考虑残余应力的螺旋锥齿轮接触疲劳裂纹萌生-扩展寿命计算方法研究  

Calculation Method of Contact Fatigue Life of Spiral Bevel Gears Considering Residual Stress

作　　者：周长江[1] 王豪野 靳广虎[2] 艾永生 ZHOU Changjiang;WANG Haoye;JIN Guanghu;AI Yongshen(State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body,Hunan University,Changsha 410082;National Key Laboratory of Science and Technology on Helicopter Transmission,Nanjing University of Aeronautics and Astronautics,Nanjing 210016;AECC Hunan Aviation Powerplant Research Institute,Zhuzhou 412002)

机构地区：[1]湖南大学汽车车身先进设计制造国家重点实验室,长沙410082 [2]南京航空航天大学直升机传动技术重点实验室,南京210016 [3]中国航发湖南动力机械研究所,株洲412002

出　　处：《机械工程学报》2022年第23期28-38,共11页Journal of Mechanical Engineering

基　　金：国家自然科学基金(5207051373);直升机传动技术重点实验室基金(HTL-O-21K01)资助项目。

摘　　要：考虑渗碳、磨齿、喷丸等工艺产生的齿面残余应力,建立齿面接触应力与残余应力的复合应力场,提出一种螺旋锥齿轮接触疲劳裂纹萌生-扩展寿命计算方法。构建齿轮有限元接触分析模型,计算多轴交变接触应力场。考虑空间螺旋曲面残余应力分布的复杂性,将变曲率齿面离散为网状节点;测量各节点表面与次表面的残余应力,建立齿面残余应力场。基于Dang Van多轴疲劳准则,构建齿面裂纹萌生模型;计及残余应力与裂纹闭合效应,构建齿面裂纹扩展模型。计算复合应力场下齿轮接触疲劳寿命,研究残余应力对齿面裂纹萌生-扩展寿命的影响规律。结果发现:复杂齿面空间变曲率会影响喷丸等工艺产生的残余应力分布,中心区域的残余压应力高出齿面边缘区域约20%;复合应力场下齿面裂纹萌生位置与寿命主要取决于接触应力,残余应力会改变齿面节点平均应力进而影响疲劳寿命;齿面裂纹扩展寿命约占全寿命的10%,表征齿轮接触疲劳快速失效至迅速断裂。上述研究对于高性能齿轮传动的长寿命、高可靠性设计具有一定的参考价值。Considering the residual stress of tooth surface produced by carburizing, tooth grinding and shot peening, the complex stress field of tooth surface contact stress and residual stress is established, and a method for calculating contact fatigue crack initiation and propagation life of spiral bevel gears is proposed. A gear finite element contact analysis model is established to calculate the multi-axis alternating contact stress field. Considering the complexity of residual stress distribution of space spiral surface, the tooth surface with variable curvature is discretized into network nodes. The residual stress field of tooth surface is established by measuring the surface and sub-surface residual stress. Based on Dang Van criterion, a tooth surface crack initiation model is established. Considering the residual stress and crack closure effect, a model of tooth surface crack propagation is established, and the gear contact fatigue life under compound stress field is calculated. The results show that the spatial curvature of tooth surface affects the distribution of residual stress caused by shot peening, and the residual compressive stress in the central region is about 20% higher than that in the edge region. The crack initiation location and the fatigue life of the tooth surface are mainly determined by the contact stress, and the residual stress will affect the average stress. The crack propagation life accounts for about 10% of the whole life, which indicates the failure to rapid fracture of gear contact fatigue. The research can be an important reference in the design of long life and high reliability gear transmission.

关 键 词：螺旋锥齿轮 复合应力场 裂纹萌生 裂纹扩展 接触疲劳寿命 

分 类 号：TG156[金属学及工艺—热处理]