人字形齿轮喷丸残余应力和粗糙度的计算与试验验证  

Numerical Research and Experimental Investigation of Residual Stress and Roughness of Double Helical Gear after Shot Peening

作　　者：王长清 张慧芸 唐进元[2] 赵久越 吕亮亮 WANG Changqing;ZHANG Huiyun;TANG Jinyuan;ZHAO Jiuyue;LYU Liangliang(AECC Harbin Dongan Engine Co.,Ltd.,Harbin 150060,China;State Key Laboratory of High-Performance Complex Manufacturing,Central South University,Changsha 410083,China)

机构地区：[1]中国航发哈尔滨东安发动机有限公司,哈尔滨150060 [2]中南大学极端服役性能精准制造国家重点实验室,长沙410083

出　　处：《表面技术》2025年第5期245-256,共12页Surface Technology

基　　金：国家重点研发计划项目(2023YFB3406404)。

摘　　要：目的探究人字形齿轮喷丸强化工艺参数对残余应力和粗糙度的影响。方法基于离散元方法(Discrete ElementMethod,DEM)建立人字形齿轮喷丸强化DEM模型,研究人字形齿轮表面不同位置的冲击速度和次数;建立基于有限元方法(FiniteElementMethod,FEM)的喷丸强化FEM模型,并采用离散元模型耦合有限元模型(DEM-FEM)的方法,将DEM模型的冲击信息导入FEM模型中,采用显示动力学仿真计算,得到喷丸后的残余应力和表面形貌信息;利用X射线衍射仪和白光干涉仪分别对实验试样进行残余应力和表面形貌的表征,以验证模型的准确性。结果1)弹丸初速度从40 m/s增加到60 m/s时,齿宽方向的表面残余压应力从-906 MPa增加到了-932 MPa;2)弹丸直径从0.30 mm增加到0.60 mm时,齿宽方向的表层残余应力从-906MPa减小到了-756MPa;3)当覆盖率<100%时,表面粗糙度Sa快速增加,残余压应力也快速增加,当覆盖率>100%时,Sa开始减小,残余压应力增幅降低。结论人字形齿轮齿面复杂,不同方向的残余应力会有所区别;齿宽和齿高方向的残余压应力均随着弹丸初速度的增加而增加,但同时会增加表面粗糙度、降低表面质量;大尺寸弹丸在带来更深残余应力质变层的同时会显著降低面质量;合理控制覆盖率既能够得到良好的表面质量,也能够降低喷丸成本。The work aims to investigate the effect of shot peening process parameters on residual stress and roughness of double helical gear.In order to more realistically approach the actual shot peening process,a discrete element shot peening model is established.DEM model is used to simulate the information after the shot is injected from the nozzle to the impact of the tooth surface,so as to simulate the actual complex shot peening process.Then,the information such as the position and velocity of the shot impacting the tooth surface is obtained.The impact information of DEM model is obtained,which is input into the finite element model as the initial conditions.The shot in the finite element model continuously impacts the surface of the target plate with the calculation results of the DEM model and the residual stress and surface topography calculated by the finite element model are extracted by the Python program.The calculated residual stress and surface morphology are characterized and it is found that the maximum calculation error is less than 15%,which indicates that the calculation results have good accuracy.It is found that the shot velocity increases from 40 m/s to 60 m/s and the surface residual compressive stress in the tooth width direction increases from-906 MPa to-932 MPa.When the shot diameter increases from 0.3 mm to 0.6 mm,the surface residual stress in the direction of tooth width decreases from-906 MPa to-756 MPa.However,the maximum residual compressive stress increases with the increase of shot diameter and velocity.When the coverage is less than 100%,both Sa and residual comprehensive stress increase rapidly.When the coverage exceeds 100%,both Sa and increase rate of residual comprehensive stress begin to decrease.The above results show that,due to the complex curved structure of double helical gear,the residual stress levels in the tooth width and tooth height are different even though the impact times are almost the same in the tooth surfaces with different rotation directions.With the increase of

关 键 词：人字形齿轮 喷丸强化 残余应力 粗糙度 离散元方法 有限元方法 

分 类 号：TG178[金属学及工艺—金属表面处理]