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基于有限长线接触斜齿轮热弹性流体动力润滑研究
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摘要
课题来源于国家“十二五”科技支撑计划资助项目“齿轮箱轻量化关键技术研究与应用(2011BAF09B07)”和“7MW级风电齿轮箱及主轴轴承产业化关键技术研究(2012BAA01B05)”。
     润滑失效是齿轮传动失效的主要方式之一,油膜破裂导致金属固体直接接触,产生局部高温,容易形成齿面磨损、胶合等失效形式。目前齿轮设计主要还是基于Hertz接触理论的经典力学设计,随着现代工业发展,齿轮传动正朝着高速、重载方向发展,现有设计理论和方法已难以满足实际需要。将齿轮的摩擦、磨损及润滑问题,同齿轮设计进行有机结合是齿轮设计的发展方向。论文以斜齿轮为研究对象,基于有限长线接触模型,开展其非牛顿流体热弹流润滑特性分析,为齿轮参数设计提供摩擦学理论依据,具有重要的理论意义和实际应用价值。
     论文主要内容如下:
     ①有限长线接触弹流润滑基础理论。将二维点接触弹流润滑算法运用到有限长线接触弹流润滑模型的计算,研究热效应、非牛顿特性及工况变化对润滑压力、膜厚、温度及摩擦系数等润滑特性的影响,提出稳定、高效的有限长线接触数值算法,为斜齿轮润滑分析奠定基础。
     ②斜齿轮经典弹流润滑分析。针对斜齿轮啮合特点将其等效为两个反向圆锥接触的润滑模型,得到啮合过程中接触齿对等效曲率半径、卷吸速度、滑滚比及载荷等参数;研究牛顿流体和等温条件下啮合过程中润滑压力、膜厚等参数变化规律和载荷、转速变化对润滑特性影响。
     ③斜齿轮非牛顿热弹流润滑研究。分别考虑热效应与流体非牛顿特性对斜齿轮润滑特性影响,选取Ree-Eyring和Power-law流体进行分析,讨论特征剪切应力和流体指数对润滑油膜压力、膜厚及温度等影响,分析非牛顿和热效应对斜齿轮啮合过程润滑参数影响。
     ④几何参数与工况变化对斜齿轮润滑特性影响。讨论斜齿轮几何设计参数对润滑特性影响,研究不同流体下,载荷与转速变化对斜齿轮润滑特性影响。
     ⑤采用准稳态方法建立粗糙度表面的斜齿轮微观弹流润滑模型,讨论粗糙度幅值、波长及工况变化对斜齿轮接触润滑特性影响。
The research subject of the dissertation stems from the " The study of keytechnologies of lightweight gearbox "and "The study of key technologies ofindustrialization for7MW wind turbine gearbox and spindle bearing" in the NationalScience and Technology Pillar Program during the Twelfth Five-year Plane Period ofChina.
     Lubrication failure is one of the major forms of gear transmission failure. The filmrupture leads to the contact between mental solid, resulting in the local hightemperature which may cause the gear wear and scuffing failure. Currently, the geardesign is mainly based on classical mechanics of Hertz contact theory. However, withthe development of modern industry, gear transmission develops with the tendency ofhigh-speed and heavy-load and the corresponding requirements cannot be met by theexisting design theory and method. The development direction of theory on gear designis the combination of friction, wear, lubrication and gear design. In this paper, takinghelical gears as the research project, based on the finite line contact model, the researchon characteristics of non-Newtonian thermal Elastohydrodynamic lubrication model isconducted. The research provides the gear design with lubrication theory basis, whichhas significant theoretical significance and practical value.
     The main contents of this dissertation are shown as follows:
     ①The basic theory of finite line contact elastohydrodynamic lubrication. Appliedthe2-dimension point contact elastohydrodynamic lubrication algorithm into thecalculation of finite line contact elstohydrodynamic lubrication model, the influence ofthermal effect, non-Newtonian features and operating condition on lubrication pressure,film thickness and friction coefficient. A efficient and effective numerical algorithm forline contact model is proposed, providing the foundation for the following helical gearlubrication analysis.
     ②The classical elastohydrodynamic lubrication analysis for helical gears.According to the meshing characteristics of helical gears, the equivalent lubricationmodel with two reverse-direction cones is built, achieving the equivalent curvature,entrainment velocity, slide-roll ratio, load and other parameters of gears during themeshing process. The research on lubrication pressure and film thickness during themeshing is conducted with newtonian fluid and isothermal condition. The influence of lubrication pressure, film thickness, load and rotational speed on the lubricationcharacteristics is analyzed.
     ③The research on non-Newtonian thermal elastohydrodynamic lubrication forhelical gears. Considering the effect of thermal effect and non-Newtonian characters offluid on the lubrication characteristics of helical gears, taking Ree-Eyring andPower-law fluid as the research project, the influence of shear stress and fluid index onlubrication pressure, film thickness and temperature and the influence of non-Newtonand thermal effect on lubrication parameters are discussed and investigated.
     ④The influence of geometrical parameters and operating conditions onlubrication characteristics for helical gears. The research on the influence of helical geargeometrical parameters, different fluid, load and rotational speed on lubricationcharacteristics are conducted.
     ⑤On the strength of quasi-stable state method, the micro-EHL model for helicalgears with roughness surface is built. According to this model, the influence ofroughness amplitude, wave length and working condition on the lubricationcharacteristics is achieved.
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