考虑残余应力与杂质的齿轮接触疲劳评估模型

刘义; 孙霖霖; 杨文瀚; 郭辉; 侯圣文; 刘更

doi:10.12141/j.issn.1000-565X.240278

华南理工大学学报(自然科学版) >

2025 , Vol. 53 >Issue 7: 50 - 59

DOI: https://doi.org/10.12141/j.issn.1000-565X.240278

机械工程

考虑残余应力与杂质的齿轮接触疲劳评估模型

刘义 ,
孙霖霖 ,
杨文瀚 ,
郭辉 ,
侯圣文 ,
刘更

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^1.西北工业大学机电学院，陕西西安 710072
^2.陕西法士特齿轮有限责任公司陕西省齿轮传动重点实验室，陕西西安 710119
^3.长安大学道路施工技术与装备教育部重点实验室，陕西西安 710064

刘义（1978—），男，博士生，正高级工程师，主要从事齿轮设计与制造研究。E-mail： liuyi@fastgroup.cn

收稿日期: 2024-06-04

网络出版日期: 2025-02-20

基金资助

国家自然科学基金项目(52205048);陕西省重点研发计划项目(2023GXLH-087);陕西省重点研发计划项目(2021ZDLGY12-03)

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A Contact Fatigue Assessment Model for Gears Considering Residual Stress and Inhomogeneities

LIU Yi ,
SUN Linlin ,
YANG Wenhan ,
GUO Hui ,
HOU Shengwen ,
LIU Geng

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^1.School of Mechanical Engineering，Northwestern Polytechnical University，Xi’an 710072，Shaanxi，China
^2.Key Laboratory of Gear Transmission of Shaanxi Province，Shaanxi Fast Auto Drive Group Co. ，Ltd. ，Xi’an 710119，Shaanxi，China
^3.Key Laboratory of Road Construction Technology and Equipment of the Ministry of Education，Chang’an University，Xi’an 710064，Shaanxi，China

刘义（1978—），男，博士生，正高级工程师，主要从事齿轮设计与制造研究。E-mail： liuyi@fastgroup.cn

Received date: 2024-06-04

Online published: 2025-02-20

Supported by

the National Natural Science Foundation of China(52205048);the Key Research and Development Program of Shaanxi Province(2023GXLH-087)

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摘要

磨齿、喷丸、表面光饰等齿轮表面处理技术会在材料内部产生残余应力，同时，金属材料中不可避免地存在杂质，残余应力与杂质对齿轮的接触疲劳寿命均有显著影响。为有效评估齿轮的接触疲劳风险，该文提出了一种综合考虑残余应力与杂质共同作用的数值模型。该模型使用等效夹杂法将齿轮内部的杂质转化为含本征应变的夹杂，并在位移方程中考虑了杂质与残余应力的耦合作用。研究过程中，计算了残余应力与杂质作用下的应力分布，并通过有限元法对模型进行了验证；使用Dang Van准则计算了等效应力，并将其代入Lundberg-Palmgren寿命模型，计算了齿面接触疲劳的最小循环次数，分析了残余应力、杂质等对齿轮接触疲劳寿命的影响规律。分析结果表明：杂质对齿轮接触疲劳寿命的影响远远大于残余应力的影响，且对疲劳最早出现的啮合位置具主导性；残余拉应力与杂质共同作用下，次表层最大应力增大且位置向材料表层偏移，齿轮更容易发生接触疲劳。

关键词： 齿轮; 接触疲劳; 残余应力; 非均质材料; 风险评估; Dang Van准则

本文引用格式

刘义 , 孙霖霖 , 杨文瀚 , 郭辉 , 侯圣文 , 刘更 . 考虑残余应力与杂质的齿轮接触疲劳评估模型[J]. 华南理工大学学报(自然科学版), 2025 , 53(7) : 50 -59 . DOI: 10.12141/j.issn.1000-565X.240278

Abstract

Gear surface treatment techniques such as gear grinding, shot peening and surface finishing may generate residual stress inside the material. Meanwhile, inhomogeneities are inevitably present in metal materials. Both residual stress and inhomogeneities have a significant impact on the contact fatigue life of gears. In order to effectively assess the contact fatigue risk of gears, this paper proposes a numerical model that comprehensively considers the combined effects of residual stress and inhomogeneities. This model uses the equivalent inclusion method to convert the inhomogeneities inside the gear into inclusions containing eigenstrains, and considers the coupling effect of inhomogeneities and residual stress in the displacement equation. During the research process, the stress distribution under the joint action of residual stress and inhomogeneities is computed, and the model is verified using the finite element method. The equivalent stress is calculated using Dang Van criterion, which is then incorporated into the Lundberg-Palmgren life model to find the minimum number of cycles, and the influence laws of residual stress and inhomogeneities on the gear’s contact fatigue life are analyzed. Analytical results show that inhomogeneities have a much greater influence on the contact fatigue life of gears than residual stress, and they predominantly determine the earliest meshing point of contact fatigue on the gear; and that, under the combined effects of residual tensile stress and inhomogeneities, the maximum stress in the sub-surface layer increases and shifts towards the material surface, making the gear more prone to contact fatigue.

Key words： gear; contact fatigue; residual stress; inhomogeneous material; risk assessment; Dang Van criterion

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