CN114216674B - Gear fatigue test piece and manufacturing method thereof - Google Patents
Gear fatigue test piece and manufacturing method thereof Download PDFInfo
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- CN114216674B CN114216674B CN202111153362.0A CN202111153362A CN114216674B CN 114216674 B CN114216674 B CN 114216674B CN 202111153362 A CN202111153362 A CN 202111153362A CN 114216674 B CN114216674 B CN 114216674B
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- 238000009661 fatigue test Methods 0.000 title claims abstract description 49
- 238000004519 manufacturing process Methods 0.000 title claims description 12
- 238000012360 testing method Methods 0.000 claims abstract description 71
- 238000013461 design Methods 0.000 claims abstract description 48
- 238000012545 processing Methods 0.000 claims abstract description 26
- 238000005520 cutting process Methods 0.000 claims abstract description 22
- 238000000034 method Methods 0.000 claims abstract description 19
- 238000004458 analytical method Methods 0.000 claims description 15
- 238000009826 distribution Methods 0.000 description 5
- 230000005284 excitation Effects 0.000 description 4
- 238000011068 loading method Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 2
- 238000005452 bending Methods 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000009347 mechanical transmission Effects 0.000 description 1
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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
- G01M13/02—Gearings; Transmission mechanisms
- G01M13/028—Acoustic or vibration analysis
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
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Abstract
The invention provides a gear fatigue test piece which is used for measuring the gear fatigue limit, and comprises a clamping side and a design side, wherein the clamping side and the design side divide gears by cutting lines passing through the center position of the end face of an original gear; the face gears on the clamping side and the design side are respectively provided with an arc-shaped cutting surface. A round slot with a radius of R1 is arranged in the center of one end surface of the clamping side, and at least two groups of arc-shaped notches and a first notch are arranged on the gear element on the design side; the gear fatigue test piece designed by the invention can be suitable for straight gears and helical gears and is used for measuring the gear fatigue limit, the test piece is directly processed from a gear original piece, the influence of factors such as structural characteristics, processing, process treatment and the like on the fatigue characteristics can be considered, and the obtained test result has more engineering practicability; the test process is simpler, the first-order frequency of the test piece is higher, and the fatigue test time with long service life under one stress level can be shortened.
Description
Technical Field
The invention belongs to the technical field of gear fatigue testing, and particularly relates to a gear fatigue test piece and a manufacturing method thereof.
Background
There are two main types of gear fatigue test pieces in the prior art that obtain the fatigue limit of the tooth root. A first type of gear fatigue test piece is shown with reference to fig. 1. The test piece is designed mainly according to a fatigue test pattern described in an industry standard with the code HB5277 issued by the aviation industry department of the people's republic of China, can be directly obtained by sampling and processing on a gear, is fixedly supported on a vibrating table, is excited by first-order natural frequency of the test piece until fatigue failure occurs to gear teeth, and is used as the fatigue limit of the root of the gear teeth. The equipment involved in the test mainly comprises a vibrating table, a laser vibration meter and the like, so that the cost is low; the second kind of gear fatigue test piece directly takes the whole gear as the fatigue test piece. The test piece is mainly used for pulse loading of gear teeth of a straight-tooth gear by utilizing a fatigue testing machine until fatigue failure occurs to the gear teeth, and the fatigue limit of the root parts of the gear teeth is measured by a laser vibration meter. The test process of the test piece needs to test a special fixture to enable the gear teeth to be loaded uniformly, the test process is complex, the equipment involved in the test is mainly a fatigue tester, a vibration exciter and the like, and the cost is high.
The first gear fatigue test piece cannot consider the structural characteristics, surface processing and process treatment conditions of gear teeth, so that the gear fatigue limit result obtained by the gear fatigue test piece has a certain difference from the actual result; the second type of gear fatigue test piece is characterized in that when the gear fatigue test piece is used for testing, the pulse load frequency of gear teeth is generally (100-300) Hz, the fatigue test of long service life (more than 10 7 cycles) under a stress level is completed, special clamps are required to be made in a trial mode to ensure uniform loading of the gear teeth, and in addition, the pulse load loading of the helical gear is difficult.
Disclosure of Invention
In view of the above problems, the present invention proposes a gear fatigue test piece for measuring a gear fatigue limit, the test piece including a holding side and a design side that divide a gear with a cutting line passing through a center position of an end face of the gear original; wherein,
The face gears on the holding side and the design side are provided with arc-shaped cutting surfaces.
The gear element on the design side is provided with at least two groups of arc-shaped notches and a first notch.
Preferably, the end face of the gear element on the design side is set to be a gear web, and the thickness of the gear web is smaller than that of the clamping side.
Preferably, a second notch is formed in a position, close to the design side, of one end face of the clamping side.
Preferably, the opening positions of the arc-shaped notch, the first notch and the second notch of the gear original are provided with chamfers.
Preferably, a first round angle is arranged at the joint of the gear amplitude plate and the clamping side, and a second round angle is arranged at the joint of the arc-shaped cutting surfaces of the end face gears of the clamping side and the design side;
The radius size of the first fillet and the second fillet is greater than the chamfer.
The invention also discloses a manufacturing method of the gear fatigue test piece, which is used for manufacturing the test piece and comprises the following steps:
Based on a gear original, performing half-cutting on the gear original by using a cutting line passing through the center position of the end face of the gear original to obtain a primary machined piece comprising a design side and a clamping side;
Cutting the center of the gear original, the gear teeth on the clamping side and the end face gear teeth on the design side by using the circles with the radiuses of R1, R2 and R3 respectively as the circle centers to obtain a secondary processing piece;
CAE analysis is carried out on the secondary processing piece, and an analysis result is obtained;
And determining the thickness dimension of the web in the gear web area in the secondary processing piece, the circle center position and the radius dimension of the arc notch and the depth and the width dimension of the first notch according to the design requirement of the test piece and the analysis result, and processing to obtain the test piece.
Preferably, the method further comprises:
And a second notch is formed in the position, close to the design side, of one end face of the clamping side, and is used for reducing stress concentration of the clamping position.
Preferably, the method comprises:
And chamfering the opening positions of the arc-shaped notch, the first notch and the second notch of the secondary processing piece, and the chamfering is used for reducing stress concentration at the corresponding positions.
Preferably, the method further comprises:
The method comprises the steps of rounding the joint of a gear amplitude plate and a clamping side to obtain a first round angle, and rounding the joint of arc-shaped cutting surfaces of the end face gears of the clamping side and a design side to obtain a second round angle.
Preferably, the design requirements of the test piece include:
The maximum vibration stress area of the first-order vibration mode of the test piece is arranged at the tooth root position of the gear;
The stress ratio of the maximum vibration stress area of the first-order vibration mode of the test piece to the maximum vibration stress area of the gear amplitude plate is 1.5-2.0;
The first-order vibration mode frequency of the test piece is 800-1200 Hz.
The gear fatigue test piece designed by the invention can be suitable for straight gears and helical gears and is used for measuring the gear fatigue limit, the test piece is directly processed from a gear original piece, the influence of structural characteristics, processing, technological treatment and other factors on the fatigue characteristics can be considered, and the obtained test result has more engineering practicability. In addition, the test piece can refer to the industry standard with the code number HB5277, the fatigue test is carried out through the vibrating table, the test process is simpler, the first-order frequency of the test piece is higher, and the fatigue test time with long service life (more than 10 7 cycles) under one stress level can be shortened.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions of the prior art, the following description will briefly explain the drawings used in the embodiments or the description of the prior art, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 shows a schematic view of a first type of fatigue test piece according to the prior art;
fig. 2 shows a schematic structural view of a spiral bevel gear according to the prior art;
FIG. 3 shows a stress distribution diagram of pitch diameter type vibration occurring in a spiral bevel gear according to the prior art;
FIG. 4 shows a schematic view of a secondary work piece according to an embodiment of the present invention;
FIG. 5 shows a schematic view of a gear fatigue test piece according to an embodiment of the invention;
FIG. 6 shows a schematic diagram of vibration stress distribution under a first order mode of vibration of a test piece according to an embodiment of the present invention;
Fig. 7 shows a schematic diagram of a strain gage patch position in accordance with an embodiment of the invention.
Reference numerals: 1. a design side; 2. a holding side; 3. a gear web; 4. an arc-shaped notch; 5. a first notch; 6. a second notch; 7. a first rounded corner; 8. a second rounded corner; 9. chamfering.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 2, the spiral bevel gear is widely used in the mechanical transmission fields of aviation, automobiles, etc. because it has the advantages of high transmission efficiency, stable transmission ratio, high bearing capacity, low noise, etc. The data indicate that pitch diameter vibration is the dominant vibration mode for spiral bevel gears.
Referring to fig. 3, since the maximum vibration stress region is located at the root of the gear tooth when the pitch diameter type vibration occurs in the gear, the fatigue limit of the root of the gear tooth must be measured when the spiral bevel gear is designed for high cycle fatigue.
In one embodiment of the invention, a spiral bevel gear is taken as an object, and the gear is designed and modified through a test piece, so that the maximum vibration stress area of the modified gear fatigue test piece is positioned at the tooth root (the maximum vibration stress area of the gear pitch diameter vibration mode), and the first-order frequency of the gear test piece in the installation state is in the vibration excitation frequency range of vibration excitation equipment.
The gear fatigue test piece is designed according with the following technical requirements by combining the technical parameters of the current domestic vibration table and the patch requirements of the strain gauge in the test:
1. In order to measure the fatigue limit of the tooth root of the gear, the maximum vibration stress area of the first-order vibration mode of the test piece needs to be ensured to be positioned at the tooth root position of the gear;
2. In order to ensure that the patch position is convenient, the stress ratio lambda between the maximum vibration stress area and the maximum vibration stress area on the gear web is enough to be large, and the recommended value is 1.5-2.0;
3. in order to reduce the fatigue test time, it is necessary to ensure that the first-order vibration mode frequency of the test piece is sufficiently high and within the excitation frequency range of the vibration table, the first-order frequency is recommended to be (800-1200) Hz.
Referring to fig. 4, the test piece was designed based on the spiral bevel gear shown in fig. 2, in which,
The test piece comprises a holding side 2 and a design side 1, wherein the holding side 2 and the design side 1 divide gears by a cutting line D passing through the center position of the end face of each gear original piece; wherein the face gears of the clamping side 2 and the design side 1 are provided with arc-shaped cutting surfaces.
The center of one end face of the clamping side 2 is provided with a round slot with a radius of R1, and the gear element of the design side 1 is provided with at least two groups of arc-shaped notches 4 and a first slot 5, as shown in reference to FIG. 5.
As in the test piece shown in fig. 5, the end face of the gear original of the design side 1 is set as a gear web 3, and the thickness of the gear web 3 is smaller than that of the holding side 2.
As shown in fig. 5, a second notch 6 is provided at a position of one end surface of the holding side 2 close to the design side 1. The opening positions of the arc notch 4, the first notch 5 and the second notch 6 of the gear original are provided with chamfers 9. A first round angle 7 is arranged at the joint of the gear amplitude plate 3 and the clamping side 2, and a second round angle 8 is arranged at the joint of the arc-shaped cutting surfaces of the end face gears of the clamping side 2 and the design side 1; the radius of the first and second fillets 7, 8 is greater than the chamfer 9.
Referring to fig. 5, the end face of the original gear of the design side 1 is set as a gear web 3, and the thickness of the gear web 3 is smaller than that of the holding side 2.
The manufacturing process of the test piece comprises the following steps:
Firstly, on a gear original as shown in fig. 2, a gear end face is cut in half by a cutting line D passing through the center position of the gear original end face; the obtained test piece comprises a holding side 2 and a design side 1, wherein one side is used for holding during test, and the other side is used for designing the test piece;
further, the center of the end face of the gear element is used as a circle center, and circles with the radius of R1, R2 and R3 are used for cutting the center of the gear element, the gear teeth on the clamping side 2 and the gear teeth on the design side 1, so that a secondary processing piece shown in fig. 4 is obtained.
CAE analysis is carried out on the secondary processing piece, and an analysis result is obtained;
Determining the thickness dimension of a web in the gear web 3 area, the circle center position and the radius dimension of the arc notch 4 and the depth and the width dimension of the first notch 5 in the secondary processing piece according to the design requirement of the test piece and the analysis result, and processing to obtain the test piece;
a second notch 6 is formed in the position, close to the design side 1, of one end face of the clamping side 2;
Chamfering the opening positions of the arc notch 4, the first notch 5 and the second notch 6 of the secondary processing piece,
The method comprises the steps of rounding the joint of the gear amplitude plate 3 and the clamping side 2 to obtain a first round angle 7, and rounding the joint of the arc-shaped cutting surfaces of the end face gears of the clamping side 2 and the design side 1 to obtain a second round angle 8.
In one embodiment of the present invention, referring to fig. 5, the arc-shaped notch 4 and the first notch 5 are symmetrically distributed along the center of the design side, the first notch 5 is distributed in an arc shape on the outer circumference of the end face of the gear, and the arc-shaped notch 4 is in a column shape and interferes with the R1 circular groove of the center of the gear.
The first-order vibration mode frequency in the technical requirements is related to the thickness dimension of the web in the area of the gear web 3, the position of the maximum vibration stress area of the test piece is related to the circle center position and the radius dimension of the arc notch 4 structure, and the stress ratio lambda of the maximum vibration stress area of the test piece to the maximum vibration stress area on the gear web is related to the thickness and the width dimension of the web in the first notch 5 structure.
Referring to fig. 6, in order to determine whether the design of the secondary processed part meets the design specifications of 3 test parts, modal analysis is performed on the secondary processed part. If the modal analysis results (frequency, vibration stress distribution and vibration stress ratio) of the secondary processing part meet the design technical requirements of 3 test parts, the secondary processing part with the designed size is the required secondary processing part; if the modal analysis result of the secondary processing part has the item which does not meet the technical requirement, correcting the thickness of the web plate in the web plate 3 area, the circle center position and the radius size of the arc notch 4 structure and the thickness and the width of the web plate in the first notch 5 structure in the secondary processing part according to the influence relation between each parameter in the technical requirement and the size of the test part until the modal analysis result of the corrected secondary processing part meets the design requirement of the test part, and obtaining the test part meeting the technical requirement.
The step of performing a fatigue test using the gear fatigue test piece includes the following:
1) Performing finite element mesh division and material addition on a test piece by adopting CAE software, applying fixed constraint on an addition side, performing test piece modal analysis on the finite element model, and solving to obtain vibration frequency and stress distribution of the test piece under a test vibration mode (first-order bending vibration mode) for fatigue test;
2) At least two positions are selected as patch positions p according to the requirements of the strain gauge patches and the size of the strain gauge, and the main stress direction of the patch positions p is taken as the patch direction of the strain gauge, and the method is shown in reference to FIG. 7;
3) According to vibration stress distribution calculation results obtained by test piece modal analysis, node vibration stress in a finite element model at a corresponding gear tooth root position (maximum vibration stress position) and node vibration stress in a finite element model at a gear web patch position are extracted, and are respectively marked as sigma Tooth root and sigma Patch , and a stress ratio lambda 1、λ2 of the gear tooth root stress to the two patch positions is obtained according to a formula lambda=sigma Tooth root /σ Patch ;
4) Since the strain gauge has a short survival time at the excitation frequency, a calibration of the stress-amplitude (σ -a) is required for this purpose before the fatigue test, the stress-amplitude relationship is denoted as α=σ/a, whereby the stress relationships α 1 and α 2 of the amplitude a of the gear web 3 and the two patch positions p are obtained, respectively. When the strain gauge fails, taking the amplitude A of the gear web 3 as a monitoring parameter;
5) Referring to an industry standard document with the code HB5277, performing a vibration fatigue test on a test piece by adopting a step-by-step load loading method to obtain the amplitude A Measuring of the corresponding gear web 3 when the root of the gear tooth is cracked;
6) According to the stress relation of the stress-amplitude calibration, the test stress sigma Measuring 1、σ Measuring 2 of the two patch positions p is obtained through conversion of a formula sigma Measuring i＝αi*A Measuring (i=1, 2);
7) According to the stress ratio lambda 1、λ2 of the tooth root stress to the two patch positions p, the formula sigma k -1＝λi*σ Measuring i (k=a, b; i=1, 2) to obtain the fatigue limit sigma a -1、σb -1 of the gear tooth root part, wherein when k=a, the corresponding value of i is 1; when k=b, the corresponding value of i is 2;
Finally, adopting an average method sigma -1＝(σa -1+σb -1)/2 to obtain the fatigue limit sigma -1 of the root of the gear tooth.
The gear fatigue test piece designed by the invention can be suitable for straight gears and helical gears and is used for measuring the gear fatigue limit, the test piece is directly processed from a gear original piece, the influence of structural characteristics, processing, technological treatment and other factors on the fatigue characteristics can be considered, and the obtained test result has more engineering practicability. In addition, the test piece can refer to the industry standard with the code number HB5277, the fatigue test is carried out through the vibrating table, the test process is simpler, the first-order frequency of the test piece is higher than that of the second-class gear fatigue test piece (100-300) Hz, and the fatigue test time of long service life (more than 10 7 cycles) under one stress level can be effectively shortened.
The gear fatigue test piece designed by the invention can directly test the root fatigue limit of the gear teeth on the vibrating table, and can greatly shorten the fatigue test time on the premise of ensuring the accuracy of test results.
Although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (10)
1. A gear fatigue test piece for measuring gear fatigue limit, characterized in that the test piece comprises a holding side (2) and a design side (1), wherein the holding side (2) and the design side (1) divide gears by a cutting line (D) passing through the center position of the end face of the gear element; wherein,
The face gears of the clamping side (2) and the design side (1) are provided with arc-shaped cutting surfaces;
The gear element of the design side (1) is provided with at least two groups of arc-shaped notches (4) and a first notch (5).
2. The gear fatigue test piece according to claim 1, wherein the gear element end face of the design side (1) is provided as a gear web (3), and the thickness of the gear web (3) is smaller than that of the clamping side (2).
3. Gear fatigue test piece according to claim 1, characterised in that the end face of the clamping side (2) is provided with a second notch (6) close to the design side (1).
4. Gear fatigue test piece according to claim 1, characterized in that the opening positions of the arc-shaped notch (4), the first notch (5) and the second notch (6) of the gear element are provided with chamfers (9).
5. The gear fatigue test piece according to claim 2, wherein a first round angle (7) is arranged at the joint of the gear amplitude plate (3) and the clamping side (2), and a second round angle (8) is arranged at the joint of the arc-shaped cutting surfaces of the end face gears of the clamping side (2) and the design side (1);
The radius size of the first round angle (7) and the second round angle (8) is larger than that of the chamfer angle (9).
6. A method of manufacturing a gear fatigue test piece for manufacturing a test piece according to any one of claims 1 to 5, the method comprising:
Based on a gear original, a cutting line (D) passing through the center position of the end face of the gear original is used for carrying out half-and-half cutting on the gear original to obtain a primary machined piece comprising a design side (1) and a clamping side (2);
Cutting the center of the gear original, the gear teeth on the clamping side (2) and the end face gear teeth on the design side (1) by using the center of the end face of the gear original as the center of a circle, and using circles with the radiuses of R1, R2 and R3 to obtain a secondary processing piece;
CAE analysis is carried out on the secondary processing piece, and an analysis result is obtained;
And determining the thickness dimension of the web in the area of the gear web (3) in the secondary processing piece, the circle center position and radius dimension of the arc notch (4) and the depth and width dimension of the first notch (5) according to the design requirement of the test piece and the analysis result, and processing to obtain the test piece.
7. The method of manufacturing a gear fatigue test piece according to claim 6, further comprising:
a second notch (6) is formed in a position, close to the design side (1), of one end face of the clamping side (2) and is used for reducing stress concentration of the clamping position.
8. The method for manufacturing a gear fatigue test piece according to claim 6, wherein the method comprises:
and chamfering is arranged at the opening positions of the arc-shaped notch (4), the first notch (5) and the second notch (6) of the secondary processing piece, and the chamfering is used for reducing stress concentration at the corresponding positions.
9. The method of manufacturing a gear fatigue test piece according to claim 6, further comprising:
The method comprises the steps of rounding the joint of a gear amplitude plate (3) and a clamping side (2) to obtain a first round angle (7), and rounding the joint of the arc-shaped cutting surfaces of the end face gears of the clamping side (2) and a design side (1) to obtain a second round angle (8).
10. The method for manufacturing a gear fatigue test piece according to claim 6, wherein the design requirements of the test piece include:
The maximum vibration stress area of the first-order vibration mode of the test piece is arranged at the tooth root position of the gear;
The stress ratio of the maximum vibration stress area of the first-order vibration mode of the test piece to the maximum vibration stress area of the gear amplitude plate (3) is 1.5-2.0;
The first-order vibration mode frequency of the test piece is 800-1200 Hz.
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| CN105334032B (en) * | 2015-10-13 | 2019-07-19 | 中国航空工业集团公司沈阳飞机设计研究所 | A kind of calculation method in model structure service life |
| DE102016224629A1 (en) * | 2016-12-09 | 2018-06-14 | Sincotec Test & Engineering Gmbh | teeth test |
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