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Three-dimensional parametric contact analysis of planetary roller screw mechanism and its application in grouping for selective assembly

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Frontiers of Mechanical Engineering 2024年第1期19卷 53-72页

作者： Huilin HE Peitang WEI huaiju liu Xuesong DU Rui HU Genshen liu Yajun WU State Key Laboratory of Mechanical Transmission for Advanced Equipment Chongqing UniversityChongqing 400044China Taiyuan Heavy Machinery Group Co. Ltd.Taiyuan 030024China

The planetary roller screw mechanism(PRSM)is a novel precision transmission mechanism that realizes the conversion between linear and rotary *** contact characteristics of helical surfaces directly determine PRSM’s performance in load-carrying capacity and transmission ***,studying the contact characteristics of PRSM forms the fundamental basis for enhancing its transmission *** this study,a three-dimensional parametric analysis method of contact characteristics is proposed based on the PRSM meshing principle and PyVista(a high-level API to the Visualization Toolkit).The proposed method considers the influence of machining errors among various thread *** effects of key machining errors on contact positions and axial clearance,as well as their sensitivities,are *** excellent solution accuracy,this method exhibits higher calculation efficiency and stronger robustness than the analytical and numerical meshing *** influence of nominal diameter and pitch errors of the screw,roller,and nut on the axial clearance follows a linear relationship,whereas flank angle errors have negligible effects on the axial *** corresponding influence coefficients for these three machining errors on the axial clearance are 0.623,0.341,and *** variations in contact positions caused by individual errors are *** angle errors and roller diameter errors result in linear displacements of the contact points,whereas pitch errors cause the contact points to move along the arc of the roller *** on the proposed threedimensional parametric contact characteristics analysis method,the Fuzzy C-Means clustering algorithm considering error sensitivity is utilized to establish a component grouping technique in the selective assembly of critical PRSM components,ensuring the rational and consistent clearances based on the given component’s machining *** study provides effective guidance for analyzing conta

关键词： planetary roller screw mechanism(PRSM) contact position axial clearance machining error grouping for selective assembly

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航空齿轮钢强化工艺与表面完整性关联规律研究

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表面技术 2024年第1期53卷 153-168页

作者：吴吉展朱才朝魏沛堂刘怀举吴少杰重庆大学机械传动国家重点实验室重庆400044

目的探究不同加工工艺与表面完整性的关联规律。方法对渗碳航空齿轮钢AISI9310进行常规喷丸、二次喷丸、微粒喷丸、滚磨光整、喷丸光整等齿轮高表面完整性强化加工工艺处理,使用白光干涉仪、X射线衍射应力仪和显微硬度计对不同工艺状... 详细信息

目的探究不同加工工艺与表面完整性的关联规律。方法对渗碳航空齿轮钢AISI9310进行常规喷丸、二次喷丸、微粒喷丸、滚磨光整、喷丸光整等齿轮高表面完整性强化加工工艺处理,使用白光干涉仪、X射线衍射应力仪和显微硬度计对不同工艺状态下的试件进行表面形貌、表面粗糙度、残余应力和显微硬度等表面完整性表征。结果喷丸能使得航空齿轮钢的表面粗糙度Sa值由磨削状态的0.68μm增加到0.96μm,而光整处理后,Sa下降到0.2μm以下;微粒喷丸使表面残余压应力提升到–1 300 MPa,相比于常规喷丸和磨削状态,其幅值分别增加了450、800 MPa;滚磨光整使得表面残余压应力幅值进一步增加到1 400MPa以上;二次喷丸及喷丸光整能显著提升表面硬度,相比磨削状态的645HV分别提升到718HV、721HV。结论二次喷丸、微粒喷丸、光整等工艺通过影响齿轮表面粗糙度、残余应力、硬度梯度等表面完整性参数,从而影响润滑状态、受力状态、应力集中、失效风险等,直接影响齿轮的服役性能。

关键词：滚动接触疲劳二次喷丸微粒喷丸滚磨光整表面完整性

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航空齿轮钢滚动接触疲劳性能预测与表面完整性优化

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机械工程学报 2024年第8期60卷 81-93页

作者：吴吉展魏沛堂吴少杰刘怀举朱才朝重庆大学机械传动国家重点实验室重庆400044

齿轮滚动接触疲劳是限制航空、航天、新能源汽车、舰艇等高端装备的重要瓶颈。高表面完整性是决定齿轮服役性能的重要保障,表面完整性与齿轮接触疲劳性能的定量关联规律成为工程及学术界的研究重点。该系列研究讨论了常规喷丸、二次喷... 详细信息

齿轮滚动接触疲劳是限制航空、航天、新能源汽车、舰艇等高端装备的重要瓶颈。高表面完整性是决定齿轮服役性能的重要保障,表面完整性与齿轮接触疲劳性能的定量关联规律成为工程及学术界的研究重点。该系列研究讨论了常规喷丸、二次喷丸、微粒喷丸、滚磨光整、喷丸光整等加工工艺对AISI 9310渗碳淬火航空齿轮钢表面完整性参数及服役性能的影响,并给出齿轮抗疲劳设计方法。针对获得的表面完整性与疲劳性能数据,开展疲劳性能预测与表面完整性设计研究。采用随机森林算法确定了表面完整性参数对滚动接触疲劳寿命的重要度;以接触应力、表面粗糙度、表面残余应力、表面硬度、有效残余应力深度、疲劳寿命可靠度为输入,滚动接触疲劳寿命为输出,采用GA-BP神经网络和SVM机器学习方法建立了滚动接触疲劳寿命预测模型,探究了表面完整性参数对滚动接触疲劳寿命的影响规律;提出了基于多元回归的滚动接触疲劳寿命预测公式,疲劳寿命预测值在1.5倍分散带以内;并在给定设计寿命下采用遗传算法对表面完整性参数进行优化,服务于传动构件抗疲劳设计。

关键词：滚动接触疲劳表面完整性疲劳性能数据驱动寿命预测

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齿轮弯曲疲劳的研究进展与发展趋势

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机械工程学报 2024年第3期60卷 83-108页

作者：刘怀举陈地发朱才朝吴吉展魏沛堂重庆大学高端装备机械传动全国重点实验室重庆400044

齿轮弯曲疲劳性能是现代齿轮传动的关键设计指标,也是影响高端齿轮装备服役性能和可靠性的关键因素。尽管齿轮弯曲疲劳研究取得显著进展,但由于基础数据建设、抗疲劳制造、主动设计方法等方面与国外先进水平存在差距,限制了我国高性能... 详细信息

齿轮弯曲疲劳性能是现代齿轮传动的关键设计指标,也是影响高端齿轮装备服役性能和可靠性的关键因素。尽管齿轮弯曲疲劳研究取得显著进展,但由于基础数据建设、抗疲劳制造、主动设计方法等方面与国外先进水平存在差距,限制了我国高性能齿轮传动产品性能。结合文献调研、行业交流与课题研究经验,详述了齿轮弯曲疲劳的研究进展与发展趋势,重点介绍了齿轮弯曲疲劳的失效机理、理论分析、试验技术、承载能力、影响因素等内容,归纳了提升齿轮弯曲疲劳性能的有效措施,期望推动我国齿轮抗疲劳技术的发展与应用。

关键词：齿轮弯曲疲劳强度极限 S-N曲线表面完整性

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喷油润滑聚醚醚酮的接触疲劳性能

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中国机械工程 2024年第2期35卷 221-228页

作者：吴若魏沛堂谢怀杰边疆卢泽华刘怀举重庆大学机械传动国家重点实验室重庆400044 吉林中研高分子材料股份有限公司长春130113

聚醚醚酮(PEEK)是一种高强度、耐热的工程塑料,但其接触疲劳基础数据的缺失制约了它在重载场合下的高可靠、长寿命服役。开展了喷油润滑下的PEEK滚子滚动接触疲劳试验与PEEK齿轮接触疲劳试验,绘制了接触疲劳S-N曲线。对比发现,PEEK滚子... 详细信息

聚醚醚酮(PEEK)是一种高强度、耐热的工程塑料,但其接触疲劳基础数据的缺失制约了它在重载场合下的高可靠、长寿命服役。开展了喷油润滑下的PEEK滚子滚动接触疲劳试验与PEEK齿轮接触疲劳试验,绘制了接触疲劳S-N曲线。对比发现,PEEK滚子滚动接触疲劳极限比齿轮接触疲劳极限高14%,接触压力135 MPa下的滚子滚动接触疲劳寿命比齿轮接触疲劳寿命长58%,进而提出PEEK的滚子-齿轮接触疲劳寿命转换公式。

关键词：聚醚醚酮齿轮滚子接触疲劳应力-寿命曲线

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Numerical study on fatigue crack propagation behaviors in lubricated rolling contact

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Chinese Journal of Aeronautics 2021年第9期34卷 24-36页

作者： Haifeng HE huaiju liu Caichao ZHU Andrea MURA State Key Laboratory of Mechanical Transmissions Chongqing UniversityChongqing 400044China Department of Mechanical and Aerospace Engineering Politecnico di TorinoTorino 10129Italy

The surface-initiated Rolling Contact Fatigue(RCF)including pitting and micro-pitting is one of the key issues affecting the reliability of tribological components such as gears and bearings used in various *** this work,a surface-initiated crack Finite Element(FE)model which considers the effect of lubricant on crack faces was developed to investigate surface-initiated RCF using an automatic crack propagating Python *** lubricating states,initial crack parameters and loading conditions were simulated to analyze the evolution of crack propagation and the Stress Intensity Factors(SIFs).The RCF crack propagation path and life were predicted by employing the Maximum Tangential Stress(MTS)criterion coupled with the Paris’s law.A typical RCF failure is predicted in the numerical *** reveal that the lubricating pressurization dominates the surface-initiated *** addition,the initial crack angle has a significant effect on the RCF crack propagation path and the fatigue life.

关键词： Fatigue crack propagation Finite element Life prediction Lubricating states Rolling Contact Fatigue(RCF) Stress Intensity Factors(SIFs)

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Simulation of the fatigue-wear coupling mechanism of an aviation gear

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Friction 2021年第6期9卷 1616-1634页

作者： Boyu ZHANG huaiju liu Caichao ZHU Yibo GE State Key Laboratory of Mechancial Transmissions Chongqing UniversityChongqing 400044China Shanghai Peentech Equipment Tech.Co.Ltd. Shanghai 201800China

The contact fatigue of aviation gears has become more prominent with greater demands for heavy-duty and high-power density ***,the coexistence of tooth contact fatigue damage and tooth profile wear leads to a complicated competitive mechanism between surface-initiated failure and subsurface-initiated contact fatigue *** address this issue,a fatigue-wear coupling model of an aviation gear pair was developed based on the elastic-plastic finite element *** tooth profile surface roughness was considered,and its evolution during repeated meshing was simulated using the Archard wear *** fatigue damage accumulation of material points on and underneath the contact surface was captured using the Brown-Miller-Morrow multiaxial fatigue *** elastic-plastic constitutive behavior of damaged material points was updated by incorporating the damage *** in the wear depth and fatigue damage around the pitch point are described,and the effect of surface roughness on the fatigue life is *** results reveal that whether fatigue failure occurs initially on the surface or sub-surface depends on the level of surface *** wear on the asperity level alleviates the local stress concentration and leads to a longer surface fatigue life compared with the result without wear.

关键词： gear contact fatigue tooth wear surface roughness damage accumulation

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Study on contact fatigue of a wind turbine gear pair considering surface roughness

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Friction 2020年第3期8卷 553-567页

作者： Heli liu huaiju liu Caichao ZHU Zhangdong SUN Houyi BAI State Key Laboratory of Mechanical Transmissions Chongqing UniversityChongqing 400030China Hubei University of Automotive Technology Shiyan 442002HubeiChina Chongqing Wangjiang Industrial Co.Chongqing 400071China

Contact fatigue issues become more and more crucial in gear industry as they significantly affect the reliability and service life of associated mechanical systems such as wind turbine *** contact fatigue behavior is mostly determined by the mechanical properties of materials and stress fields near the contact area,which is further influenced by the lubrication and surface roughness due to pressure *** this study,a numerical model incorporating the lubrication state,tooth surface roughness,residual stress,and mechanical properties of the material is developed to determine the contact fatigue behavior of a megawatt level wind turbine carburized *** variations of the hardness and residual stress along the depth were characterized by the Vickers hardness measurement and X-ray diffraction test,*** elastohydrodynamic lubrication theory was applied to predict the contact pressure distribution,highlighting the influence of the surface roughness that stemed from the original measurement through an optical *** stress histories of the studied material points during a complete contact loading cycle were fast calculated using the discreteconcrete fast Fourier transformation(DC-FFT)*** Dang Van diagrams under different working conditions were determined to estimate the contact fatigue failure *** effect of the root mean square(RMS)value of the surface roughness on the failure risk at critical material points were discussed in *** revealed that the surface roughness significantly increases the contact fatigue failure risk within a shallow area,and the maximum risk appears near the surface.

关键词： carburized gear contact fatigue surface roughness residual stress Dang Van criterion

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Tribological behavior of coated spur gear pairs with tooth surface roughness

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Friction 2019年第2期7卷 117-128页

作者： huaiju liu Heli liu Caichao ZHU Peitang WEI Jinyuan TANG State Key Laboratory of Mechanical Transmissions Chongqing University State Key Laboratory of High Performance Complex Manufacturing Central South University

Coating is an effective way to reduce friction and wear and to improve the contact-fatigue lives of gear components, which further guarantees a longer service life and better reliability of industrial machinery. The fact that the influence coefficient linking the tractions and stress components could not be expressed explicitly increases the difficulty of coated solids contact analysis. The complicated tribological behavior between tooth surfaces influenced by lubrication and surface roughness further adds difficulty to the coated gear pair contact problems. A numerical elastohydrodynamic lubricated(EHL) contact model of a coated gear pair is proposed by considering the coupled effects of gear kinematics, coating properties, lubrication, and surface roughness. The frequency response function and the discrete convolute, fast Fourier transformation(DC-FFT) method are combined to calculate the surface deformation and the subsurface stress fields at each meshing position along the line of action(LOA). The Ree-Eyring fluid is assumed to incorporate the non-Newtonian effect, which is represented in the generalized Reynolds equation. Influences of the ratio between the Young's modulus of the coating and the substrate on the contact performance, such as pressure, film thickness, tooth friction coefficient, and subsurface stress field, are studied. The effect of the root mean square(RMS) value of the tooth surface roughness is studied by introducing the roughness data, deterministically measured by an optical profiler.

关键词： coating gear elastohydrodynamic lubrication (EHL) surface roughness

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同向平双齿轮传动系统设计分析软件开发

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机械传动 2024年第1期48卷 52-60页

作者：刘桂源张磊魏沛堂刘根伸胡明珠何志强刘怀举重庆大学高端装备机械传动全国重点实验室重庆400044 江阴天澄机械装备有限公司江苏无锡214400

同向平双齿轮传动系统设计过程复杂、参数众多,型号更迭导致结构参数匹配困难、工作量大,亟待开发专用设计分析软件以提高设计效果和效率。建立了同向平双齿轮传动系统优化模型,基于C++语言与Qt应用程序框架开发了同向平双齿轮传动系统... 详细信息

同向平双齿轮传动系统设计过程复杂、参数众多,型号更迭导致结构参数匹配困难、工作量大,亟待开发专用设计分析软件以提高设计效果和效率。建立了同向平双齿轮传动系统优化模型,基于C++语言与Qt应用程序框架开发了同向平双齿轮传动系统专用设计分析软件;结合工程案例对软件的可运行性、优化效果、信效度进行了对比分析,验证了软件的有效性和可靠性。结果表明,所开发的软件实现了某同向平双齿轮传动系统比现有水平减重7.98%,优化结果稳定收敛且收敛精度达99.02%,齿轮安全系数偏差率控制在8%以内,实现了良好的高功率密度设计,有望推动行业设计方法转型升级。

关键词：同向平双齿轮传动系统设计分析结构参数优化软件开发

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