新型Hy-Vo齿形链多元变异设计方法及其疲劳可靠性试验研究
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摘要
Hy-Vo齿形链是齿形链产品中的一种重要类型，具有高速性能好，承载能力强，耐磨性好等优点。由于Hy-Vo齿形链的“变节距”在啮合过程中能够显著减少传动中的多边形效应、降低传动噪声，因而近年来广泛应用于汽车变速箱、分动箱、汽轮机工业泵等高速传动中。齿形链按照啮合机制的不同主要分为外啮合机制Hy-Vo齿形链、内-外复合啮合机制Hy-Vo齿形链和外啮合+内-外复合啮合机制Hy-Vo齿形链。
本论文是在国家自然科学基金项目“基于多元变异的新型Hy-Vo齿形链啮合设计理论（50975117）”和“基于复杂约束边界条件下的多轴高速齿形链系统啮合设计理论”（51275207）以及国家高技术研究发展计划项目（863）“基于复杂多元变异的Hy-Vo齿形链数字化方法研究及平台开发（2009AA04Z109）”的资助和支持下，对Hy-Vo齿形链的啮合机理进行了深入的研究，并针对Hy-Vo齿形链的多元变异特性进行了通用设计方法的研究，同时研究了其啮合设计体系、动力学仿真技术、导板设计方法以及疲劳试验方法。
论文在分析比较Hy-Vo齿形链分类及不同啮合机制的基础上，针对Hy-Vo齿形链啮合机制变异、形状变异、参数变异等变异特性进行了系统的研究，基于学科与行业技术发展趋势，首次提出多元变异的概念，并指出以啮合机制与传动特性变异为主体的多元变异过程，就是Hy-Vo齿形链产品系列创新升级的过程，也是行业需求和技术进步的必然趋势。
论文在分析研究链轮滚刀与链轮滚切原理的基础上，根据Hy-Vo齿形链与链轮的啮合原理，首次构建了基于多元变异的Hy-Vo齿形链啮合设计体系，并指出将Hy-Vo齿形链工作链板齿形视为滚刀法向齿形，是建立Hy-Vo齿形链-链轮-刀具齿条的啮合设计体系的基本条件。通过分析Hy-Vo齿形链与链轮的啮合原理，首次提出Hy-Vo齿形链相邻工作链板的基准圆圆心连线延长线的交点位于齿槽对称中心线上是实现Hy-Vo齿形链正确啮合定位的必要条件，这与套筒滚子链传动以及齿轮传动的正确啮合条件是根本不同的。
论文以同一规格、同一节距的两种变异HV3型非圆形基准孔的内-外复合啮合Hy-Vo齿形链为例，通过设计计算与分析，并提出在满足Hy-Vo齿形链-链轮-刀具齿条三者正确啮合的条件下，可以通过多元变异手段，设计出参数不同的一族新型传动，以满足众多主机不同的“个性化”需求。同时，通过两种链条系统的平稳传动试验结果表明，基于多元变异的Hy-Vo齿形链设计方法是科学的，切实可行的。并提出多元变异设计方法是实现Hy-Vo齿形链产品创新升级和知识产权保护的重要手段。
论文在参考精密滚子链疲劳可靠性试验方法的基础上，首次对Hy-Vo齿形链疲劳试验方法进行了研究，并提出了为节约试验时间，可提高一个载荷系数等级获得24F-N方法试验数据；提高试验载荷后的疲劳寿命曲线相比未提高试验载荷的曲线要保守一些。通过对比研究14F-N方法和24F-N方法，提出粗估链条寿命时，可采用14F-N方法并提高一个载荷系数；R=50%的R-F-N曲线可以由14F-N方法获得；14F-N方法和24F-N方法所得到的疲劳寿命曲线形式基本一致。论文同时对新型Hy-Vo齿形链进行了疲劳试验研究，结果表明链条在满足抗拉强度要求的情况下，不一定能够满足疲劳性能要求，证明研究链条疲劳寿命的重要性。
论文在分析齿形链导板的作用及导板对Hy-Vo齿形链装配及受力影响的基础上，通过对Hy-Vo齿形链导板的研究，首次提出了Hy-Vo齿形链导板的设计方法，并进行了有限元分析和试验研究。研究发现，在不影响导板抗拉强度的条件下，蝴蝶状导板腰部上端圆弧半径RG越大越好；在满足导板抗拉强度的条件下，尽量减小HG的高度，如果中间圆弧最低点高于销轴中心连线，应适当加大两者之间的距离。研究结果表明Hy-Vo齿形链可以通过设计合理的蝴蝶状导板在拉伸过程中的变形来补偿间隙。同时研究成果应用于工程实际，给相关行业带来了良好的经济效益。
论文在分析多体动力学接触搜索算法的理论基础上，采用Recurdyn动力学仿真软件，针对多元变异设计方法设计出的三种不同链板型式组合的新型Hy-Vo齿形链进行了多链节的运动学和动力学仿真分析。仿真结果表明，采用多元变异设计方法获得的Hy-Vo齿形链，通过不同啮合机制链板的有序组合，可以根据用户的个性化需求派生出多种Hy-Vo齿形链新产品。通过分析研究三种Hy-Vo齿形链的多边形效应变化规律发现，在一定范围内，新型Hy-Vo齿形链中内-外复合链板数越多，多边形效应越小，且有序排列的新型Hy-Vo齿形链综合性能要优于纯外啮合机制Hy-Vo齿形链和纯内-外复合啮合机制Hy-Vo齿形链。通过分析研究新型Hy-Vo齿形链的动态接触响应发现，同一新型Hy-Vo齿形链在同一时间和同一水平位置时，同一链板所对应的两对销轴的接触力并不相同，因此不能简单的通过分析一个链节的受力，判断其它链节的受力情况，为Hy-Vo齿形链动力学研究提供了重要的理论指导。
Hy-Vo silent chain is an important type of silent chain products, whichcharacterizes good high-speed performance, strong bearing capacity, greatabrasion resistance, etc. The variable pitch characteristic of Hy-Vo silentchain can apparently depress chordal action, impact and noise during silentchain meshes with the sprocket, as a result the Hy-Vo silent chain is widelyused for automobile gear box, transmission box, industry pump and otherhigh velocity transmission. According to the difference of the meshingmechanism, the silent chain is divided into three types: outer meshingmechanism Hy-Vo silent chain, inner-outer meshing mechanism Hy-Vosilent chain and outer and inner-outer meshing mechanism Hy-Vo silentchain.
Supported by the Project of National Natural Science Foundation ofChina the Meshing and Design Theories Based on the Multi-variant andNew Hy-Vo Silent Chain (50975117) and the Design Theory ofMultiaxial High Speed Silent Chain System Based on Complex ConstraintBoundary Conditions (51275207) and National High Technological andDevelopmental Plan Project(863)titled Digital Method Research and Platform Development Based on the Sophisticated and Divesified Hy-VoSilent Chain (2009AA04Z109)，the meshing mechanism of Hy-Vo silentchain, a deep research is conducted on the general design method of Hy-Vosilent chain’s multi variation characteristic and meshing design system anddynamic simulation technology and guide design method and fatigue testingmethod.
Based on analysis and comparison of different Hy-Vo silent chain typesand meshing mechanism, a systematic study is carried on Hy-Vo silent chainmeshing mechanism variation and shape variation and parameters variationand other variation characteristics. Based on the development trend ofdiscipline and industry technology, this thesis firstly raises the concept ofmulti variation, and points out that the multi variation process which ischaracterized by meshing mechanism and transmission characteristics, is justthe process of Hy-Vo silent chain products innovation and upgrade, as wellas the inevitable trend of industry requirements and technology progress.
Based on analysis and study of the theory of sprocket hob and rollingcut of sprocket, according to the meshing mechanism of Hy-Vo silent chainand sprocket, Hy-Vo silent chain meshing design system based on multivariation is firstly constructed, and point that regarding Hy-Vo silent chainworking plate shape as rolling hob shape is the essential condition of settingup Hy-Vo silent chain-sprocket-hob design system. By analyzing themeshing mechanism of Hy-Vo silent chain and sprocket, the theory that theintersection point of extension cords of attachment of center points of basiccircle of working plate next to Hy-Vo silent chain is firstly raised, which is fundamentally different from the correct meshing condition of sleeve rollerchain transmission and gear transmission.
Based on inner-outer meshing Hy-Vo silent chain with two differentHV3noncircular benchmark holes of the same specification and pitchcharacteristic, through design calculating and analysis，the theory that undercondition of correct meshing of Hy-Vo silent chain-sprocket-hob, a series ofnew transmission with different parameters is designed by multi variablemethod, in order to satisfy different personalized need of machines. At thesame time, through the experiment of steady transmission of two chainsystem, it is indicated that the Hy-Vo silent chain design method based onmulti variation is scientific and feasible, and multi variation design method isan important means of realizing Hy-Vo silent chain products upgrade and theprotection of intellectual property rights.
Based on the fatigue reliability test of precision transmission rollerchain, the fatigue test method of Hy-Vo silent chain is firstly researched, andit is mentioned that in order to save test time, the level of one load factor canbe raised in24F-N method test figures. The fatigue strength curve afterraising test load is more conservative. By comparison research of14F-Nmethod and24F-N method, the14F-N method can be adopted and the loadcoefficient can be raised when roughly estimating chain life. R=50%R-F-Ncurve can be gained by14F-N method; The fatigue life curves through14F-N method and24F-N method are basically consistent. At the same time,the fatigue test research is carried on to Hy-Vo silent chain, the resultindicates that the chain may not meet the satisfaction of fatigue performance when meeting the requirement of strength, which proved the importance ofchain fatigue life research.
Based on the analysis of the role of silent chain guide plate and its effecton Hy-Vo silent chain assemble and stress, the Hy-Vo silent chain guideplate design method is firstly put forward by researching on Hy-Vo silentchain guide plate, and the finite element analysis and test research is carriedout. By researching, the bigger the circular arc radius Rg at the top ofbutterfly-shape guide plate waist, the better. In condition of meeting therequirement of guide plate strength, the height of Hg should be reduced, anddistance between the lowest point of middle arc and pin stress center shouldbe increased. The research indicates that clearance can be compensated bydesigning reasonable butterfly-shape guide plate in the process of drawing inHy-Vo silent chain. At the same time, the result can be used in engineeringpractice, and brings much economic benefits to related industries.
Based on the analysis of multi-body dynamics contact searchingalgorithm, and through using dynamics simulation software Recurdyn, themulti chain kinematics and dynamics simulation is carried out on new Hy-Vosilent chain of three different plate types designed through multi designmethod. By comparison research on the polygon effect of three differentHy-Vo silent chain, the Hy-Vo silent chain plate designed by multi variablemethod can become a new product by orderly combination, which proves thefeasibility of multiple design method again. At the same time, throughanalysis and research of Hy-Vo silent chain dynamic trait, the result suggeststhat the contact force of two counter shafts of the plate of the same new Hy-Vo silent chain plate is totally different, so it is not simply to judge otherchain’s stress by analyzing one chain’s stress, which provides an importanttheoretical guidance for Hy-Vo silent chain dynamics research.
本论文是在国家自然科学基金项目“基于多元变异的新型Hy-Vo齿形链啮合设计理论（50975117）”和“基于复杂约束边界条件下的多轴高速齿形链系统啮合设计理论”（51275207）以及国家高技术研究发展计划项目（863）“基于复杂多元变异的Hy-Vo齿形链数字化方法研究及平台开发（2009AA04Z109）”的资助和支持下，对Hy-Vo齿形链的啮合机理进行了深入的研究，并针对Hy-Vo齿形链的多元变异特性进行了通用设计方法的研究，同时研究了其啮合设计体系、动力学仿真技术、导板设计方法以及疲劳试验方法。
论文在分析比较Hy-Vo齿形链分类及不同啮合机制的基础上，针对Hy-Vo齿形链啮合机制变异、形状变异、参数变异等变异特性进行了系统的研究，基于学科与行业技术发展趋势，首次提出多元变异的概念，并指出以啮合机制与传动特性变异为主体的多元变异过程，就是Hy-Vo齿形链产品系列创新升级的过程，也是行业需求和技术进步的必然趋势。
论文在分析研究链轮滚刀与链轮滚切原理的基础上，根据Hy-Vo齿形链与链轮的啮合原理，首次构建了基于多元变异的Hy-Vo齿形链啮合设计体系，并指出将Hy-Vo齿形链工作链板齿形视为滚刀法向齿形，是建立Hy-Vo齿形链-链轮-刀具齿条的啮合设计体系的基本条件。通过分析Hy-Vo齿形链与链轮的啮合原理，首次提出Hy-Vo齿形链相邻工作链板的基准圆圆心连线延长线的交点位于齿槽对称中心线上是实现Hy-Vo齿形链正确啮合定位的必要条件，这与套筒滚子链传动以及齿轮传动的正确啮合条件是根本不同的。
论文以同一规格、同一节距的两种变异HV3型非圆形基准孔的内-外复合啮合Hy-Vo齿形链为例，通过设计计算与分析，并提出在满足Hy-Vo齿形链-链轮-刀具齿条三者正确啮合的条件下，可以通过多元变异手段，设计出参数不同的一族新型传动，以满足众多主机不同的“个性化”需求。同时，通过两种链条系统的平稳传动试验结果表明，基于多元变异的Hy-Vo齿形链设计方法是科学的，切实可行的。并提出多元变异设计方法是实现Hy-Vo齿形链产品创新升级和知识产权保护的重要手段。
论文在参考精密滚子链疲劳可靠性试验方法的基础上，首次对Hy-Vo齿形链疲劳试验方法进行了研究，并提出了为节约试验时间，可提高一个载荷系数等级获得24F-N方法试验数据；提高试验载荷后的疲劳寿命曲线相比未提高试验载荷的曲线要保守一些。通过对比研究14F-N方法和24F-N方法，提出粗估链条寿命时，可采用14F-N方法并提高一个载荷系数；R=50%的R-F-N曲线可以由14F-N方法获得；14F-N方法和24F-N方法所得到的疲劳寿命曲线形式基本一致。论文同时对新型Hy-Vo齿形链进行了疲劳试验研究，结果表明链条在满足抗拉强度要求的情况下，不一定能够满足疲劳性能要求，证明研究链条疲劳寿命的重要性。
论文在分析齿形链导板的作用及导板对Hy-Vo齿形链装配及受力影响的基础上，通过对Hy-Vo齿形链导板的研究，首次提出了Hy-Vo齿形链导板的设计方法，并进行了有限元分析和试验研究。研究发现，在不影响导板抗拉强度的条件下，蝴蝶状导板腰部上端圆弧半径RG越大越好；在满足导板抗拉强度的条件下，尽量减小HG的高度，如果中间圆弧最低点高于销轴中心连线，应适当加大两者之间的距离。研究结果表明Hy-Vo齿形链可以通过设计合理的蝴蝶状导板在拉伸过程中的变形来补偿间隙。同时研究成果应用于工程实际，给相关行业带来了良好的经济效益。
论文在分析多体动力学接触搜索算法的理论基础上，采用Recurdyn动力学仿真软件，针对多元变异设计方法设计出的三种不同链板型式组合的新型Hy-Vo齿形链进行了多链节的运动学和动力学仿真分析。仿真结果表明，采用多元变异设计方法获得的Hy-Vo齿形链，通过不同啮合机制链板的有序组合，可以根据用户的个性化需求派生出多种Hy-Vo齿形链新产品。通过分析研究三种Hy-Vo齿形链的多边形效应变化规律发现，在一定范围内，新型Hy-Vo齿形链中内-外复合链板数越多，多边形效应越小，且有序排列的新型Hy-Vo齿形链综合性能要优于纯外啮合机制Hy-Vo齿形链和纯内-外复合啮合机制Hy-Vo齿形链。通过分析研究新型Hy-Vo齿形链的动态接触响应发现，同一新型Hy-Vo齿形链在同一时间和同一水平位置时，同一链板所对应的两对销轴的接触力并不相同，因此不能简单的通过分析一个链节的受力，判断其它链节的受力情况，为Hy-Vo齿形链动力学研究提供了重要的理论指导。
Hy-Vo silent chain is an important type of silent chain products, whichcharacterizes good high-speed performance, strong bearing capacity, greatabrasion resistance, etc. The variable pitch characteristic of Hy-Vo silentchain can apparently depress chordal action, impact and noise during silentchain meshes with the sprocket, as a result the Hy-Vo silent chain is widelyused for automobile gear box, transmission box, industry pump and otherhigh velocity transmission. According to the difference of the meshingmechanism, the silent chain is divided into three types: outer meshingmechanism Hy-Vo silent chain, inner-outer meshing mechanism Hy-Vosilent chain and outer and inner-outer meshing mechanism Hy-Vo silentchain.
Supported by the Project of National Natural Science Foundation ofChina the Meshing and Design Theories Based on the Multi-variant andNew Hy-Vo Silent Chain (50975117) and the Design Theory ofMultiaxial High Speed Silent Chain System Based on Complex ConstraintBoundary Conditions (51275207) and National High Technological andDevelopmental Plan Project(863)titled Digital Method Research and Platform Development Based on the Sophisticated and Divesified Hy-VoSilent Chain (2009AA04Z109)，the meshing mechanism of Hy-Vo silentchain, a deep research is conducted on the general design method of Hy-Vosilent chain’s multi variation characteristic and meshing design system anddynamic simulation technology and guide design method and fatigue testingmethod.
Based on analysis and comparison of different Hy-Vo silent chain typesand meshing mechanism, a systematic study is carried on Hy-Vo silent chainmeshing mechanism variation and shape variation and parameters variationand other variation characteristics. Based on the development trend ofdiscipline and industry technology, this thesis firstly raises the concept ofmulti variation, and points out that the multi variation process which ischaracterized by meshing mechanism and transmission characteristics, is justthe process of Hy-Vo silent chain products innovation and upgrade, as wellas the inevitable trend of industry requirements and technology progress.
Based on analysis and study of the theory of sprocket hob and rollingcut of sprocket, according to the meshing mechanism of Hy-Vo silent chainand sprocket, Hy-Vo silent chain meshing design system based on multivariation is firstly constructed, and point that regarding Hy-Vo silent chainworking plate shape as rolling hob shape is the essential condition of settingup Hy-Vo silent chain-sprocket-hob design system. By analyzing themeshing mechanism of Hy-Vo silent chain and sprocket, the theory that theintersection point of extension cords of attachment of center points of basiccircle of working plate next to Hy-Vo silent chain is firstly raised, which is fundamentally different from the correct meshing condition of sleeve rollerchain transmission and gear transmission.
Based on inner-outer meshing Hy-Vo silent chain with two differentHV3noncircular benchmark holes of the same specification and pitchcharacteristic, through design calculating and analysis，the theory that undercondition of correct meshing of Hy-Vo silent chain-sprocket-hob, a series ofnew transmission with different parameters is designed by multi variablemethod, in order to satisfy different personalized need of machines. At thesame time, through the experiment of steady transmission of two chainsystem, it is indicated that the Hy-Vo silent chain design method based onmulti variation is scientific and feasible, and multi variation design method isan important means of realizing Hy-Vo silent chain products upgrade and theprotection of intellectual property rights.
Based on the fatigue reliability test of precision transmission rollerchain, the fatigue test method of Hy-Vo silent chain is firstly researched, andit is mentioned that in order to save test time, the level of one load factor canbe raised in24F-N method test figures. The fatigue strength curve afterraising test load is more conservative. By comparison research of14F-Nmethod and24F-N method, the14F-N method can be adopted and the loadcoefficient can be raised when roughly estimating chain life. R=50%R-F-Ncurve can be gained by14F-N method; The fatigue life curves through14F-N method and24F-N method are basically consistent. At the same time,the fatigue test research is carried on to Hy-Vo silent chain, the resultindicates that the chain may not meet the satisfaction of fatigue performance when meeting the requirement of strength, which proved the importance ofchain fatigue life research.
Based on the analysis of the role of silent chain guide plate and its effecton Hy-Vo silent chain assemble and stress, the Hy-Vo silent chain guideplate design method is firstly put forward by researching on Hy-Vo silentchain guide plate, and the finite element analysis and test research is carriedout. By researching, the bigger the circular arc radius Rg at the top ofbutterfly-shape guide plate waist, the better. In condition of meeting therequirement of guide plate strength, the height of Hg should be reduced, anddistance between the lowest point of middle arc and pin stress center shouldbe increased. The research indicates that clearance can be compensated bydesigning reasonable butterfly-shape guide plate in the process of drawing inHy-Vo silent chain. At the same time, the result can be used in engineeringpractice, and brings much economic benefits to related industries.
Based on the analysis of multi-body dynamics contact searchingalgorithm, and through using dynamics simulation software Recurdyn, themulti chain kinematics and dynamics simulation is carried out on new Hy-Vosilent chain of three different plate types designed through multi designmethod. By comparison research on the polygon effect of three differentHy-Vo silent chain, the Hy-Vo silent chain plate designed by multi variablemethod can become a new product by orderly combination, which proves thefeasibility of multiple design method again. At the same time, throughanalysis and research of Hy-Vo silent chain dynamic trait, the result suggeststhat the contact force of two counter shafts of the plate of the same new Hy-Vo silent chain plate is totally different, so it is not simply to judge otherchain’s stress by analyzing one chain’s stress, which provides an importanttheoretical guidance for Hy-Vo silent chain dynamics research.
引文
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