花键微动磨损和损伤累积的耦合机制及寿命预测

doi:10.3901/JME.2023.03.133

机械工程学报 ›› 2023, Vol. 59 ›› Issue (3): 133-143.doi: 10.3901/JME.2023.03.133

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花键微动磨损和损伤累积的耦合机制及寿命预测

陈壮^1,2, 董庆兵^1,2, 罗振涛^1,2, 魏静^1,2, 孟凡明^1,2, 戚勍³

1. 重庆大学机械传动国家重点实验室重庆 400030
2. 重庆大学机械与运载工程学院重庆 400030
3. 中国航发沈阳发动机研究所沈阳 110015

收稿日期:2022-02-23 修回日期:2022-06-23 出版日期:2023-02-05 发布日期:2023-04-23
通讯作者: 董庆兵(通信作者),男,1985年出生,博士,教授,博士研究生导师。主要研究方向为传动件的接触摩擦、润滑优化技术、界面疲劳断裂等。E-mail:Qdong002@cqu.edu.cn
作者简介:陈壮,男,1993年出生,博士研究生。主要研究方向为接触摩擦、界面疲劳断裂等。E-mail:20200701033@cqu.edu.cn
基金资助:
国家重点研发计划(2020YFB2010101)，国家自然科学基金(51905051，52275175)和机械传动国家重点实验室(SKLMT-ZZKT-2021M06)资助项目。

Coupling Mechanism of Fretting Wear and Damage Accumulation of Spline Couplings and Service Life Prediction

CHEN Zhuang^1,2, DONG Qingbing^1,2, LUO Zhentao^1,2, WEI Jing^1,2, MENG Fanming^1,2, QI Qing³

1. State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing 400030;
2. College of Mechanical and Vehicle Engineering, Chongqing University, Chongqing 400030;
3. AECC Shenyang Engine Research Institute, Shenyang 110015

Received:2022-02-23 Revised:2022-06-23 Online:2023-02-05 Published:2023-04-23

摘要/Abstract

摘要： 渐开线花键联轴器在航空领域应用广泛,花键在复杂工况下往往达不到预期寿命,其中花键轴不对中对花键服役寿命产生较大影响。基于有限元方法建立了高效的花键三维仿真模型,分析内外花键轴偏斜0.3°时花键各齿载荷分布规律,基于Archard磨损模型计算接触区域各节点的磨损深度,并基于ABAQUS的UMESHMOTION子程序和Arbitrary Lagrangian-Eulerian技术更新网格,采用Brown-Miller和Smith-Watson-Topper临界平面准则充分考虑花键齿面和齿根区域的应力状态差异,并拟合花键循环寿命、最大磨损深度与磨损系数之间的关联规律,采用试验方法测试表面磨损形貌,验证模型的有效性,为花键联轴器的设计和校核提供指导依据。结果表明:磨损演化逐渐改变初始应力集中区域的几何形状,从而减少了应力集中效应,提高了花键剩余寿命。当磨损系数较大时,花键以磨损失效为主,当磨损系数较小时,花键以疲劳裂纹萌生失效为主。

关键词: 航空花键, 轴不对中, 微动磨损, 疲劳分析, 有限元开发

Abstract: Spline couplings are widely used in the aviation field. The splines often fail to reach their expected life under complex working conditions, and the angular misalignment between spline shafts has a greater impact on the service life of the couplings. An efficient three-dimensional simulation model is established based on the finite element method to analyze the load distribution of spline teeth when the internal spline deviates 0.3° from the external spline. The wear depth of each node in the contact area is calculated based on the Archard wear model, and the UMESHMOTION subroutine and Arbitrary Lagrangian-Eulerian technique are adopted to remesh the calculation domain after each cycle. The critical plane methods, Brown-Miller and Smith-Watson-Topper, are used to predict fatigue life based on the analysis of stress states on the tooth surface and those near the tooth root. Expressions are fitted involving the cyclic life, maximum wear depth and wear coefficient. An experimental study is conducted to verify the model. The conclusions may provide guidance for the design and verification of the spline coupling. The results show that the stress concentrations are gradually released along with the surface evolution, which can elongate the residual life of splines. The splines fail to work due to wear when a large wear coefficient is produced and due to fatigue crack initiation when the wear coefficient is relatively small.

Key words: aviation spline coupling, angular misalignment, fretting wear, fatigue analysis, development of finite element method

中图分类号:

TH131

陈壮, 董庆兵, 罗振涛, 魏静, 孟凡明, 戚勍. 花键微动磨损和损伤累积的耦合机制及寿命预测[J]. 机械工程学报, 2023, 59(3): 133-143.

CHEN Zhuang, DONG Qingbing, LUO Zhentao, WEI Jing, MENG Fanming, QI Qing. Coupling Mechanism of Fretting Wear and Damage Accumulation of Spline Couplings and Service Life Prediction[J]. Journal of Mechanical Engineering, 2023, 59(3): 133-143.

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花键微动磨损和损伤累积的耦合机制及寿命预测

Coupling Mechanism of Fretting Wear and Damage Accumulation of Spline Couplings and Service Life Prediction

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