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Experimental investigation of the relation between the surface integrity and bending fatigue strength of carburized gears

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Science China(Technological Sciences) 2023年第1期66卷 33-46页

作者： CHEN DiFa zhu jiazan LIU HuaiJu WEI PeiTang MAO TianYu State Key Laboratory of Mechanical Transmissions Chongqing UniversityChongqing 400044China China Gas Turbine Establishment Chengdu 710025China

Bending fatigue is an essential parameter that needs to be considered in the improvement process of the power density and reliability of gear drives. Quantitative relations among the manufacturing parameters, surface integrities, and fatigue performance are not clear, which seriously limits the effectiveness of an anti-fatigue design. For this work, tooth-bending fatigue tests of carburized gears with different surface integrities were performed using a pulsator. The effects of the manufacturing parameters and surface integrities on the gear fatigue, such as surface hardness and residual stress, were investigated. The experimental results revealed that due to the improvement of surface integrities after shot peening, the nominal bending stress number(fatigue limit) increased by 6.3%–31.1%, with an amplitude range of 39–143 MPa. A supervised learning algorithm of a random forest was implemented to determine the contribution of the surface hardness and surface residual stress to the nominal stress number. An empirical formula was proposed to predict the nominal stress number considering the surface integrities. The prediction error was less than 7.53%, as verified by several gear-bending fatigue tests. This provided theoretical support for the modern, anti-fatigue design of the gears.

关键词： carburized gear surface integrity bending fatigue design formula

System Life and Reliability Modeling of a Multiple Power Takeoffs Accessory Gearbox Transmission

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Journal of Shanghai Jiaotong university(Science) 2022年第6期27卷 855-866页

作者： WANG Kai WANG Xianliang zhu jiazan OU Daisong PAN Daifeng AECC Sichuan Gas Turbine Establishment Chengdu 610500China

A mathematical model for system life and reliability of a multiple power takeoffs aeroengine accessory gearbox transmission is *** geometry model of gear train is distributed into several subsystems by different transmitted *** lives of each component are combined to determine the units,subsystems and entire system lives sequentially according to a strict series probability *** unit and subsystem interface models are defined to dispose the loads of common *** algorithm verification is presented and a numerical example is given to illustrate the use of this *** initial design could not fulfill the life requirement.A design modification shows that the gear train has a more balanced life distribution by strengthening the weak parts,and the overall life of entire system is increased above the design *** program can help the designer to approach an optimal accessory gearbox transmission design efficiently.

关键词： aeroengine accessory gearbox power takeoff gear train life model reliability numerical program

Simulation and Springback Prediction of integral panel with high ribs in Age Forming

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Simulation and Springback Prediction of integral panel with ...

Structure of Mold Surface for Stress Relaxation Forming of Integral Panel of 2124 Aluminum Alloy

2012 International Conference on Mechanical Engineering and Materials(ICMEM 2012)

作者： Zhong Gan Haibing Tan jiazan zhu Key Laboratory of Contemporary Design and integrated Manufacturing Technology Northwestern Polytechnical UniversityMinistry of Education

Age forming is the best forming method of integral panel parts of aircrafts,which have large amount of springback and the springback’s accuracy,is hard to control,so a method which can make an accurate prediction of the springback after forming is *** article which is based on creep test data and CPT,fits the creep constitutive equation and obtained the material *** numerical simulation is adopted to process age forming simulation on springback of T-specimen of aluminum 2124,and the simulation result is compared with the test result to do revision of the material parameter;the revised material parameter is applied into the numerical simulation of age forming of the integral panel which is of high *** tests which can confirm the error ranges from-1mm to +1mm,this method’s accuracy is proved.

关键词： Creep constitutive equation Age forming Numerical simulation Springback predic tion

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Structure of Mold Surface for Stress Relaxation Forming of I...

2012 International Conference on Mechanical Engineering and Materials(ICMEM 2012)

作者： Zhong Gan Yuping Wu jiazan zhu Haibing Tan Key Laboratory of Contemporary Design and integrated Manufacturing Technology Northwestern Polytechnical UniversityMinistry of Education

This paper proposed a method and process of stress relaxation forming based on initial geometric springback compensation-finite element optimization-revision by experiment *** material parameters of 2124 aluminum alloy by a series of foundation craft experiments;springback law on the structure of 2124 aluminum alloy by foundation experiment of autoclave forming of T test specimens,that use to compensate the mold surface with the geometric *** precision of the geometric springback compensation of the mold surface is about 3 mm;while after the finite element iteration optimization on the mold surface with the initial geometric springback compensation,the deviation of that between the testing date and the theory appearance of specimens can reach the magnitude about ±1.2 *** use the mold "frequency domain" revision algorithm based on experiment iteration to revise local mold surface of the stress relaxation *** testing date shows the precision control in ±0.5 mm that satisfied with the application of engineering.

关键词： stress relaxation forming geometric springback compensation finite element optimization mold revision among frequency domain

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铝合金整体壁板时效成形模具型面构造

机械工程学报 2012年第16期48卷 74-79页

作者：甘忠熊仕鹏朱加赞庄振民西北工业大学现代设计与集成制造技术教育部重点实验室西安710072 中国燃气涡轮研究院成都610500

时效成形是飞机整体壁板的主要成形工艺之一,由于成形过程中回弹量大的特点,需要对模具进行补偿以消除回弹对零件成形精度的影响。为了有效消除回弹影响,提出一种有限元模拟与物理试验相结合的思路,基于有限元模具型面回弹补偿—试验迭... 详细信息

时效成形是飞机整体壁板的主要成形工艺之一,由于成形过程中回弹量大的特点,需要对模具进行补偿以消除回弹对零件成形精度的影响。为了有效消除回弹影响,提出一种有限元模拟与物理试验相结合的思路,基于有限元模具型面回弹补偿—试验迭代的频域模具型面修正方法。以2124铝合金材料为例,以零件理论外形作为初始模具型面对整体壁板进行仿真回弹补偿迭代,经过6次补偿,零件成形误差减小到0.47 mm,把有限元迭代所得模具型面进行工艺试验,验证结果表明,仿真迭代所得模具型面成形零件的误差为0.63 mm;达不到0.5 mm的外形误差要求。进一步采用模具'频域'修正算法对时效成形模具型面进行修正,经过2次修正,成形零件误差降低至0.484 mm,满足使用要求,结果表明该方法可行。

关键词：时效成形有限元法频域修正模具型面回弹补偿

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基于DEM-FEM的微粒喷丸仿真分析

中国表面工程 2022年第4期35卷 204-212页

作者：张博宇刘怀举魏沛堂朱加赞重庆大学机械传动国家重点实验室重庆400044 中国航发四川燃气涡轮研究院成都610500

微粒喷丸作为一种新兴的喷丸工艺,由于工艺试验数据与仿真技术的缺失,其作用机理尚未探明。基于ABAQUS二次开发,采用离散元与有限元(DEM-FEM)相结合的方法,构建考虑初始残余应力与硬化层梯度的随机多弹丸微粒喷丸弹塑性模型,探究微粒喷... 详细信息

微粒喷丸作为一种新兴的喷丸工艺,由于工艺试验数据与仿真技术的缺失,其作用机理尚未探明。基于ABAQUS二次开发,采用离散元与有限元(DEM-FEM)相结合的方法,构建考虑初始残余应力与硬化层梯度的随机多弹丸微粒喷丸弹塑性模型,探究微粒喷丸的喷射速度与覆盖率对残余应力分布和表面粗糙度的影响规律。发现随着微粒喷丸喷射速度的增加,靶体表面粗糙度的算术平均偏差Sa线性增加;覆盖率达到100%后,覆盖率大小对Sa与残余压应力分布影响不大;喷射速度对于微粒喷丸的最大残余压应力值影响不大,但对残余应力层的厚度有显著影响。通过DEM-FEM耦合方法对微粒喷丸机理进行探究,为工艺参数的制定提供理论支撑。

关键词：微粒喷丸离散元覆盖率残余应力表面粗糙度

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基于参数化设计的时效成形模架自动装配技术

兵器材料科学与工程 2011年第3期34卷 61-64页

作者：甘忠朱加赞张磊西北工业大学现代设计与集成制造技术教育部重点实验室陕西西安710072 西安光机所陕西西安710072

研究基于参数化的可实现模架自动装配的方法。时效成形模架由底板、型板和框板组成,分别提取主要关键尺寸,将其参数化;找出底板、型板和框板之间的装配关系,建立三者间的装配函数关系,应用VB软件对CATIA进行二次开发,通过修改零部件几... 详细信息

研究基于参数化的可实现模架自动装配的方法。时效成形模架由底板、型板和框板组成,分别提取主要关键尺寸,将其参数化;找出底板、型板和框板之间的装配关系,建立三者间的装配函数关系,应用VB软件对CATIA进行二次开发,通过修改零部件几个关键尺寸建立一个新的装配体,实现时效模架的自动装配。结果表明,该方法满足设计要求。

关键词：参数化自动装配 CATIA 时效成形模架

低碳合金钢18CrNiMo7-6齿轮弯曲疲劳试验研究与误差分析

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重庆大学学报 2023年第1期46卷 1-15页

作者：陈地发刘怀举朱加赞徐永强魏沛堂何海风重庆大学机械传动国家重点实验室重庆400044 中国航发四川燃气涡轮研究院成都610599

齿轮弯曲疲劳试验是评价齿轮弯曲疲劳性能的重要手段,为保证试验结果的准确性,探究试验过程误差对试验结果的影响。根据GB/T 14230—1993《齿轮弯曲疲劳强度试验方法》中的B试验法以跨五齿对称加载方式制定弯曲疲劳试验方案,进行有限元... 详细信息

齿轮弯曲疲劳试验是评价齿轮弯曲疲劳性能的重要手段,为保证试验结果的准确性,探究试验过程误差对试验结果的影响。根据GB/T 14230—1993《齿轮弯曲疲劳强度试验方法》中的B试验法以跨五齿对称加载方式制定弯曲疲劳试验方案,进行有限元仿真与电阻应变片测试验证试验方案的正确性,采用升降法开展18CrNiMo7-6喷丸齿轮弯曲疲劳试验,分析齿轮几何精度、装夹误差以及设备加载精度对弯曲疲劳试验结果的影响。结果表明:试验方案计算齿根弯曲应力与有限元仿真以及电阻应变测试的结果最大误差为8.7%,满足工程需求;99%可靠度下18CrNiMo7-6喷丸齿轮弯曲疲劳极限为642 MPa,相比国标中MQ级的500 MPa提高28%,标准设计偏保守。齿轮的几何精度以及试验设备精度对弯曲疲劳试验结果影响较大,考虑误差综合作用对试验结果的影响为2.43%。

关键词：齿轮弯曲疲劳试验应变测试有限元仿真误差分析

渐开线圆柱齿轮胶合承载能力计算标准比较研究

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机械传动 2022年第12期46卷 86-92页

作者：贾晨帆朱才朝刘怀举魏沛堂朱加赞徐永强重庆大学机械传动国家重点实验室重庆400044 中国航发四川燃气涡轮研究院四川成都610599

以新一代航空发动机传动系统等为代表的高端传动装备面临高速、高温、重载等极端服役环境挑战,使得胶合失效成为齿轮主要失效形式之一,严重影响系统寿命和可靠性。针对国内常用的3个齿轮胶合评价标准在齿轮胶合承载能力计算结果之间差... 详细信息

以新一代航空发动机传动系统等为代表的高端传动装备面临高速、高温、重载等极端服役环境挑战,使得胶合失效成为齿轮主要失效形式之一,严重影响系统寿命和可靠性。针对国内常用的3个齿轮胶合评价标准在齿轮胶合承载能力计算结果之间差异较大,且标准公式适用范围存在差异的问题,详细研究了闪温法和积分温度法,从理论分析、公式对比和案例分析三个方面开展了渐开线圆柱齿轮胶合承载能力标准对比研究;并针对FZG A型齿轮,进行了对比计算分析。结果表明,由于HB/Z 84.4的平均摩擦因数计算结果偏高,与GB/Z 6413.2相比计算结果偏大,HB/Z 84.4结果偏保守。GB/Z 6413.1和GB/Z 6413.2在较大的转矩、油温、转速范围内,齿面温度计算结果相差不大;但是,随着模数的减小,二者的齿面温度计算结果差异变大;模数在4~7 mm内,二者齿面温度计算结果相差不大。

关键词：圆柱齿轮胶合标准闪温法积分温度法