CN111985062A - Diesel engine timing gear lubrication state prediction method considering three-dimensional surface machining roughness - Google Patents

Diesel engine timing gear lubrication state prediction method considering three-dimensional surface machining roughness Download PDF

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CN111985062A
CN111985062A CN202010854998.7A CN202010854998A CN111985062A CN 111985062 A CN111985062 A CN 111985062A CN 202010854998 A CN202010854998 A CN 202010854998A CN 111985062 A CN111985062 A CN 111985062A
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gear
timing gear
lubricating
diesel engine
meshing
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史修江
孙文
华德良
冯彦
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Harbin Engineering University
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    • G06—COMPUTING; CALCULATING OR COUNTING
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Abstract

The invention aims to provide a method for predicting the lubricating state of a diesel engine timing gear by considering three-dimensional surface machining roughness, which can realize the prediction of the lubricating state of the gears under different roughness machining processes and different working conditions by establishing a gear lubricating state predicting method by considering real three-dimensional surface machining roughness, transient geometrical characteristics, kinematic performance and load distribution in the meshing process, can analyze the influence rule of structural characteristic parameters on the dynamic contact characteristic and the lubricating performance of the gears, and can provide a theoretical basis for the selection of the machining process of the diesel engine timing gear and the optimization of the structural performance. The prediction model of the invention takes the influence factors of real three-dimensional surface processing roughness, transient meshing geometry of the timing gear, transient motion characteristics, transient distribution load and the like into account, has high prediction precision of the lubricating state and can guide the optimal design of the gear structure from the aspect of tribology.

Description

Diesel engine timing gear lubrication state prediction method considering three-dimensional surface machining roughness
Technical Field
The invention relates to a diesel engine performance prediction method, in particular to a diesel engine timing gear prediction method.
Background
The timing gear is a core transmission component for the operation of the marine diesel engine, and the reliability and the high efficiency of the operation process of the diesel engine are greatly influenced by the lubricating performance of the timing gear. The gear often works in a mixed lubrication severe environment with lubrication-contact coexistence under heavy load and high variable load working conditions, particularly the existence of three-dimensional real surface roughness can cause local rough peak contact and stress concentration on a gear interface, and further induce the problem of gear abrasion failure, and the early abnormal failure mode has the characteristics of strong concealment and great diagnosis difficulty, and is not easy to find in the early stage. Therefore, the development of an advanced prediction method for the lubricating state of the timing gear pair of the marine diesel engine is an important precondition for accurately analyzing the gear wear mechanism.
In the conventional spur gear line contact lubrication model, considering that the tooth surface contact area length is usually much larger than the contact width, a common solution is to simplify the tooth surface contact area length into a two-dimensional model. This simplification may be more suitable for smooth surfaces, and when adding actual three-dimensional machining roughness to a gear lubrication model, it is difficult for the two-dimensional model to describe the effect of roughness on the lubrication performance local distribution details.
Disclosure of Invention
The invention aims to provide a method for predicting the lubricating state of a timing gear of a diesel engine by considering three-dimensional surface machining roughness, which can overcome the problem of accurately predicting the wear of the timing gear of the diesel engine.
The purpose of the invention is realized as follows:
the invention relates to a method for predicting the lubricating state of a timing gear of a diesel engine by considering three-dimensional surface machining roughness, which is characterized by comprising the following steps of:
(1) dynamic contact load of timing gear pair
When the straight-tooth cylindrical gear rotates at a constant speed, the single gear and the double gear are alternately meshed in one meshing period, the load transmitted on the gear teeth is suddenly changed, and a straight-tooth cylindrical gear line contact standard load distribution model of the following formula is adopted:
Figure BDA0002646119500000021
in the formula, w0At steady state load, w is the time varying transmitted dynamic load;
(2) dynamic coupling ratio of timing gear pair
The rotating angular speeds of two gears of the diesel engine timing gear pair are respectively omega1And ω2The base radius is Rb1And Rb2The root circle radius is Rl1And Rl2The root circle radius is Rh1And Rh2The comprehensive curvature radius R of the meshing point is R at the meshing point of the two contact cylinders1And R2The equivalent radius of curvature is calculated as:
Figure BDA0002646119500000022
Figure BDA0002646119500000023
Figure BDA0002646119500000024
in which the gear pitch circle pressure angle is
Figure BDA0002646119500000025
s is the distance of the mesh point from the node,
s(t)＝ω2Rb2(t-t0)
Figure BDA0002646119500000026
in the formula, Rh2Is the diameter of addendum circle, t0The time from the engagement point to the node;
(3) dynamic speed of timing gear pair
The moving speed of two gear surfaces of a diesel engine timing gear pair at a meshing point is equivalent to the moving speed between two cylinders:
Figure BDA0002646119500000027
Figure BDA0002646119500000028
defining half of the sum of tangential speeds of two mutually sliding surfaces as a sucking speed U, and defining the ratio of the relative sliding to the sucking speed as a sliding-rolling ratio S:
Figure BDA0002646119500000031
Figure BDA0002646119500000032
(4) oil film pressure
Under the condition of lubrication-contact coexistence of the gear meshing pair, the contact micro-area is separated by partial oil film and local rough peak contact, and the oil film pressure is solved by adopting a unified three-dimensional mixed lubrication Reynolds equation considering the gear transient speed:
Figure BDA0002646119500000033
in the formula, p is the pressure of the lubricating film, h is the thickness of the lubricating film, rho is the density of the lubricating oil, and eta is the viscosity of the lubricating oil;
(5) thickness of oil film
Considering the transient curvature of the gear, the film thickness equation of the gear lubricating film consists of three parts of macroscopic meshing geometry, surface elastic deformation v and microscopic surface roughness:
Figure BDA0002646119500000034
Figure BDA0002646119500000035
in the formula, h0(t) represents the normal approximation of the two surfaces,1and2true surface roughness for both surfaces;
(6) oil film viscosity/density
The viscosity-pressure relationship and the density-pressure relationship of the lubricating oil are expressed as follows,
η＝η0exp{(lnη0+9.67)·[-1+(1+5.1×10-9p)z]}
Figure BDA0002646119500000036
in the formula eta0Represents the viscosity of the lubricating oil at room temperature, ρ0Represents the lubricant density at room temperature;
(7) oil film bearing
And (3) integrating the pressure distribution of the whole contact area to obtain a lubricating film bearing equation by considering the transient load distribution influence:
Figure BDA0002646119500000041
the invention has the advantages that:
(1) a method for predicting the lubricating state of a timing gear of a diesel engine by considering three-dimensional surface machining roughness is established based on a quasi-system numerical analysis method, has good universality and can predict the lubricating state of the timing gear under any real surface roughness and working conditions.
(2) A method for predicting the lubricating state of a timing gear of a diesel engine by considering three-dimensional surface machining roughness is characterized in that influence factors such as real three-dimensional surface machining roughness, transient meshing geometry of the timing gear, transient motion characteristics, transient distribution load and the like are included in a prediction model, the lubricating state prediction precision is high, and the optimal design of a gear structure can be guided from the aspect of tribology.
Drawings
FIG. 1 is a schematic diagram of the structure and load distribution of a timing gear for a diesel engine used in the present invention;
FIG. 2 is a schematic diagram of the equivalent curvature and speed of the meshing of a timing gear pair of a diesel engine employed in the present invention;
fig. 3a is a three-dimensional roughness distribution diagram (polished surface) of a real surface of a diesel timing gear pair under different processing techniques adopted by the invention, fig. 3b is a three-dimensional roughness distribution diagram (honed surface) of a real surface of a diesel timing gear pair under different processing techniques adopted by the invention, fig. 3c is a three-dimensional roughness distribution diagram (cubic boron nitride grinding surface) of a real surface of a diesel timing gear pair under different processing techniques adopted by the invention, and fig. 3d is a three-dimensional roughness distribution diagram (shaved surface) of a real surface of a diesel timing gear pair under different processing techniques adopted by the invention;
FIG. 4 is a flow chart of the analysis of the lubrication status of the timing gear pair of the diesel engine employed in the present invention;
fig. 5a is three-dimensional oil film pressure distribution (shaving surface pressure) of the diesel engine timing gear pair of different processing techniques employed in the present invention, fig. 5b is three-dimensional oil film pressure distribution (grinding surface pressure) of the diesel engine timing gear pair of different processing techniques employed in the present invention, fig. 5c is three-dimensional oil film pressure distribution (honing surface pressure) of the diesel engine timing gear pair of different processing techniques employed in the present invention, and fig. 5d is three-dimensional oil film pressure distribution (polishing surface pressure) of the diesel engine timing gear pair of different processing techniques employed in the present invention;
FIG. 6a is a graph showing the effect of the machining process adopted by the present invention on the center film thickness and the center pressure of the diesel engine timing gear pair (center film thickness and pressure of the polished surface), and FIG. 6b is a graph showing the effect of the machining process adopted by the present invention on the center film thickness and the center pressure of the diesel engine timing gear pair (center film thickness and pressure of the shaved surface);
FIG. 7 is a graph of the effect of modulus employed in the present invention on the ratio of the contact area of a diesel timing gear pair.
Detailed Description
The invention will now be described in more detail by way of example with reference to the accompanying drawings in which:
the invention discloses a theoretical prediction method of a wear mechanism of a certain diesel engine timing gear by combining with figures 1-7, realizes the prediction of the lubrication state of gears under different roughness processing technologies and different working conditions by establishing a gear lubrication state prediction method considering real three-dimensional surface processing roughness, transient geometrical characteristics, kinematic performance and load distribution in the meshing process, can analyze the influence rule of structural characteristic parameters on the dynamic contact characteristic and the lubrication performance of the gears, and can provide a theoretical basis for the processing technology selection and the structural performance optimization of the diesel engine timing gear.
The method specifically comprises the following steps:
dynamic mesh analysis of timing gear pair of first aspect
(1) Dynamic contact load analysis of timing gear pair
The structure and load distribution of the diesel engine timing gear are shown in fig. 1, where a is the start point of the meshing line and F is the end point of the meshing line. The line segment AF is a locus at an actual meshing point, called an actual meshing line, and NN' is a theoretical meshing line. When the straight spur gear rotates at a constant speed, the alternate meshing of the single gear and the double gear in one meshing period has certain influence on the load on the gear teeth, and is the root cause of the periodic impact load of the transmission of the straight gear, namely, the load transmitted on the gear teeth can change suddenly, and the straight spur gear line contact standard load distribution model shown in formula 1 is adopted.
Figure BDA0002646119500000051
In the formula, w0For steady state loads, w is the delivered dynamic load over time.
(2) Dynamic joint curvature analysis of timing gear pair
The equivalent curvature of the meshing of the timing gear pair of the diesel engine is shown in FIG. 2, and the rotation angular speeds of the two gears are respectively omega1And ω2The base radius is Rb1And Rb2The root circle radius is Rl1And Rl2The root circle radius is Rh1And Rh2The comprehensive curvature radius R of the meshing point is R at the meshing point of the two contact cylinders1And R2The equivalent radius of curvature of (a), the equivalent radius is calculated as,
Figure BDA0002646119500000052
Figure BDA0002646119500000053
Figure BDA0002646119500000061
in which the gear pitch circle pressure angle is
Figure BDA0002646119500000062
s is the distance of the mesh point from the node,
s(t)＝ω2Rb2(t-t0)
Figure BDA0002646119500000063
in the formula, Rh2Is the diameter of addendum circle, t0The time from the point of engagement to the node.
(3) Dynamic speed analysis of timing gear pair
Fig. 2 also shows a schematic diagram of the meshing equivalent speed of the timing gear pair of the diesel engine, the moving speed of the two gear flanks at the meshing point can be equivalent to the moving speed between two cylinders,
Figure BDA0002646119500000064
Figure BDA0002646119500000065
defining half of the sum of tangential speeds of two mutually sliding surfaces as a sucking speed U, the ratio of the relative sliding to the sucking speed is a sliding-rolling ratio S,
Figure BDA0002646119500000066
Figure BDA0002646119500000067
second aspect lubrication condition analysis considering three-dimensional surface roughness
(1) Oil film pressure analysis
Under the condition of the lubrication-contact coexistence of the gear meshing pair, the contact micro-area is usually separated by partial oil film and local rough peak contact, the oil film pressure is solved by adopting a unified three-dimensional mixed lubrication Reynolds equation considering the gear transient speed,
Figure BDA0002646119500000068
wherein p is the lubricating film pressure, h is the lubricating film thickness, ρ is the lubricating oil density, and η is the lubricating oil viscosity.
(2) Oil film thickness analysis
Considering the transient curvature of the gear, the film thickness equation of the gear lubricating film consists of three parts of macroscopic meshing geometry, surface elastic deformation v and microscopic surface roughness,
Figure BDA0002646119500000071
Figure BDA0002646119500000072
in the formula, h0(t) represents the normal approximation of the two surfaces,1and2the true surface roughness of both surfaces is shown in fig. 3.
(3) Oil film viscosity/Density analysis
The viscosity-pressure relationship and the density-pressure relationship of the lubricating oil are expressed as follows,
η＝η0exp{(lnη0+9.67)·[-1+(1+5.1×10-9p)z]}
Figure BDA0002646119500000073
in the formula eta0Represents the viscosity of the lubricating oil at room temperature, ρ0Indicating the lubricant density at room temperature.
(4) Oil film bearing analysis
Considering the transient load distribution effect, integrating the pressure distribution of the whole contact area can obtain the bearing equation of the lubricating film,
Figure BDA0002646119500000074
the gear lubrication state solving equation set has strong nonlinearity, the convergence of the traditional direct iteration method is slow, particularly under the conditions of heavy load and low speed (or thin oil film), the oil film becomes extremely thin or the oil film is zero, the pressure flow becomes weak or disappears, the coefficient matrix cannot keep diagonal dominance, and the convergence is difficult or even overflows to obtain a numerical solution. The quasi-system numerical method can be used for correcting and overcoming the problems, and the principle is that the film thickness in the entrainment flow at the right end of the Reynolds equation is also regarded as a function of unknown node pressure, so that the entrainment flow is included when an algebraic equation coefficient matrix is constructed. Therefore, even under the condition of heavy load and low speed, the coefficient matrix can still keep diagonal dominance, and the convergence and the stability of the solution are greatly improved, so that the problem of analyzing the lubricating state of the timing gear of the diesel engine is solved by adopting a quasi-system method, a discrete convolution fast Fourier transform method is adopted for calculating the elastic deformation, and the solving flow is shown in figure 3.
Predicting the lubricating state of a timing gear pair of a certain diesel engine to obtain a simulation result under the action of three-dimensional real surface roughness, and obtaining a three-dimensional oil film pressure distribution map, an oil film thickness distribution map and a contact area distribution map of the timing gear; the parameters of the simulation examples are shown in the following table.
TABLE 1 structural parameters and Material parameters of timing gears for marine diesel engines
Figure BDA0002646119500000081
The numerical simulation solves the three-dimensional oil film pressure distribution of the diesel engine timing gear pair 3-4 with different processing surface roughness, as shown in fig. 4, the central oil film thickness distribution is shown in fig. 5, and the gear contact area ratio under different moduli is shown in fig. 6. As can be seen from the figure, the distribution of oil film pressure, thickness and contact area ratio is obviously changed by the existence of the three-dimensional surface roughness, and partial rough peak dry contact is generated, so that local stress concentration is brought, and further gear abrasion is inevitably caused.

Claims (1)

1. A method for predicting the lubricating state of a timing gear of a diesel engine by considering three-dimensional surface machining roughness is characterized by comprising the following steps of:
(1) dynamic contact load of timing gear pair
When the straight-tooth cylindrical gear rotates at a constant speed, the single gear and the double gear are alternately meshed in one meshing period, the load transmitted on the gear teeth is suddenly changed, and a straight-tooth cylindrical gear line contact standard load distribution model of the following formula is adopted:
Figure FDA0002646119490000011
in the formula, w0At steady state load, w is the time varying transmitted dynamic load;
(2) dynamic coupling ratio of timing gear pair
The rotating angular speeds of two gears of the diesel engine timing gear pair are respectively omega1And ω2The base radius is Rb1And Rb2The root circle radius is Rl1And Rl2Root of toothThe radius of the circle is Rh1And Rh2The comprehensive curvature radius R of the meshing point is R at the meshing point of the two contact cylinders1And R2The equivalent radius of curvature is calculated as:
Figure FDA0002646119490000012
Figure FDA0002646119490000013
Figure FDA0002646119490000014
in which the gear pitch circle pressure angle is
Figure FDA0002646119490000015
s is the distance of the mesh point from the node,
s(t)＝ω2Rb2(t-t0)
Figure FDA0002646119490000016
in the formula, Rh2Is the diameter of addendum circle, t0The time from the engagement point to the node;
(3) dynamic speed of timing gear pair
The moving speed of two gear surfaces of a diesel engine timing gear pair at a meshing point is equivalent to the moving speed between two cylinders:
Figure FDA0002646119490000021
Figure FDA0002646119490000022
defining half of the sum of tangential speeds of two mutually sliding surfaces as a sucking speed U, and defining the ratio of the relative sliding to the sucking speed as a sliding-rolling ratio S:
Figure FDA0002646119490000023
Figure FDA0002646119490000024
(4) oil film pressure
Under the condition of lubrication-contact coexistence of the gear meshing pair, the contact micro-area is separated by partial oil film and local rough peak contact, and the oil film pressure is solved by adopting a unified three-dimensional mixed lubrication Reynolds equation considering the gear transient speed:
Figure FDA0002646119490000025
in the formula, p is the pressure of the lubricating film, h is the thickness of the lubricating film, rho is the density of the lubricating oil, and eta is the viscosity of the lubricating oil;
(5) thickness of oil film
Considering the transient curvature of the gear, the film thickness equation of the gear lubricating film consists of three parts of macroscopic meshing geometry, surface elastic deformation v and microscopic surface roughness:
Figure FDA0002646119490000026
Figure FDA0002646119490000027
in the formula, h0(t) represents the normal approximation of the two surfaces,1and2true surface roughness for both surfaces;
(6) oil film viscosity/density
The viscosity-pressure relationship and the density-pressure relationship of the lubricating oil are expressed as follows,
η＝η0exp{(lnη0+9.67)·[-1+(1+5.1×10-9p)z]}
Figure FDA0002646119490000031
in the formula eta0Represents the viscosity of the lubricating oil at room temperature, ρ0Represents the lubricant density at room temperature;
(7) oil film bearing
And (3) integrating the pressure distribution of the whole contact area to obtain a lubricating film bearing equation by considering the transient load distribution influence:
Figure FDA0002646119490000032
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CN113283032A (en) * 2021-06-01 2021-08-20 哈尔滨工程大学 Marine gear subsurface stress calculation method related to mixed lubrication-contact state
CN113312729A (en) * 2021-06-24 2021-08-27 南京航空航天大学 Method and system for identifying lubricating state of splash lubrication spiral bevel gear
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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112541267A (en) * 2020-12-11 2021-03-23 哈尔滨工程大学 Diesel engine transmission gear friction flash temperature prediction method based on real surface morphology
CN113283032A (en) * 2021-06-01 2021-08-20 哈尔滨工程大学 Marine gear subsurface stress calculation method related to mixed lubrication-contact state
CN113283032B (en) * 2021-06-01 2023-01-03 哈尔滨工程大学 Marine gear subsurface stress calculation method related to mixed lubrication-contact state
CN113312729A (en) * 2021-06-24 2021-08-27 南京航空航天大学 Method and system for identifying lubricating state of splash lubrication spiral bevel gear
CN113779720A (en) * 2021-09-01 2021-12-10 哈尔滨工程大学 Marine cam-tappet pair three-dimensional mixed lubrication state analysis method considering real machining roughness

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