齒輪減速機嚙合面積小致輪齒斷裂分析

文章出處(chu)：admin 人氣：發(fa)表時間：2019-09-23 15:51

齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)減(jian)速機(ji)嚙合面(mian)(mian)(mian)(mian)積小(xiao)致輪(lun)(lun)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)斷(duan)裂(lie)分(fen)析。某臺(tai)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)減(jian)速機(ji)中(zhong)的(de)大(da)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)面(mian)(mian)(mian)(mian)在(zai)靠近節線的(de)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)根(gen)(gen)部(bu)(bu)(bu)分(fen)有小(xiao)坑，其中(zhong)三個(ge)輪(lun)(lun)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)發生(sheng)局(ju)部(bu)(bu)(bu)斷(duan)裂(lie)和脫落，兩個(ge)輪(lun)(lun)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)局(ju)部(bu)(bu)(bu)有明(ming)顯裂(lie)紋且(qie)已(yi)松動，裂(lie)紋處小(xiao)坑較(jiao)為密集并(bing)連通，齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)減(jian)速機(ji)斷(duan)裂(lie)及裂(lie)紋均起始于(yu)(yu)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)根(gen)(gen)靠近節線處，斷(duan)裂(lie)的(de)輪(lun)(lun)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)破斷(duan)面(mian)(mian)(mian)(mian)分(fen)為2個(ge)部(bu)(bu)(bu)分(fen)，其中(zhong)部(bu)(bu)(bu)分(fen)斷(duan)面(mian)(mian)(mian)(mian)的(de)顆粒細小(xiao)，斷(duan)面(mian)(mian)(mian)(mian)較(jiao)光滑，有不平(ping)坦而類似階(jie)梯形的(de)層(ceng)狀(zhuang)外觀。另部(bu)(bu)(bu)分(fen)斷(duan)面(mian)(mian)(mian)(mian)的(de)顆粒較(jiao)大(da)，斷(duan)口較(jiao)為粗(cu)糙。對齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)減(jian)速電機(ji)進行全面(mian)(mian)(mian)(mian)檢查和測量后發現，沿齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)長方(fang)向(xiang)接(jie)觸(chu)僅(jin)百分(fen)之(zhi)八(ba)(ba)十五，在(zai)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)右側(ce)長45毫米的(de)嚙合面(mian)(mian)(mian)(mian)完全未(wei)接(jie)觸(chu)，齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)高方(fang)向(xiang)接(jie)觸(chu)百分(fen)之(zhi)八(ba)(ba)十，兩傳動軸平(ping)行度(du)偏差(cha)(cha)0.13mm/m. 根(gen)(gen)據齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)面(mian)(mian)(mian)(mian)接(jie)觸(chu)疲(pi)(pi)(pi)勞(lao)強(qiang)度(du)理(li)論(lun)，齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)面(mian)(mian)(mian)(mian)接(jie)觸(chu)疲(pi)(pi)(pi)勞(lao)應力應小(xiao)于(yu)(yu)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)許用(yong)疲(pi)(pi)(pi)勞(lao)極限(xian)。該齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)減(jian)速機(ji)主要(yao)是(shi)由于(yu)(yu)安裝(zhuang)質量較(jiao)差(cha)(cha)造成齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)嚙合接(jie)觸(chu)面(mian)(mian)(mian)(mian)減(jian)小(xiao)，使齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)面(mian)(mian)(mian)(mian)接(jie)觸(chu)疲(pi)(pi)(pi)勞(lao)應力大(da)于(yu)(yu)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)許用(yong)疲(pi)(pi)(pi)勞(lao)極限(xian)而產生(sheng)了(le)點蝕，降低了(le)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)的(de)傳動性能(neng)，終(zhong)導致伺(si)服減(jian)速機(ji)輪(lun)(lun)齒(chi)(chi)(chi)(chi)(chi)(chi)(chi)疲(pi)(pi)(pi)勞(lao)斷(duan)裂(lie)。

鵠興牌R87減速機，齒輪減速機
R127硬齒面減速機廠家

原因分(fen)(fen)析：兩(liang)傳動軸平行度(du)(du)偏(pian)差造成齒(chi)(chi)輪(lun)嚙合(he)面(mian)(mian)(mian)接觸面(mian)(mian)(mian)積(ji)減小，使齒(chi)(chi)輪(lun)嚙合(he)面(mian)(mian)(mian)上(shang)的(de)(de)接觸應(ying)力超過了疲(pi)(pi)勞(lao)(lao)極(ji)限，在(zai)齒(chi)(chi)輪(lun)減速(su)電機(ji)(ji)齒(chi)(chi)輪(lun)的(de)(de)齒(chi)(chi)面(mian)(mian)(mian)產生(sheng)疲(pi)(pi)勞(lao)(lao)裂(lie)(lie)(lie)紋，裂(lie)(lie)(lie)紋進步(bu)擴展(zhan)使齒(chi)(chi)面(mian)(mian)(mian)小塊(kuai)金(jin)屬(shu)剝落，形(xing)成小坑，造成了齒(chi)(chi)輪(lun)嚙合(he)面(mian)(mian)(mian)的(de)(de)疲(pi)(pi)勞(lao)(lao)點蝕(shi)，故大齒(chi)(chi)輪(lun)表面(mian)(mian)(mian)失(shi)效形(xing)式為(wei)疲(pi)(pi)勞(lao)(lao)點蝕(shi)。齒(chi)(chi)輪(lun)減速(su)電機(ji)(ji)的(de)(de)輪(lun)齒(chi)(chi)齒(chi)(chi)面(mian)(mian)(mian)硬度(du)(du)較(jiao)高，實測為(wei)HRC54,在(zai)運行中無(wu)法使齒(chi)(chi)面(mian)(mian)(mian)的(de)(de)承載(zai)面(mian)(mian)(mian)積(ji)增加(jia)，早期由于接觸疲(pi)(pi)勞(lao)(lao)形(xing)成的(de)(de)點蝕(shi)繼(ji)續擴展(zhan)，在(zai)靠近(jin)節(jie)線齒(chi)(chi)根(gen)部(bu)分(fen)(fen)的(de)(de)點蝕(shi)越來越嚴重，小坑的(de)(de)面(mian)(mian)(mian)積(ji)和深(shen)度(du)(du)加(jia)大，在(zai)齒(chi)(chi)輪(lun)減速(su)機(ji)(ji)齒(chi)(chi)輪(lun)齒(chi)(chi)面(mian)(mian)(mian)上(shang)的(de)(de)范圍也(ye)進步(bu)擴展(zhan)，形(xing)成擴展(zhan)性點蝕(shi)，其中較(jiao)深(shen)的(de)(de)蝕(shi)坑成為(wei)強烈應(ying)力集(ji)中源，先在(zai)此(ci)部(bu)分(fen)(fen)產生(sheng)微觀疲(pi)(pi)勞(lao)(lao)裂(lie)(lie)(lie)紋。

此(ci)外，由于(yu)(yu)齒(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)減速(su)電(dian)機(ji)兩平(ping)(ping)行度(du)的(de)(de)(de)(de)(de)偏差造成(cheng)齒(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)嚙合(he)面(mian)(mian)接觸面(mian)(mian)積減小，輪(lun)(lun)齒(chi)(chi)(chi)(chi)(chi)(chi)局(ju)(ju)部(bu)(bu)載荷(he)增大(da)，隨著點蝕的(de)(de)(de)(de)(de)加劇，齒(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)的(de)(de)(de)(de)(de)傳動能力(li)(li)(li)受(shou)(shou)到(dao)破壞(huai)，輪(lun)(lun)齒(chi)(chi)(chi)(chi)(chi)(chi)的(de)(de)(de)(de)(de)疲(pi)勞(lao)(lao)極限(xian)(xian)由于(yu)(yu)蝕坑面(mian)(mian)積和深度(du)的(de)(de)(de)(de)(de)加大(da)而逐步降低，當齒(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)減速(su)機(ji)受(shou)(shou)外載荷(he)應(ying)力(li)(li)(li)高于(yu)(yu)疲(pi)勞(lao)(lao)極限(xian)(xian)而應(ying)力(li)(li)(li)且循環(huan)次數(shu)又超過(guo)定(ding)(ding)數(shu)值(zhi)后，微觀疲(pi)勞(lao)(lao)裂(lie)(lie)紋擴展(zhan)生(sheng)長(chang)，發展(zhan)成(cheng)為(wei)貫穿許多晶粒的(de)(de)(de)(de)(de)宏觀疲(pi)勞(lao)(lao)裂(lie)(lie)縫(feng)，應(ying)力(li)(li)(li)變(bian)化使裂(lie)(lie)縫(feng)張合(he)。裂(lie)(lie)縫(feng)合(he)攏時(shi)(shi)，其表面(mian)(mian)接觸發生(sheng)壓縮和磨損，齒(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)減速(su)電(dian)機(ji)輪(lun)(lun)齒(chi)(chi)(chi)(chi)(chi)(chi)齒(chi)(chi)(chi)(chi)(chi)(chi)根經受(shou)(shou)交變(bian)應(ying)力(li)(li)(li)，疲(pi)勞(lao)(lao)破斷(duan)部(bu)(bu)分被長(chang)時(shi)(shi)間壓縮、磨損，裂(lie)(lie)縫(feng)的(de)(de)(de)(de)(de)表面(mian)(mian)變(bian)得光滑，形(xing)成(cheng)了(le)斷(duan)裂(lie)(lie)輪(lun)(lun)齒(chi)(chi)(chi)(chi)(chi)(chi)破斷(duan)面(mian)(mian)上較為(wei)光滑的(de)(de)(de)(de)(de)斷(duan)面(mian)(mian)。疲(pi)勞(lao)(lao)裂(lie)(lie)縫(feng)的(de)(de)(de)(de)(de)擴展(zhan)是有選(xuan)擇性的(de)(de)(de)(de)(de)，當應(ying)力(li)(li)(li)超過(guo)疲(pi)勞(lao)(lao)極限(xian)(xian)時(shi)(shi)，疲(pi)勞(lao)(lao)裂(lie)(lie)縫(feng)從個(ge)局(ju)(ju)部(bu)(bu)弱金(jin)屬部(bu)(bu)分擴展(zhan)另個(ge)局(ju)(ju)部(bu)(bu)弱金(jin)屬部(bu)(bu)分，這種選(xuan)擇性的(de)(de)(de)(de)(de)結果使破斷(duan)部(bu)(bu)分表面(mian)(mian)出現(xian)了(le)不平(ping)(ping)坦(tan)而類似階梯形(xing)的(de)(de)(de)(de)(de)層(ceng)狀外觀。在疲(pi)勞(lao)(lao)裂(lie)(lie)紋擴展(zhan)過(guo)程中，應(ying)力(li)(li)(li)集中促進了(le)裂(lie)(lie)紋的(de)(de)(de)(de)(de)發展(zhan)速(su)度(du)，后使齒(chi)(chi)(chi)(chi)(chi)(chi)根剩余斷(duan)面(mian)(mian)的(de)(de)(de)(de)(de)應(ying)力(li)(li)(li)達到(dao)靜強度(du)極限(xian)(xian)，經過(guo)定(ding)(ding)數(shu)量的(de)(de)(de)(de)(de)應(ying)力(li)(li)(li)循環(huan)后，齒(chi)(chi)(chi)(chi)(chi)(chi)輪(lun)(lun)減速(su)機(ji)的(de)(de)(de)(de)(de)輪(lun)(lun)齒(chi)(chi)(chi)(chi)(chi)(chi)就發生(sheng)了(le)疲(pi)勞(lao)(lao)斷(duan)裂(lie)(lie)破壞(huai)。

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