残余应力对齿轮弯曲疲劳的量化影响研究

doi:10.3901/JME.2023.04.053

机械工程学报 ›› 2023, Vol. 59 ›› Issue (4): 53-61.doi: 10.3901/JME.2023.04.053

扫码分享

残余应力对齿轮弯曲疲劳的量化影响研究

何海风¹, 刘怀举¹, 朱才朝¹, 李高萌², 陈地发¹

1. 重庆大学机械传动国家重点实验室重庆 400044;
2. 中国航发四川燃气涡轮研究院成都 610599

收稿日期:2022-03-26 修回日期:2022-10-21 出版日期:2023-02-20 发布日期:2023-04-24
通讯作者: 刘怀举(通信作者),男,1986年出生,博士,教授,博士研究生导师。主要研究方向为齿轮抗疲劳设计、齿轮高表面完整性制造以及齿轮分析软件系统开发。E-mail:huaijuliu@cqu.edu.cn
作者简介:何海风,男,1994年出生,博士研究生。主要研究方向为齿轮疲劳。E-mail:Hehaifeng@cqu.edu.cn
基金资助:
国家重点研发计划资助项目(2018YFB2001300)。

Quantitative Effect of Residual Stress on Gear Bending Fatigue

HE Haifeng¹, LIU Huaiju¹, ZHU Caichao¹, LI Gaomeng², CHEN Difa¹

1. State Key Laboratory of Mechanical Transmissions, Chongqing University, Chongqing 400044;
2. Sichuan Gas Turbine Research Institute, Aero Engine Corporation of China, Chengdu 610599

Received:2022-03-26 Revised:2022-10-21 Online:2023-02-20 Published:2023-04-24

摘要/Abstract

摘要： 随着风电、高铁、掘进等高端装备对齿轮功率密度、服役寿命等要求的提高，齿轮的弯曲疲劳问题日益显著。为提升齿轮弯曲疲劳性能，通过渗碳热处理、喷丸强化等工艺为齿轮引入较高的残余压应力已逐渐成为工业界的标配。为揭示残余应力对齿轮弯曲疲劳性能的量化影响，在最大主应变寿命预测准则中引入残余应力影响项，通过弯曲疲劳试验确定最优残余应力影响系数，进而采用新的试验数据验证模型的准确性。基于工程应用出发，引入修正应力的概念统一不同残余应力状态下的齿轮弯曲应力-寿命(S-N)曲线，研究结果显示，最大主应变准则中，残余应力影响系数取值为0.15时，可实现较高的寿命预测精度，而修正的S-N曲线中，最佳残余应力影响系数为0.25。研究成果可用于工程实际中齿轮弯曲疲劳快速评估。

关键词: 齿轮弯曲疲劳, 残余应力, 疲劳试验, 寿命预测

Abstract: The gears bending fatigue problem has become increasingly prominent due to the increasing requirement of gear power density and service life for sophisticated equipment such as wind turbines, high-speed rails, shield tunneling et al. In order to improve the bending fatigue performance of gears, carburizing heat treatment, shot peening and other processes have become commonly used methods to introduce high compressive residual stress (RS) on gear. The RS influence coefficient is introduced into the maximum principal strain life prediction criterion to quantitatively reveal the influence of RS on gear bending fatigue performance. The optimal RS influence coefficient is determined through bending fatigue test, and then verified by the new test data. Based on engineering applications, the concept of modified stress is introduced to unify gear bending stress-life (S-N) curves under different residual stress states. The research results show that the optimal RS influence coefficient in the maximum principal stress criterion is 0.15. The best RS influence coefficient in the revised and unify S-N curve is found as 0.25. The research results can be used for rapid assessment of gear bending fatigue in engineering practice.

Key words: gear bending fatigue, residual stress, experimental test, life prediction

中图分类号:

TG156

何海风, 刘怀举, 朱才朝, 李高萌, 陈地发. 残余应力对齿轮弯曲疲劳的量化影响研究[J]. 机械工程学报, 2023, 59(4): 53-61.

HE Haifeng, LIU Huaiju, ZHU Caichao, LI Gaomeng, CHEN Difa. Quantitative Effect of Residual Stress on Gear Bending Fatigue[J]. Journal of Mechanical Engineering, 2023, 59(4): 53-61.

参考文献

[1] ZOU Ting,SHAKER M,ANGELES J,et al. An innovative tooth root profile for spur gears and its effect on service life[J]. Meccanica,2017,52(8):1825-1841.
[2] LU Zehua,LIU Huaiju,WEI Peitang,et al. The effect of injection molding lunker defect on the durability performance of polymer gears[J]. International Journal of Mechanical Sciences,2020,180:105665.
[3] OLSSON E,OLANDER A,BERG M. Fatigue of gears in the finite life regime-Experiments and probabilistic modelling[J]. Engineering Failure Analysis,2016,62:276-286.
[4] LEWIS W. Investigation of the strength of gear teeth[J]. Proceedings of Engineers Club,Philadelphia,1893,16:10.
[5] 王明旭,李永祥,秦超,等. A35CrNiMo感应淬火齿轮弯曲疲劳强度试验[J]. 机械设计与研究,2018,34(6):74-77,87.
WANG Mingxu,LI Yongxiang,QIN Chao,et al. Experimental study on bend fatigue strength of induction hardened gears of a35crnimo[J]. Machine Design and Research,2018,34(6):74-77,87.
[6] GORLA C,ROSA F,CONRADO E,et al. Bending and contact fatigue strength of innovative steels for large gears[J]. Proceedings of the Institution of Mechanical Engineers,Part C:Journal of Mechanical Engineering Science,2014,228(14):2469-2482.
[7] 张民,王忠,冯显磊,等. 20CrMnTi钢齿轮疲劳寿命研究[J]. 热处理,2017,32(6):9-12.
ZHANG Min,WANG Zhong,FENG Xianlei,et al. Research on fatigue life of 20CrMnTi steel gear[J]. Heat Treatment,2017,32(6):9-12.
[8] MENEGHETTI G,DENGO C,CONTE F. Bending fatigue design of case-hardened gears based on test specimens[J]. Proceedings of the Institution of Mechanical Engineers,Part C:Journal of Mechanical Engineering Science,2018,232(11):1953-1969.
[9] STRINGER D,DYKAS B,LABERGE K,et al. A new high-speed,high-cycle,gear-tooth bending fatigue test capability[C/CD]//The American Helicopter Society,2011,Annual Forum.
[10] HONG I,KAHRAMAN A,ANDERSON N. A rotating gear test methodology for evaluation of high-cycle tooth bending fatigue lives under fully reversed and fully released loading conditions[J]. International Journal of Fatigue,2020,133:105432.1-105432.11.
[11] GHAFFARI M,PAHL E,XIAO S. Three dimensional fatigue crack initiation and propagation analysis of a gear tooth under various load conditions and fatigue life extension with boron/epoxy patches[J]. Engineering Fracture Mechanics,2015,135:126-146.
[12] 李刚. 高速动车组齿轮箱斜齿轮副弯曲疲劳寿命仿真分析[D]. 太原:太原理工大学,2017.
LI Gang. Bending fatigue life simulation analysis of helical gear pair of high-EMU gearbox[D]. Taiyuan:Taiyuan University of Technology,2017.
[13] Lin Yulong,Liu Shourong,Zhao Xueyan,et al. Fatigue life prediction of engaging spur gears using power density[J]. Proceedings of the Institution of Mechanical Engineers Part C-Journal of Mechanical Engineering Science,2018,232(23):4332-4341.
[14] 王雯雯. 某地铁齿轮箱齿轮弯曲疲劳试验与仿真研究[D]. 北京:北京建筑大学,2017.
WANG Wenwen. Research on bending fatigue test and simulation of a metro gear[D]. Beijing:Beijing University of Civil Engineering and Architecture,2017.
[15] BONAITI L,BAYOUMI A,CONCLI F,et al. Gear root bending strength:A comparison between single tooth bending fatigue tests and meshing gears[J]. Journal of Mechanical Design,2021,143(10):1-17.
[16] 李贞子,何才,王云龙,等. 20CrMoH齿轮弯曲疲劳强度研究[J]. 汽车工艺与材料,2011(9):21-24.
LI Zhenzi,HE Cai,WANG Yunlong,et al. The study of bending fatigue strength of 20CrMoH gear[J]. Automobile Technology and Material,2011(9):21-24.
[17] WINKLER K,SCHURER S,TOBIE T,et al. Investigations on the tooth root bending strength and the fatigue fracture characteristics of case-carburized and shot-peened gears of different sizes[J]. Proceedings of the Institution of Mechanical Engineers Part C-Journal of Mechanical Engineering Science,2019,233(21-22):7338-7349.
[18] SHAW B. The role of residual stress on the fatigue strength of high performance gearing[J]. International Journal of Fatigue,2003,25(9-11):1279-1283.
[19] SAVARIA V,BRIDIER F,BOCHER P. Predicting the effects of material properties gradient and residual stresses on the bending fatigue strength of induction hardened aeronautical gears[J]. International Journal of Fatigue,2016,85:70-84.
[20] WANG Wei,LIU Huaiju,ZHU Caichao,et al. Effect of the residual stress on contact fatigue of a wind turbine carburized gear with multiaxial fatigue criteria[J]. International Journal of Mechanical Sciences,2019,151:263-273.
[21] HE Haifeng,LIU Huaiju,ZHU Caichao,et al. Study on the gear fatigue behavior considering the effect of residual stress based on the continuous damage approach[J]. Engineering Failure Analysis,2019,104:531-544.
[22] WANG Wei,LIU Huaiju,ZHU Caichao,et al. Evaluation of rolling contact fatigue of a carburized wind turbine gear considering the residual stress and hardness gradient[J]. Journal of Tribology-Transactions of the ASME,2018,140(6):061401.
[23] 王伟,唐良芬,倪佳俊,等. 42CrMo齿轮渗氮处理R-S-N弯曲疲劳性能研究[J]. 金属加工(热加工),2018(11):54-57.
WANG Wei,TANG Liangfen,NI Jiajun,et al. Study on R-S-N bending fatigue properties of 42CrMo gear nitriding treatment[J]. MW Metal Forming,2018(11):54-57.
[24] HE Haifeng,LIU Huaiju,ZHU Caichao,et al. Study of rolling contact fatigue behavior of a wind turbine gear based on damage-coupled elastic-plastic model[J]. International Journal of Mechanical Sciences,2018,141:512-519.
[25] BASQUIN O. The exponential law of endurance test[J]. Proceedings of the American Society for Testing and Material,1910(10):625-630.
[26] COFFIN L. Study of the effect of cyclic thermal stresses on a ductile metal[J]. Transactions of the ASME,1954,76:931-950.
[27] BAUMEL A,SEEGER T. Materials data for cyclic loading-supplement 1[M]. New York:Elsevier Science Publishing Company,1990.
[28] SMITH K,WATSON P,TOPPER T. A stress-strain function for the fatigue of metals[J]. Journal of Materials,1970,5(4):767-778.

残余应力对齿轮弯曲疲劳的量化影响研究

Quantitative Effect of Residual Stress on Gear Bending Fatigue

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价

[1]	陈钊杰, 谢晋, 刘军汉, 熊长新, 李迪帆. 脉冲放电驱动磨料流辅助磨削单晶碳化硅研究[J]. 机械工程学报, 2024, 60(9): 383-392.
[2]	吴吉展, 魏沛堂, 吴少杰, 刘怀举, 朱才朝. 航空齿轮钢滚动接触疲劳性能预测与表面完整性优化[J]. 机械工程学报, 2024, 60(8): 81-93.
[3]	张军辉, 刘施镐, 徐兵, 黄伟迪, 吕飞, 黄晓琛. 轴向柱塞泵智能化关键技术研究进展及发展趋势[J]. 机械工程学报, 2024, 60(4): 32-49.
[4]	胡龙, 刘红艳, 成慧梅, 陈维奇, 冯广杰, 叶延洪, 邓德安. 超高强耐磨钢NM500多层多道对接接头残余应力的研究[J]. 机械工程学报, 2024, 60(4): 335-344.
[5]	刘怀举, 陈地发, 朱才朝, 吴吉展, 魏沛堂. 齿轮弯曲疲劳的研究进展与发展趋势[J]. 机械工程学报, 2024, 60(3): 83-108.
[6]	纪佳馨, 彭程, 项冲, 黄乐, 郭飞. 考虑变速条件的斯特封磨损寿命预测方法[J]. 机械工程学报, 2024, 60(3): 191-202.
[7]	马泳涛, 孙宁, 王俊龙, 李春凡, 卢春生, 张彬, 刘兰荣. 前混合水射流喷丸覆盖率计算及对渗碳钢表面完整性的影响研究[J]. 机械工程学报, 2024, 60(3): 393-404.
[8]	张伟, 李如俊, 葛士涛, 彭艳. 基于内禀耗散理论的高周疲劳双尺度伤演分析[J]. 机械工程学报, 2024, 60(20): 120-133.
[9]	刘小峰, 张天瑀, 韦代平, 柏林, 陈兵奎. 复合材料基体裂纹损伤演化的自适应粒子滤波预测[J]. 机械工程学报, 2024, 60(18): 32-42.
[10]	陈健, 孟义兴, 袁慎芳, 徐秋慧, 王卉. 融合导波监测的搭接结构裂纹扩展寿命孪生预测[J]. 机械工程学报, 2024, 60(16): 34-42.
[11]	赵雷, 张利宾, 宋恺, 徐连勇, 韩永典, 郝康达. 新型马氏体耐热钢耦合控制下蠕变-疲劳循环变形研究[J]. 机械工程学报, 2024, 60(16): 118-129.
[12]	朱挺, 陈兆祥, 周笛, 陈震, 胡兵, 潘尔顺. 基于Bayesian-LSTM神经网络的热轧轧辊剩余寿命预测及不确定性评估[J]. 机械工程学报, 2024, 60(11): 181-190.
[13]	张吉银, 姚倡锋, 谭靓, 崔敏超, 周征, 孙蕴齐, 李国喜, 樊怡. 喷丸强化残余应力对疲劳性能和变形控制影响研究进展[J]. 机械工程学报, 2023, 59(6): 46-60.
[14]	刘志状, 吴昊. 一种基于参数影响的数据驱动下的疲劳寿命预测方法[J]. 机械工程学报, 2023, 59(4): 71-79.
[15]	王宇, 刘秋发, 彭一真. 非均匀监测条件下滚动轴承剩余寿命预测方法[J]. 机械工程学报, 2023, 59(23): 96-104.