CN111144044A - Plastic gear contact fatigue life assessment method considering temperature influence - Google Patents
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Abstract
The invention discloses a plastic gear contact fatigue life evaluation method considering temperature influence, which comprises the following steps: step 1, testing the temperature-related mechanical behavior of the plastic according to a standard; step 2, fitting a plastic thermal elastic plastic constitutive equation according to test data, and writing a subprogram UMAT of ABAQUS; step 3, determining the temperature of the plastic gear in the operation process by adopting calculation or test; step 4, establishing a two-dimensional gear complete thermal coupling contact finite element model on the ABAQUS platform; step 5, fitting an ultimate tensile stress equation changing along with temperature according to the material test parameters, and obtaining plastic fatigue parameters according to the conversion relation between the tensile yield limit and the fatigue parameters; and 6, calculating the fatigue life of the plastic gear by using a Brown-Miller multi-axial fatigue rule. The invention has the technical effects that: the problem of contact fatigue failure of the plastic gear under the influence of the operating temperature is solved.
Description
Technical Field
The invention belongs to an analysis method of contact fatigue failure of mechanical parts, and particularly relates to a plastic gear contact fatigue life evaluation method.
Background
Compared with metal materials, the plastic gear has the advantages of light weight, corrosion resistance, small vibration and the like, and is widely applied to the fields of household appliances, automobiles, medical treatment and the like. The common materials of the plastic gear at present are Polyformaldehyde (POM), nylon (PA), polyether ether ketone (PEEK) and composite materials thereof, the mechanical properties of the materials are closely related to the temperature, and the failure mode of the materials is usually represented as tooth surface contact fatigue failure in a lubrication state. However, the current plastic gear design method and theory are still limited to the linear elastic constitutive relation, influence of temperature on mechanical properties of the plastic gear is neglected, the critical fatigue life and friction and wear problems in the service process of the plastic gear still stay in the empirical formula stage, and great difficulty is brought to prediction of the bearing capacity and failure mode of the plastic gear.
Disclosure of Invention
The invention aims to solve the technical problem of providing a plastic gear contact fatigue life evaluation method considering temperature influence, which can analyze the contact fatigue failure problem of a plastic gear under the influence of operating temperature, has accurate analysis result, reduces the risk of contact fatigue failure of the plastic gear and improves the operation reliability of used equipment.
The technical problem to be solved by the invention is realized by the technical scheme, which comprises the following steps:
step 1, obtaining an elastic modulus, an ultimate tensile stress and a true plastic stress strain curve of a gear material along with temperature change according to a standard GB1040-92 plastic tensile property test method;
step 2, according to the gear material test data in the step 1, fitting the parameters of a gear material thermo-elastic-plastic constitutive equation, wherein the constitutive equation fully considers the influence of temperature on the mechanical behavior of the gear material;
step 3, defining the temperature of the gear body in the gear running process according to a standard VDI 2736 plastic gear body temperature calculation empirical formula, or testing the temperature of the plastic gear body according to a test;
step 4, establishing a two-dimensional gear complete thermal coupling contact finite element model on an ABAQUS platform, and writing an ABAQUS subprogram UMAT to define a plastic gear material according to the gear material thermal elastic plastic constitutive equation in the step 2;
step 5, fitting an ultimate tensile stress equation changing along with temperature according to the gear material test parameters in the step 1, and selecting a proper lubrication coefficient according to a lubrication state;
step 6, calculating a critical surface of each gear material point, and a shear strain amplitude, a positive strain amplitude and a positive stress mean value on the critical surface; the fatigue life of plastic gears was calculated using the Brown-Miller multi-axial fatigue criterion.
The invention has the technical effects that:
under the condition of considering the temperature effect, the contact fatigue failure problem of the plastic gear is analyzed, the contact fatigue life is predicted, the obtained analysis result is well matched with test data, a basis is provided for the manufacture and the use of the plastic gear, and accidents and economic damages caused by the contact fatigue failure of the plastic gear in the engineering practice are reduced.
Drawings
The drawings of the invention are illustrated as follows:
FIG. 1 is a graph of the elastic modulus of a plastic gear material as a function of temperature;
FIG. 2 is the ultimate tensile stress of a plastic gear material as a function of temperature;
FIG. 3 is a true plastic stress-strain curve of a plastic gear material as a function of temperature;
FIG. 4 is a response curve of a plastic gear material thermo-elastic-plastic constitutive;
FIG. 5 is a two-dimensional gear complete thermal coupling contact finite element model;
FIG. 6 is a schematic view of a critical plane of material;
FIG. 7 is a graph of the results of shear strain amplitude, positive strain amplitude and positive stress amplitude;
FIG. 8 is a cloud of life spans of plastic gear teeth;
FIG. 9 is a graph comparing predicted risk locations to test results;
FIG. 10 is a graph comparing fatigue life test data with calculated results.
Detailed Description
The invention is further illustrated by the following examples in conjunction with the accompanying drawings:
the invention comprises the following steps:
step 1, testing the tensile mechanical property of the plastic gear material along with the temperature change
According to a standard GB1040-92 plastic tensile property test method, an elastic modulus, an ultimate tensile stress and a real plastic stress strain curve of the gear material along with temperature change are obtained, and refer to fig. 1, fig. 2 and fig. 3.
Step 2, establishing a plastic gear material thermo-elastic-plastic constitutive equation
According to the relationship that the elastic modulus of the gear material changes along with the temperature, a thermal elastic constitutive equation is established as follows:
σ＝(αT+E0)ε
where σ is the stress, T is the material temperature, T is the maximum temperature experienced by the meshing gear teeth during thermal coupling analysis, E0The elastic modulus of the material at the temperature of 0 ℃ is shown, epsilon is strain, and α is a material constant.
The constitutive equations for thermoplastic plastics gear materials can be expressed in Johnson-Cook empirical relations, which are presented by Johnson in the article "Fracture characteristics of three metals to variable strains, strain rates and pressures", Engineering Fracture Mechanics, Vol.21, 1985, pp.31-48,1985. Gonzalez is used in the paper "Mechanical impact viewer of polyether-ether-ketone (PEEK)", Composite Structures, pp.88-99,2015 ("Mechanical impact Properties of Polyetheretherketone (PEEK)", Composite Structure 2015, pp.88-99) to describe the Mechanical behavior of plastic PEEK. The Johnson-Cook constitutive equation can be expressed as:
in the formula, σPIn terms of flow stress, in MPa, A is the yield stress at the reference temperature and strain rate, B is the hardening coefficient, n is the strain hardening coefficient, εPIs the true plastic strain of the material to be measured,
is the rate of strain, and is,
the strain rate is referred, C is a strain rate sensitive coefficient, and C is 0 because the influence of the strain rate is not considered; t is*mTo normalize the temperature coefficient, it can be expressed as:
T*m＝(T-Troom)/(Tmelt-Troom)
wherein T is the material temperature, TroomIs a reference temperature, TmeltIs the melting point of the material.
And fitting to obtain parameters of the constitutive equation according to the elastic modulus of the gear material changing along with the temperature and the real plastic stress-strain curve. And (3) drawing a gear material thermo-elastic-plastic constitutive response curve by combining a thermo-elastic constitutive equation and a Johnson-Cook constitutive equation, and describing a plastic gear material thermo-elastic-plastic stress-strain relationship, which is shown in FIG. 4.
Step 3, determining the temperature of the tooth surface of the plastic gear
According to a standard VDI 2736 plastic gear tooth surface temperature calculation empirical formula or other methods, the tooth surface temperature in the gear running process is defined:
in the formula (I), the compound is shown in the specification,
is the tooth surface temperature in units of;
is ambient temperature; p is nominal output power and has the unit of W;
is the plastic gear heat transfer coefficient; mu is a friction coefficient; hVThe gear tooth loss coefficient; b is the tooth width in mm; z is the number of plastic gear teeth; v. oftIs tangential velocity, in m/s; m isnNominal modulus in mm; rλ,GIs a plastic gearThermal resistance; a. theGThe tooth surface heat dissipation coefficient; ED is the relative engagement time.
Step 4, establishing a plastic gear finite element analysis model
Establishing a two-dimensional gear complete thermal power coupling contact finite element model on an ABAQUS platform, referring to FIG. 5, writing an ABAQUS user-defined material subprogram UMAT to define plastic gear materials according to the plastic gear material thermal elastic plastic constitutive equation established in step 2, and setting the plastic gear surface temperature as the initial temperature in the finite element model according to the plastic gear surface temperature determined in step 3.
Step 5, determining fatigue parameters of plastic gear material
Fitting an ultimate tensile stress equation as a function of temperature according to the material test parameters of step 1, see fig. 2:
σ′u＝βT+σ′0
in formula (II), sigma'uIs ultimate tensile stress, β is the material constant, σ'0Is the ultimate tensile stress at a reference temperature of 0 ℃. Obtaining a fatigue strength coefficient sigma 'according to the conversion relation between the fatigue parameters and the tensile strength'fAnd fatigue ductility coefficient ε'fFatigue strength index b and c fatigue ductility index. Conversion relationships such as those proposed by Seeger in Materials data for cyclic loading-supplement 1 (cyclic loading Materials data-supplement 1, EscherWell scientific publishing Co., 1990):
σ′f＝L67σ′u，ε′f＝0·35，b＝-0·095，c＝-0·69
step 6, calculating the contact fatigue life of the plastic gear
Fatigue damage was calculated using the Brown-Miller multi-axial fatigue criterion, which defines the plane with the greatest shear strain as the critical plane. To find the location of the critical plane, the stress strain at each angle of each material point needs to be calculated according to the calculation formula described in the Book "Theory of Elasticity", mcgraw hill Book Company, 1970 ("elastodynamics", s.p. timoshenko, j.n. goodier, h.n. abramson mcgraw hill Book Company, 1970) as follows:
in the formula, σθRepresenting positive stress on a critical plane at an angle theta to the rolling direction, epsilonθRepresenting positive strain, gamma, in a critical plane at an angle theta to the rolling directionθRepresenting the shear strain, σ, in a critical plane at an angle θ to the rolling directionx、σzAnd τxzRespectively representing two principal stresses and one shear stress, epsilonx、εzAnd gammaxzTwo principal stresses and one shear stress are indicated, respectively. Based on the calculated shear strain value, the angle at which the maximum shear strain occurs in one cycle is taken as the critical plane, and a schematic diagram of the critical plane of the material is shown in fig. 6.
Calculating the shear strain amplitude Deltagamma on the critical surfacemaxPositive strain amplitude delta epsilonnAnd positive stress mean value sigmamThe calculation formula is as follows:
in the formula, gammamax、εmaxAnd σmaxThe maximum shear strain, the maximum positive strain and the maximum positive stress on the critical surface in the cyclic loading process are respectively gammamin、εminAnd σminThe minimum shear strain, the minimum positive strain and the minimum positive stress on the critical surface in the cyclic loading process are respectively.
According to the obtained shearing strain amplitude delta gamma on the critical surfacemaxPositive strain amplitude delta epsilonnAnd positive stress mean value sigmamFatigue life was calculated using the Brown-Miller multiaxial fatigue criterion. According to K.J.Miller and M.W.Brown in the article "Atheology for failure end multi-axial stress-conditions", Proc.Inst.Mech.Eng.187(1973)745 @.755. ("fatigue theory under multiaxial stress-strain conditions", England Engineers, volume 187, 1973, page 745 @) and C.H.Wang and M.W.Brown in the article "A path-independent parameter for failure end entry promotion al and non-proportionalloading”,FATIGUE&FRACTURE OF ENGINEERING MATERIALS&STRUCTURES, 16(1993) 1285-1298. ("Path independent fatigue parameters under proportional and non-proportional loads", fatigue fracture of engineering materials and structures, Vol.16, 1993, p.1285-1298) the Brown-Miller multiaxial fatigue life calculation formula is as follows:
in the formula, Δ γmaxFor amplitude of shear strain, Δ εnIs the magnitude of positive strain, σ, on the critical planemS is the material parameter, σ ', determined by torsion and tensile experiments as the mean stress on the critical faces'fAnd epsilon'fRespectively a fatigue strength coefficient and a fatigue ductility coefficient, b is a fatigue strength index, c is a fatigue ductility index, 2NfMaterial parameter C for calculating fatigue life of material point based on stress strain field at the moment1And C2Respectively is C1＝1.3+0.7S，C2＝1.5+0.5S。
Because the lubricating state can influence the fatigue strength of the material, the lubricating coefficient omega is introduced into the Brown-Miller multiaxial fatigue life calculation formula, and the Brown-Miller multiaxial fatigue life calculation formula is modified into
And selecting different lubrication coefficients omega according to different lubrication states, wherein the value range is from 0.2 to 1.5.
Examples
The main geometric parameters of the gear pair are as follows:
the pinion is a driving wheel and is made of carburizing steel 18CrNiMo 7-6; the bull gear is the driven wheel, and the material is POM (M90-44), and the material basic parameter is as follows:
step 1, testing the tensile mechanical property of the plastic gear material along with the temperature change
According to a standard GB1040-92 plastic tensile property test method, the elastic modulus, the ultimate tensile stress and the real plastic stress strain curve of the POM gear material along with the temperature change are obtained, and refer to figures 1-3.
Step 2, establishing a plastic gear material thermo-elastic-plastic constitutive equation
The elastic phase thermoelasticity constitutive equation of the plastic gear material is as follows:
σ＝(αT+E0)ε
the plastic constitutive equation of the plastic gear material in the plastic stage is as follows:
T*m＝(T-Troom)/(Tmelt-Troom)
according to the elastic modulus and the real plastic stress-strain curve of the POM gear material along with the temperature change, referring to fig. 1 and fig. 3, constitutive equation parameters are obtained by fitting, and are shown in the following table:
therefore, a thermo-elastic constitutive response curve of the POM gear material in the present embodiment is drawn by combining the thermo-elastic constitutive equation and the thermoplastic constitutive equation, and see fig. 4.
Step 3, determining the temperature of the tooth surface of the plastic gear
An empirical formula is calculated according to the tooth surface temperature of a standard VDI 2736 plastic gear:
the POM gear was calculated to have a face temperature of about 30 c in this example.
Step 4, establishing a plastic gear finite element analysis model
A two-dimensional gear complete thermal coupling contact finite element model is established on an ABAQUS platform, and is shown in figure 5. The cell type is chosen to be CPE4 RT. The formula of the friction of the contact surface is selected as a penalty function algorithm, and the friction coefficient is 0.04. The driven wheel applies torque, and the main gear applies rotation speed of 1500 r/min. Writing an ABAQUS user-defined material subprogram UMAT to define the plastic gear material according to the thermal elastic-plastic constitutive equation of the plastic gear material established in the step 2, determining the temperature of the tooth surface of the plastic gear according to the step 3, and setting the initial temperature in an analysis model to be 30 ℃;
step 5, determining fatigue parameters of plastic gear material
From the material test parameters, an ultimate tensile stress equation with temperature change was fitted, see fig. 2:
σ′u＝βT+σ′0
in formula (II), sigma'uβ is the ultimate tensile stress and is the material constant, and is-0.505, sigma'0Is the ultimate tensile stress at a reference temperature of 0 ℃ and is taken to be 74.3 MPa.
The POM gear fatigue strength coefficient σ 'was obtained from the conversion relationship proposed by Seeger in Materials data for cyclic loading-supplement 1 (cyclic loading Materials data-supplement 1, 1990, EscherWell scientific publishing Co., Ltd.)'fAnd fatigue ductility coefficient ε'fFatigue strength index b and c fatigue ductility index:
σ′f＝L67σ′u，ε′f＝0·35，b＝-0·095，c＝-0·69
step 6, calculating the contact fatigue life of the plastic gear
Since the test was carried out under oil lubrication, the lubrication coefficient ω was 1.2 and S was 0.5, the Brown-Miller multiaxial fatigue criterion was modified in this example to
Find each material point rollingDefining the angle of the maximum shearing stress in the contact process as the critical surface of the material point, and calculating the shearing strain amplitude delta gamma max and the positive strain amplitude delta epsilon on the critical surfacenAnd mean of positive stress σmThe results of the shear strain amplitude, the positive strain amplitude and the positive stress amplitude are shown in fig. 7. Fatigue life was calculated using the modified Brown-Miller multi-axial fatigue criterion, and its life cloud is shown in fig. 8. As seen in fig. 8: the minimum fatigue life is located on the sub-surface of the node; the low-life zone extends from the node point in the depth direction and the profile direction as the loading level or room temperature increases.
The comparison result of the contact fatigue risk position and the simulation result is shown in fig. 9, the calculated life is compared with the test life, as shown in fig. 10, the analysis result of the invention is well matched with the test data, and the feasibility and the effectiveness of the invention are verified.
Claims (8)
1. A plastic gear contact fatigue life assessment method considering temperature influence is characterized by comprising the following steps:
step 1, obtaining an elastic modulus, an ultimate tensile stress and a true plastic stress strain curve of a gear material along with temperature change according to a standard GB1040-92 plastic tensile property test method;
step 2, according to the gear material test data in the step 1, fitting the parameters of a gear material thermo-elastic-plastic constitutive equation, wherein the constitutive equation fully considers the influence of temperature on the mechanical behavior of the gear material;
step 3, defining the temperature of the gear body in the gear running process according to a standard VDI 2736 plastic gear body temperature calculation empirical formula, or testing the temperature of the plastic gear body according to a test;
step 4, establishing a two-dimensional gear complete thermal coupling contact finite element model on an ABAQUS platform, and writing an ABAQUS subprogram UMAT to define a plastic gear material according to the gear material thermal elastic plastic constitutive equation in the step 2;
step 5, fitting an ultimate tensile stress equation changing along with temperature according to the gear material test parameters in the step 1, and selecting a proper lubrication coefficient according to a lubrication state;
step 6, calculating a critical surface of each gear material point, and a shear strain amplitude, a positive strain amplitude and a positive stress mean value on the critical surface; the fatigue life of plastic gears was calculated using the Brown-Miller multi-axial fatigue criterion.
2. The method for evaluating the contact fatigue life of the plastic gear considering the temperature influence according to claim 1, wherein in the step 2, a thermal-elastic constitutive equation is established according to the temperature variation relationship of the elastic modulus of the gear material, and the thermal-elastic constitutive equation is as follows:
σ＝(αT+E0)ε
where σ is the stress, T is the material temperature, E0The elastic modulus of the material at the temperature of 0 ℃ is shown, and epsilon is strain, α is a material constant;
the plastic gear material thermoplastic constitutive equation is expressed by Johnson-Cook constitutive equation as follows:
in the formula, σPFor flow stress, A is the yield stress at the reference temperature and strain rate, B is the hardening coefficient, n is the strain hardening coefficient, εPIs the true plastic strain of the material to be measured,
is the rate of strain, and is,
the reference strain rate, C is the strain rate sensitivity coefficient, and C is 0 in the local area; t is*mTo normalize the temperature coefficient, it can be expressed as:
T*m＝(T-Troom)/(Tmelt-Troom)
in the formula, TroomIs a reference temperature, TmeltIs the melting point of the material;
and fitting to obtain parameters of the constitutive equation according to the elastic modulus of the gear material changing along with the temperature and the real plastic stress-strain curve.
3. The method for evaluating the contact fatigue life of the plastic gear considering the temperature influence as claimed in claim 2, wherein in step 3, the tooth surface temperature during the gear running is defined according to an empirical formula of standard VDI 2736 plastic gear tooth surface temperature calculation:
in the formula, thetaflankIs the tooth surface temperature in units of; theta0Is ambient temperature; p is nominal output power and has the unit of W; k is a radical ofθ,flankIs the plastic gear heat transfer coefficient; mu is a friction coefficient; hVThe gear tooth loss coefficient; b is the tooth width in mm; z is the number of plastic gear teeth; v. oftIs tangential velocity, in m/s; m isnNominal modulus in mm; rλ,GThermal resistance of the plastic gear; a. theGThe tooth surface heat dissipation coefficient; ED is the relative engagement time.
4. The method for evaluating contact fatigue life of plastic gear in consideration of temperature influence according to claim 3, wherein in step 4, the plastic gear tooth surface temperature is determined from step 3 and set as an initial temperature in the finite element model.
5. The method for evaluating contact fatigue life of plastic gear according to claim 4, wherein in step 5, based on the material test parameters of step 1, the equation of ultimate tensile stress with temperature change is fitted as follows:
σ′u＝βT+σ′0
in formula (II), sigma'uIs ultimate tensile stress, β is the material constant, σ'0Is the ultimate tensile stress at a reference temperature of 0 ℃. Obtaining a fatigue strength coefficient sigma 'according to the conversion relation between the fatigue parameters and the tensile strength'fAnd fatigue ductility coefficient ε'fFatigue strength indices b and c fatigueAnd (4) ductility index.
6. The method for evaluating contact fatigue life of plastic gear according to claim 5, wherein in step 6, the shear strain amplitude Δ γ at the critical plane ismaxPositive strain amplitude delta epsilonnAnd positive stress mean value sigmamIs calculated as follows:
in the formula, gammamax、εmaxAnd σmaxThe maximum shear strain, the maximum positive strain and the maximum positive stress on the critical surface in the cyclic loading process are respectively gammamin、εminAnd σminThe minimum shear strain, the minimum positive strain and the minimum positive stress on the critical surface in the cyclic loading process are respectively.
7. The method for evaluating contact fatigue life of a plastic gear in consideration of temperature influence according to claim 6, wherein in step 6, the Brown-Miller multi-axial fatigue life calculation formula is as follows:
in the formula, Δ γmaxFor amplitude of shear strain, Δ εnIs the magnitude of positive strain, σ, on the critical planemS is the material parameter, σ ', determined by torsion and tensile experiments as the mean stress on the critical faces'fAnd epsilon'fRespectively a fatigue strength coefficient and a fatigue ductility coefficient, b is a fatigue strength index, c is a fatigue ductility index, 2NfMaterial parameter C for calculating fatigue life of material point based on stress strain field at the moment1And C2Respectively is C1＝1.3+0.7S，C2＝1.5+0.5S。
8. The method for evaluating contact fatigue life of a plastic gear considering temperature influence according to claim 7, wherein in step 6, under the oil lubrication condition, the modified Brown-Miller multi-axial fatigue life calculation formula is:
omega is a lubrication coefficient and the value range is from 0.2 to 1.5.
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| CN113010973A (en) * | 2021-01-21 | 2021-06-22 | 重庆大学 | Plastic gear accelerated fatigue test method considering temperature effect |
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| CN111323316B (en) * | 2020-01-06 | 2021-07-13 | 湖南大学 | Multi-axial fatigue life prediction method and device |
| CN111709176A (en) * | 2020-07-27 | 2020-09-25 | 上海圣之尧智能科技有限公司 | Finite element simulation method and system considering plasticity and damage constitutive relation |
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