發(fā)布時間：2018-09-07 08:28

【摘要】：齒輪產(chǎn)業(yè)是裝備制造業(yè)的基礎(chǔ)性產(chǎn)業(yè)，具有產(chǎn)業(yè)關(guān)聯(lián)度高、吸納就業(yè)強、技術(shù)資金密集的特點，是我國從制造大國走向制造強國的標志性產(chǎn)業(yè)。國內(nèi)骨干齒輪企業(yè)已達200多家，但很多高性能、長壽命齒輪只能依靠進口，因此只有重視自主研發(fā)與自主創(chuàng)新才能扭轉(zhuǎn)這種被動的局面。 目前有很多方法和措施都能提高齒輪的使用性能和服役壽命，但這些方法并不能完美地解決所有問題，都存在這樣或那樣的不足有待改進。仿生研究發(fā)現(xiàn)，很多具有耐磨和抗疲勞特性的生物（如穿山甲和貝類）體表面往往是非光滑的、軟硬相間的。所以本文就從仿生學(xué)的角度出發(fā)，基于仿生非光滑表面理論，借鑒吉林大學(xué)工程仿生教育部重點實驗室已有的研究成果，結(jié)合激光淬火處理技術(shù)設(shè)計了9種與貝類等生物體體表相似的、軟硬相間的、具有不同微小寬度和深度的（寬度為160-260μm，深度為3μm左右）并規(guī)則排列的條紋狀仿生表面形態(tài)，并把優(yōu)選后的仿生表面形態(tài)制備到輪齒表面上獲得仿生齒輪。齒輪嚙合傳動試驗的結(jié)果表明仿生齒輪具有較好的抗疲勞特性和耐磨特性，這不僅擴展了仿生學(xué)的應(yīng)用范圍，而且為工程仿生技術(shù)在齒輪傳動上的實際應(yīng)用打下了良好的基礎(chǔ)。論文的主要研究工作如下： 首先，在全面考慮了貝類等生物體體表的非光滑表面形態(tài)、齒輪傳動的特點、齒輪和圓柱滾子試件的尺寸、齒輪的疲勞失效原因以及現(xiàn)有設(shè)備的加工精度等級后，精心設(shè)計了9種不同參數(shù)的、軟硬相間的仿生表面形態(tài)。為了節(jié)約成本、簡化試驗并提高效率，根據(jù)齒輪傳動過程中既有滾動又有滑動的特點，將齒輪的傳動簡化成了圓柱滾子試件的對滾，從而通過圓柱滾子試件的對滾試驗選出最優(yōu)仿生表面形態(tài)，進而制備仿生齒輪。 其次，用激光淬火設(shè)備把上述9種不同參數(shù)的仿生表面形態(tài)制備到9個圓柱滾子試件的外圓面上得到仿生圓柱滾子試件，分別觀測了試件表面形態(tài)的2D、3D形貌，分析了試件的斷面形態(tài)、金相組織以及顯微硬度。然后用磨損試驗機分別進行了仿生圓柱滾子試件、普通圓柱滾子試件（外圓面光滑）和激光淬火圓柱滾子試件（外圓面全部淬火）的模擬齒輪嚙合傳動過程的對滾試驗，試驗結(jié)果表明仿生圓柱滾子試件的耐磨性要明顯好于普通圓柱滾子試件和激光淬火圓柱滾子試件，其中2號仿生圓柱滾子試件（條紋寬度為185μm，激光掃描速度為120mm/s，條紋的周向中心距為457μm）的耐磨性能最好，磨損率為0.0279%，比普通圓柱滾子試件和激光淬火圓柱滾子試件的耐磨性有了很大程度的提高。 第三，為了進一步探究仿生表面形態(tài)對齒輪綜合性能的影響，把上述最優(yōu)仿生表面形態(tài)制備到齒輪輪齒表面上得到仿生齒輪，并用齒輪試驗機分別進行了普通齒輪和仿生齒輪的嚙合傳動試驗，所用設(shè)備為CL-100A齒輪試驗機。通過對比試驗前后二者齒廓總偏差和螺旋線總偏差的變化量對齒輪的耐磨性進行了評定；通過對比試驗后二者的單齒點蝕面積率對齒輪的疲勞壽命進行了評定。 試驗結(jié)果表明普通大齒輪與普通小齒輪在嚙合試驗前后的齒廓總偏差變化量分別為25.750μm、9.175μm，，螺旋線總偏差變化量分別為3.500μm、3.750μm；而仿生大齒輪與仿生小齒輪在嚙合試驗前后的齒廓總偏差變化量分別為3.825μm、6.500μm，螺旋線總偏差變化量分別為2.450μm、3.625μm。普通大齒輪與普通小齒輪的平均單齒點蝕面積率分別為1.26%、1.55%；而仿生大齒輪與仿生小齒輪的平均單齒點蝕面積率分別為0.58%、1.04%。由此可見仿生齒輪的耐磨性和疲勞壽命均要好于普通齒輪；論文最后還對仿生齒輪的耐磨與抗疲勞機理做了探討性分析。
[Abstract]:Gear industry is the basic industry of equipment manufacturing industry, which has the characteristics of high industrial correlation, strong employment absorption, and intensive technology and capital. It is a symbolic industry of China from a big manufacturing country to a strong manufacturing country. Only with independent innovation can we reverse this passive situation.
At present, there are many methods and measures to improve the performance and service life of gears, but these methods can not solve all the problems perfectly. There are some shortcomings to be improved. From the point of view of bionics, based on the theory of bionic non-smooth surface and the existing research results of Key Laboratory of Engineering bionic education of Jilin University, nine kinds of surface similar to shellfish and other organisms with different micro-width and depth were designed by using laser quenching technology. The results of gear meshing transmission test show that the bionic gear has better fatigue resistance and wear resistance, which not only extends the application of bionics. The main research work of this paper is as follows:1.
Firstly, after considering the non-smooth surface morphology of shellfish and other organisms, the characteristics of gear transmission, the sizes of gear and cylindrical roller specimens, the fatigue failure causes of gears and the machining accuracy levels of existing equipment, nine bionic surface morphologies with different parameters, soft and hard, were designed carefully. According to the characteristics of both rolling and sliding in the process of gear transmission, the transmission of the gear is simplified as the counter-rolling of the cylindrical roller specimen, and the optimal bionic surface shape is selected through the counter-rolling test of the cylindrical roller specimen, and then the bionic gear is prepared.
Secondly, the bionic cylindrical roller specimens with 9 different parameters were fabricated on the outer surface of 9 cylindrical roller specimens by laser quenching equipment. The surface morphologies of the specimens were observed in 2D and 3D. The fracture morphology, metallographic structure and microhardness of the specimens were analyzed. The counter-rolling test of the meshing transmission process of the simulated gears of the bionic cylindrical roller specimen, the ordinary cylindrical roller specimen (smooth outer cylindrical surface) and the laser quenched cylindrical roller specimen (all quenched outer cylindrical surface) was carried out. The results show that the wear resistance of the bionic cylindrical roller specimen is obviously better than that of the ordinary cylindrical roller specimen and the laser quenched cylindrical roller specimen. Among the specimens, the wear resistance of the bionic cylindrical roller specimen No. 2 (stripe width 185 micron, laser scanning speed 120 mm/s, stripe circumferential center distance 457 micron) is the best, and the wear rate is 0.0279%, which is much higher than that of the common cylindrical roller specimens and laser quenched cylindrical roller specimens.
Thirdly, in order to further explore the influence of bionic surface morphology on the comprehensive performance of gears, the above-mentioned optimal bionic surface morphology was prepared on the surface of gear teeth to get bionic gears, and the meshing transmission tests of common gears and bionic gears were carried out by gear testing machine, using CL-100A gear testing machine. The wear resistance of the gears was evaluated by the variation of the total tooth profile deviation and the total helix deviation before and after testing, and the fatigue life of the gears was evaluated by comparing the pitting area ratio of the two teeth.
The test results show that the total deviation of the tooth profile of the ordinary big gear and the ordinary small gear before and after the meshing test are 25.750 micron, 9.175 micron, 3.500 micron and 3.750 micron respectively, while that of the bionic big gear and the bionic small gear before and after the meshing test is 3.825 micron, 6.500 micron and screw respectively. The average pitting area ratio of single tooth of the ordinary big gear and the ordinary small gear is 1.26% and 1.55% respectively, while the average pitting area ratio of the bionic big gear and the bionic small gear is 0.58% and 1.04% respectively. Finally, the mechanism of wear resistance and fatigue resistance of bionic gears is discussed.
【學(xué)位授予單位】：吉林大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2012
【分類號】：TH132.417

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