加工粗糙度和任意卷吸夹角的三维热弹流混合润滑模型，揭示了弧齿锥齿轮传动界面的热耦合混合润滑机理；建立了混合润滑下啮合界面摩擦温升和抗胶合承载能力预测模型，揭示了弧齿锥齿轮的胶合特性；建立了弧齿锥齿轮接触界面粗糙峰滑滚接触微应力循环接触疲劳寿命模型，揭示了不同参数下滑滚接触疲劳寿命演变的规律。开展了齿面润滑摩擦相关实验验证研究，验证了本项目建立相关模型的科学性。培养教育部青年长江学者1名，获授权发明专利6项，在Friction、Tribology International 等国内外权威期刊发表SCI/EI论文23篇，培养博士研究生3名，硕士研究生5名，培养学生获2022年度“挑战杯”全国大学生课外学术科技作品竞赛全国特等奖。