CN110907171A - Polymer gear durability test method - Google Patents
Polymer gear durability test method Download PDFInfo
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- CN110907171A CN110907171A CN201911238505.0A CN201911238505A CN110907171A CN 110907171 A CN110907171 A CN 110907171A CN 201911238505 A CN201911238505 A CN 201911238505A CN 110907171 A CN110907171 A CN 110907171A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
- G01M13/02—Gearings; Transmission mechanisms
- G01M13/021—Gearings
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M13/00—Testing of machine parts
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- G01M13/025—Test-benches with rotational drive means and loading means; Load or drive simulation
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Abstract
The invention discloses a polymer gear durability test method, which comprises the following steps: 1. carrying out initial detection and characterization on the tested high-molecular gears, 2, dividing the tested high-molecular gears into 2 groups, and mounting the high-molecular gears on a durability test bed; 3. testing the 1 st group of polymer gears, confirming that the tested polymer gears have failed, and recording the cycle timesNAnd failure modes; 4. testing the 2 nd group of polymer gears according to stages, performing staged detection and characterization on the tested polymer gears until the gears fail, stopping the test, and recording failure forms and cycle times; 5. carrying out data analysis on the stage data measured by the 2 nd group of polymer gear tests and the service lives N of the 1 st group of durability tests and the 2 nd group of durability tests; 6. make tooth surface contact stressσ H And fitting with a scatter diagram of the cycle number N to obtain an SN curve of the polymer gear. The test result of the invention can be used for using the polymer gearFor the basis.
Description
Technical Field
The invention belongs to a gear fatigue life testing technology, and particularly relates to a polymer gear durability test method.
Background
Compared with a steel gear, the polymer gear has the advantages of low processing cost, low noise, low density, low vibration, self-lubrication and the like, and is widely applied to the fields of printers, intelligent furniture, clocks and watches, automatic gear boxes, small engines and the like by virtue of the advantages. In engineering applications, polymer gears are commonly used in different working conditions, such as dry contact, grease lubrication, oil lubrication, and the like. The material and the working condition have great influence on the failure form and the service performance of the high-molecular gear, so a systematic endurance test method is needed to explore the failure form and the service performance of the high-molecular gear, and the method has important significance for establishing a high-molecular gear performance database and improving the durability and the reliability of a high-molecular gear product.
The polymer gear is made of organic polymer materials such as polyformaldehyde resin, polyether-ether-ketone, polyketone resin, carbon fiber and glass fiber. At present, no endurance test method for testing the failure mode and the service performance of the polymer gear exists.
Disclosure of Invention
Aiming at the problems in the prior art, the invention aims to provide a polymer gear durability test method which can record the failure process of a polymer gear and reflect the failure form and service performance of the polymer gear under different materials and different working conditions.
The technical problem to be solved by the invention is realized by the technical scheme, which comprises the following steps:
step 6, testing under different lubrication conditions or/and different output torques, analyzing by the cycle number N, and making the tooth surface contact stress sigmaHAnd fitting points in the scatter diagram with the cycle number N by using a least square method to obtain an SN curve of the polymer gear.
The invention has the technical effects that:
1. a polymer gear endurance test method is established, and the blank of the polymer gear fatigue life test field is filled;
2. not only can obtain the failure form and the service performance of the polymer gear, but also can obtain the important parameters (the total tooth profile offset F) of the polymer gear in the service processαSurface roughness Ra, etc.);
3. the fatigue life SN curve of the polymer gear can be obtained, and a basis is provided for the use of the polymer gear.
Drawings
The drawings of the invention are illustrated as follows:
FIG. 1 is a technical roadmap for one embodiment of the present method;
FIG. 2 is a failure mode versus life profile for a first set of experiments of an example;
FIG. 3 shows the total tooth profile offset F in the exampleαHistogram with lifetime N;
FIG. 4 is a graph of mass change versus cycle number for an example embodiment;
FIG. 5 is a histogram of roughness versus life at 60Nm output torque for the example;
FIG. 6 is a tooth surface micro-topography evolution feature diagram under an output torque of 60Nm in an embodiment;
FIG. 7 shows a tooth surface contact stress σ in the exampleHA graph relating to lifetime N.
Detailed Description
The invention is further illustrated by the following examples in conjunction with the accompanying drawings:
the technical route diagram of one embodiment of the method is shown in figure 1, and comprises the following steps:
Weighing the polymer gear with an electronic balance with the precision of 0.001g, weighing for 3 times, recording in sequence, and taking the average value of the 3 times of weighing as m0(unit is g). Gear precision detector for high molecular gear tooth profile total offset FαThe detection is carried out, 5 teeth are measured in sequence, and the average value of the total deviation amount of the tooth profile of the 5 teeth is taken as Fα0(unit is μm). The surface roughness Ra of the tooth surface of the polymer gear is represented by a micro-topography measuring instrument, 5 gear teeth are sequentially selected, the tooth crest region and the pitch line region are respectively represented, data are recorded and then processed by AFM software and other software, the roughness Ra of 5 tooth surfaces is obtained, and the average value of the roughness Ra of 5 tooth surfaces is recorded as Ra0. Observing the tooth profile of the polymeric gear by an optical microscope, and sequentially selecting 5 teethAnd respectively observing the tooth crest region and the pitch line region, and photographing and recording.
And 3, testing the group 1 high polymer gear, continuously detecting the temperature of the running-in gear by using an infrared heat sensor in the testing process, stopping when the vibration acceleration of the main shaft of the running-in high polymer gear reaches a set value, confirming that the tested high polymer gear is failed, and recording the cycle number N and the failure mode.
The set value of the vibration acceleration of the main shaft of the running-in polymer gear is 0.1g, and g is the local gravity acceleration. The high molecular gear is disassembled after the machine is stopped, and is cleaned by industrial anhydrous alcohol in an ultrasonic cleaning machine. And (5) observing whether the polymer gear has broken teeth, and recording the cycle number N and the failure mode if the polymer gear has broken teeth.
And if no broken tooth appears, observing whether the tooth surface has pitting corrosion, and if the pitting corrosion area of a single tooth surface exceeds 50% of the whole tooth surface, recording the cycle number N and the failure mode.
If no pitting corrosion appears, the polymer gear is weighed by an electronic balance, the weighing is carried out for three times, the three times are recorded in sequence, and the average value m of the three times of weighing is taken1And with the initial mass m0Comparing, and if the mass variation delta m is more than or equal to 0.05m0Wherein Δ m ═ m0-m1The number of cycles N and the failure mode are recorded.
If the mass change amount Δ m<0.05m0Then using the gear precision detector to measure the total deviation F of the tooth profile of the counter gearαThe detection is carried out, 5 teeth are measured in sequence, and the average value of the total deviation amount of the tooth profile of the 5 teeth is taken as Fα1，ΔFα＝Fαi-Fαi-1If the change of the total tooth profile offset is Δ FαNot less than 0.1S (wherein S is the tooth thickness at the reference circle)
m is the modulus of the polymer gear), the number of cycles N and the failure mode are recorded.
If the gear mass variation amount is Deltam<0.05m0And the variation quantity delta F of the total tooth profile offsetα<0.1S, continuously assembling the polymer gear on an endurance test bed to perform a running-in test for the 2 nd time; and repeating the test process, increasing the vibration acceleration of the main shaft of the running-in polymer gear every time, and continuing running-in. Specifically, when the vibration acceleration of the main shaft of the running-in high-molecular gear is increased by 0.05g, the running-in high-molecular gear is stopped, the high-molecular gear is detached and the detection items are repeated, if one item reaches the index, the cycle number N and the failure mode are recorded, and the like, and if the failure does not occur, the ith running-in test is carried out until one item in the index is met, and the cycle number N and the failure mode are recorded.
Taking n as an example, the specific process of each stage of the test is as follows:
when the number of cycles reaches N1When the gear weighing machine is stopped, the high-molecular gear is disassembled, is cleaned by industrial absolute alcohol in an ultrasonic cleaning machine, is subjected to stage detection and characterization, is weighed by an electronic balance, is weighed for 3 times and is recorded in sequence, and the average value of 3 times of weighing is taken and recorded as m1. Total offset F of tooth profile of counter gear by using gear precision detectorαPerforming detection in turnMeasuring 5 teeth, taking the average value of the total deviation of the tooth profile of 5 teeth as Fα1. The surface roughness Ra of the tooth surface of the polymer gear is represented by a non-contact micro-topography measuring instrument, 5 gear teeth are sequentially selected, the tooth crest region and the pitch line region are respectively represented, data are recorded and are subsequently processed by AFM software and the like to obtain the roughness Ra of the tooth surface of 5 teeth, and the average value of the roughness of the tooth surface of 5 teeth is recorded as Ra1. Observing the tooth profile of the macromolecular gear by using an optical microscope, sequentially selecting 5 teeth, observing the tooth top region and the pitch line region respectively, and photographing and recording. After the detection and the characterization are finished, the polymer gear is assembled on an endurance test bed to carry out a 2 nd running-in test, the temperature of the running-in gear is continuously detected by using an infrared heat sensor in the test process, the temperature is recorded, and when the cycle number reaches N2When the device is stopped, the high-molecular gear is disassembled, cleaned by industrial absolute alcohol in an ultrasonic cleaning machine, subjected to stage detection and characterization, and sequentially and respectively marked as m2，Fα2，Ra2. After the detection and characterization are completed, the polymer gear is assembled on a durability test bed to carry out a running-in test for the 3 rd time. And so on until the cycle number reaches N5Until now, the high molecular gear is disassembled by stopping the machine, cleaned by industrial absolute alcohol in an ultrasonic cleaning machine, and subjected to stage detection and characterization, which are respectively marked as m5，Fα5，Ra5。
There may be some uncertainty in the test that will result in the number of cycles N for gear set 2iBelow or above the number N of cycles of group 1 gear.
When N is presenti<NnWhen i is less than n, stopping the machine to disassemble the high molecular gear, cleaning the high molecular gear by industrial absolute alcohol in an ultrasonic cleaning machine, and calculating the delta mi＝mi-m0，ΔFαi＝Fαi-Fαi-1Confirming that the tested high-molecular gear fails, and recording the cycle number N at the momentiAnd failure mode, and performing staged detection and characterization, which are sequentially and respectively marked as mi，Fαi，Rai，i<n, stop the test.
When N is presenti>NnWhen i is>And n, repeating the test process, increasing the vibration acceleration of the main shaft of the running-in polymer gear every time, and continuing running-in. Stopping the machine when the vibration acceleration value of the main shaft of the running-in polymer gear is increased, and carrying out staged detection and characterization on the tested polymer gear; repeating the steps in sequence, and calculating the delta mi＝mi-m0，ΔFαi＝Fαi-Fαi-1Confirming that the tested high-molecular gear fails, and recording the cycle number NiAnd failure modes; and performing staged detection and characterization, sequentially and respectively recording as mi，Fαi，RaiThe test was stopped.
The increase value of the vibration acceleration of the main shaft of the running-in polymer gear is 0.05 g.
origin pair F by using mathematical analysis softwareα1、Fα2、…、FαiAnalyzing to obtain total tooth profile offset FαObtaining the variation delta F of the total tooth profile offset according to the histogram of the life variationαiTrend of change over life cycle;
to m1、m2、…、miAnalyzing to obtain mass variation Δ miThe variation of mass Δ m can be obtained from the life-time curveiThe change rule in the whole life cycle;
variation amount of total tooth profile offset Δ FαiAnd amount of mass change Δ miThe wear condition of the polymer gear in the whole service life process can be reliably reflected.
For Ra1、Ra2、…、RaiAnd analyzing to obtain a histogram of the surface roughness Ra changing along with the service life, and obtaining the evolution rule of the surface quality of the tooth surface of the polymer gear in the whole service life cycle.
The evolution characteristics of the tooth surface micro-topography (such as pitting, scratching, thermal damage and the like) can be obtained by comparing and analyzing the photos of observing the tooth surface topography of the high molecular gear by using an optical microscope at each service life stage.
Step 6, testing under different lubrication conditions or/and different output torques, analyzing by the cycle number N, and making the tooth surface contact stress sigmaHAnd fitting points in the scatter diagram with the cycle number N by using a least square method to obtain an SN curve of the polymer gear.
Examples
In the embodiment, a POM gear with a modulus of 3mm is selected for a durability test to obtain the failure mode and the service performance of the gear.
Weighing for 3 times, sequentially recording, and taking average value m of 3 times of weighing0. Total offset F of tooth profile of counter gear by using gear precision detectorαThe test was performed and 5 teeth were measured in sequence. The surface roughness Ra of the tooth surface of the polymer gear is represented by a non-contact type micro-topography measuring instrument, 5 gear teeth are sequentially selected, the tooth crest area and the pitch line area are respectively represented, and data are recorded and then processed by AFM software. Observing the tooth profile of the macromolecular gear by using an optical microscope, sequentially selecting 5 teeth, observing the tooth top region and the pitch line region respectively, and photographing and recording.
TABLE 1 POM Gear durability test basic information
The test bed is selected from a multi-purpose transmission tribology test bed CQU-AMH-195, the torque loading range of the test bed is 0-200 Nm, and the test bed has basic functions of temperature online monitoring, main shaft vibration online monitoring and the like.
And 3, testing the 1 st group of polymer gears, and continuously detecting the temperature of the running-in gear by using an infrared heat sensor in the testing process. When the vibration acceleration of the main shaft of the running-in polymer gear reaches a set value of 0.1g, the machine is stopped, the polymer gear is disassembled, and the polymer gear is cleaned by industrial anhydrous alcohol in an ultrasonic cleaning machine. It was found that tooth breakage occurred in the region between the tooth tip and the pitch line, and failure mode and cycle number were recorded, and the test results are shown in fig. 2, and are seen from fig. 2: the failure mode of the POM gear is that the gear teeth generate fatigue fracture in the pitch line and the tooth crest area, and the failure mode of the POM gear is not changed along with the increase of the load torque, which shows that the failure mode of the POM gear is not changed by the change of the load under the oil lubrication condition
And 5, processing data, and utilizing the Origin of mathematical analysis software to perform F under 4 output torquesα1、Fα2、…、FαiAnalyzing to obtain the total tooth profile offset FαHistogram with lifetime N, as shown in fig. 3, can be seen in fig. 3: total deviation F of tooth profile of POM gear bearing surface under the output torques of 60Nm and 40NmαWith a slightly increasing trend from first to failure, the deviation can be as high as 70 μm or more in a short time when the load level is large.
FIG. 4 shows the mass change Δ miWith age, it can be seen from FIG. 4 that the mass change is of a small magnitude as the number of cycles increasesAn increase in this indicates a slight wear of the tooth flanks.
Fig. 5 is a bar graph of the surface roughness Ra of the output torque 60Nm as a function of the lifetime, and it can be seen from fig. 5 that the average roughness of the tooth surface is gradually increasing as the number of cycles increases.
And comparing the 60Nm surface micro-topography maps to obtain an evolution diagram of the tooth surface micro-topography under the output torque of 60Nm, as shown in FIG. 6. As can be seen from fig. 6, at an output torque of 60Nm, a large number of machining cuts in the tooth width direction are initially distributed over the entire tooth surface. When the POM gear is operated to 1.4 multiplied by 106When the gear is rotated, the machining cutting marks in the tooth crest area are gradually ground flat, and the machining cutting marks in the pitch line area are still clearly visible; the POM gear is at 2.6 multiplied by 106Failure occurred, but it can be seen in the figure that there was still some machining cut in the nodal line region.
Step 6, analyzing the cycle times N under the 4 output torques to obtain the tooth surface contact stress sigmaHThe SN curve obtained by fitting a scatter plot of lifetime N to the least square method is shown in FIG. 7. The fitting formula is:
it is noted that this formula is only applicable to POM gear pair steel gears under oil lubrication conditions. It may no longer be effective if gear dimensions, manufacturing processes, mating material types, or lubrication conditions change.
Claims (10)
1. A polymer gear durability test method is characterized by comprising the following steps:
step 1, carrying out initial detection and characterization on a tested polymer gear, wherein the initial detection and characterization comprises mass weighing, tooth profile total offset detection, tooth surface roughness characterization, surface micro-topography observation and photographing record;
step 2, dividing the tested high-molecular gears into 2 groups, mounting the high-molecular gears on a durability test bed, and setting the materials, the output torque, the experimental conditions and the input rotating speed of the mating meshed gears; the durability test bed has the functions of torque loading, temperature online monitoring and main shaft vibration online monitoring;
step 3, testing the group 1 high polymer gear, continuously detecting the temperature of the running-in gear by using an infrared heat sensor in the testing process, stopping when the vibration acceleration of a main shaft of the running-in high polymer gear reaches a set value, confirming that the tested high polymer gear is failed, and recording the cycle number N and the failure mode;
step 4, dividing the cycle number N obtained by the 1 st group of tests into at least 3 stages which are respectively marked as N1、N2、…、NnAnd N is the number of stages, then the 2 nd group of polymer gears are tested according to stages, the temperature of the running-in gear is continuously detected by an infrared heat sensor in the test process, and the cycle number reaches N1、N2、…、NnStopping the machine in each stage, performing staged detection and characterization on the tested high-molecular gear until the gear fails, stopping the test, and recording failure forms and cycle times;
step 5, carrying out data analysis on the stage data measured by the 2 nd group of polymer gear tests and the service lives N of the 1 st group and the 2 nd group of two endurance tests to obtain the total tooth profile offset FαHistogram of change with age, mass change Δ miA graph changing with the service life, a histogram of surface roughness Ra changing with the service life, and evolution characteristics of tooth surface pitting, scratching and thermal damage;
step 6, testing under different lubrication conditions or/and different output torques, analyzing by the cycle number N, and making the tooth surface contact stress sigmaHAnd fitting points in the scatter diagram with the cycle number N by using a least square method to obtain an SN curve of the polymer gear.
2. The method for testing the durability of a polymer gear according to claim 1, wherein the polymer gear is detected and characterized by: weighing the polymer gear by using a balance, weighing for 3 times, sequentially recording, and taking an average value of the 3 times of weighing; gear precision detector for total deviation of macromolecular gear tooth profileQuantity FαDetecting, sequentially measuring 5 teeth, and taking the average value of the total offset of the tooth profiles of the 5 teeth; characterizing the surface roughness Ra of the tooth surface of the polymer gear by using a micro-topography measuring instrument, sequentially selecting 5 gear teeth, respectively characterizing the tooth crest region and the pitch line region, recording data, subsequently processing the data by using AFM (atomic force microscopy) and other software to obtain the roughness Ra of 5 tooth surfaces, and taking the average value of the roughness of 5 tooth surfaces; observing the tooth profile of the macromolecular gear by using an optical microscope, sequentially selecting 5 teeth, observing the tooth top region and the pitch line region respectively, and photographing and recording.
3. The polymer gear durability test method according to claim 2, wherein: in step 3, the set value of the vibration acceleration of the main shaft of the running-in polymer gear is 0.1g, and g is the local gravity acceleration.
4. The polymer gear durability test method according to claim 3, wherein: in step 4, the number of stages n is 5.
5. The method for testing the durability of a polymer gear according to any one of claims 1 to 4, wherein in the step 3 and the step 4, the polymer gear failure in the test is confirmed by:
1) whether the polymer gear has broken teeth or not, and if the broken teeth occur, the polymer gear fails;
2) if no broken tooth appears, observing whether the tooth surface has pitting corrosion, and if the pitting corrosion area of a single tooth surface exceeds 50% of the whole tooth surface, the polymer gear fails;
3) if no pitting corrosion appears, weighing the polymer gear by using an electronic balance, weighing for three times, recording in sequence, and taking the average value m of the three-time weighingiAnd with the initial mass m0Comparing, if the mass variation quantity delta mi≥0.05m0Wherein Δ mi＝mi-m0If i is the test times, the polymer gear fails;
4) if the mass change amount is Δ mi<0.05m0Then using the gear precision detector to measure the total offset F of the tooth profile of the counter gearαThe detection is carried out, 5 teeth are measured in sequence, and the average value of the total deviation amount of the tooth profile of the 5 teeth is taken as Fαi，ΔFαi＝Fαi-Fαi-1If the change of the total tooth profile offset is Δ F αiAnd more than or equal to 0.1S, wherein S is the tooth thickness at the reference circle, and the polymer gear fails.
6. The method for testing durability of a polymer gear according to claim 5, wherein: in step 3, the gear mass change amount Δ m<0.05m0And the variation quantity delta F of the total tooth profile offsetα<Under the condition of 0.1S, continuously assembling the high-molecular gear on a durability test bed to perform a running-in test for the 2 nd time; and repeating the test process, increasing the vibration acceleration of the main shaft of the running-in polymer gear every time, and continuing running-in until the gear fails.
7. The polymer gear durability test method according to claim 6, wherein: the increase value of the vibration acceleration of the main shaft of the running-in polymer gear is 0.05 g.
8. The method for testing durability of a polymer gear according to claim 5, wherein: in step 4, when N isi>NnWhen i is>And n, repeating the test process, increasing the vibration acceleration of the main shaft of the running-in polymer gear every time, and continuing running-in until the gear fails.
9. The polymer gear durability test method according to claim 8, wherein: the increase value of the vibration acceleration of the main shaft of the running-in polymer gear is 0.05 g.
10. The polymer gear durability test method according to claim 8, wherein: in step 5, the data is analyzed as follows:
origin pair F by using mathematical analysis softwareα1、Fα2、…、FαiAnalyzing to obtain total tooth profile offset FαObtaining the variation delta F of the total tooth profile offset according to the histogram of the life variationαiTrend of change over life cycle;
to m1、m2、…、miAnalyzing to obtain mass variation Δ miObtaining the mass variation Deltam according to the service life variation curve chartiThe change rule in the whole life cycle;
for Ra1、Ra2、…、RaiAnalyzing, and making a histogram of the surface roughness Ra changing along with the service life to obtain the evolution rule of the surface quality of the tooth surface of the polymer gear in the whole service life period;
and (4) comparing and analyzing the photos observed on the tooth surface appearance of the high molecular gear by using an optical microscope at each service life stage to obtain the evolution characteristics of the tooth surface micro appearance.
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