CN108256241A - A kind of Forecasting Methodology of heavy-duty gear subsurface crack initiation - Google Patents
A kind of Forecasting Methodology of heavy-duty gear subsurface crack initiation Download PDFInfo
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Abstract
The invention discloses a kind of Forecasting Methodologies of heavy-duty gear subsurface crack initiation, it includes the following steps:1st, based on Hertzian contact theory, gear pair contact is simplified, and position of engagement parameter is calculated according to geometry motion, establishes contact analysis model;2nd, based on gear pair contact analysis model, using numerical computation method, surface contact pressure of the analysis model under fully loaded transportation condition is obtained;3rd, the solution of the material constant related with crack initiation life;4th, based on continuum damage mechanics theory, judge whether subsurface is cracked using Critical Damage amount, and establish the Gear Contact Elastic-plastic Constitutive equation of Coupling Damage;5th, it calculates crack initiation life and obtains the position of crack initiation.The present invention solves the long-standing technical barrier of machinery industry, can effectively predict position and the service life of heavy-duty gear subsurface crack initiation, and for the design of gear, manufacture, using providing foundation.
Description
Technical field
The present invention relates to a kind of appraisal procedures of component of machine contact fatigue failure risk, and in particular to one kind is based on company
The Forecasting Methodology of the prediction heavy-duty gear subsurface crack initiation of continuous damage mechanics.
Background technology
With the continuous development of modern industry, at a high speed, heavy duty, high power density has become large scale equipment and is constantly progressive
Mark.Such variation has higher requirement to the power density and service life of the important spare parts such as gear, bearing.
However under fully loaded transportation condition, the reliable of the mechanical equipments such as wind turbine, helicopter, ships will be significantly affected by subsurface crackle
Property and service life, extreme influence man-machine safety and economic benefit.Since the germinating of subsurface crackle will cause gear to be sent out quickly
Raw such as broken teeth, the failures such as peels off, but simultaneously working gear when subsurface crackle detection be difficult to realize again, to gear subsurface
The assessment prediction of crack initiation belongs to the technical barrier of art technology.
Invention content
The technical problems to be solved by the invention are just to provide a kind of Forecasting Methodology of heavy-duty gear subsurface crack initiation,
It can effectively predict position and the service life of heavy-duty gear subsurface crack initiation, according to prediction result, on the one hand avoid because
The generation of gear internal crackle and the burst accident for leading to equipment downtime etc., on the other hand can carry to the manufacturing of gear
For foundation, and then improve the service life of gear.
The technical problems to be solved by the invention are that technical solution in this way realizes that it includes the following steps:
Step 1, based on Hertzian contact theory, gear pair contact is simplified, and engagement is calculated according to geometry motion
Location parameter establishes contact analysis model;
Step 2, the normal load being plastically deformed based on gear pair contact analysis model, application generation are soft by finite element
The numerical simulation of part obtains surface contact pressure distribution of the analysis model under fully loaded transportation condition;
Step 3 solves the material constant related with crack initiation life;
Step 4, based on continuum damage mechanics theory, judge whether subsurface cracked, and builds using Critical Damage amount
The Gear Contact Elastic-plastic Constitutive equation of vertical Coupling Damage;
Step 5 calculates crack initiation life and obtains the position of crack initiation.
The solution have the advantages that:
It solves the long-standing technical barrier of machinery industry, can effectively predict heavy-duty gear subsurface crack initiation
Position and service life, and for the design of gear, manufacture, using providing foundation.
Description of the drawings
The description of the drawings of the present invention is as follows:
Fig. 1 simplifies procedure chart for Gear Contact analysis;
Fig. 2 is the gear surface contact distribution map that numerical simulation obtains under fully loaded transportation condition;
Fig. 3 is simplified finite element model figure;
Fig. 4 germinates iterative algorithm flow chart for gear crack;
Fig. 5 is the transmission diagram of the 2MW wind turbine gearboxes in embodiment;
Fig. 6 is the damage process curve (i.e. crack initiation life prognostic chart) of embodiment middle gear;
Fig. 7 is amount of damage curve (i.e. crack initiation position prediction figure) of the gear along change in depth in embodiment.
Specific embodiment
The invention will be further described with reference to the accompanying drawings and examples:
Present method invention includes the following steps:
Step 1, based on Hertzian contact theory, gear pair contact is simplified, and engagement is calculated according to geometry motion
Location parameter establishes contact analysis model.
According to Hertzian contact theory, the simplification process of Gear Contact model is as shown in Figure 1:(a) it represents to transmit torque
The contact of two-wheeled between cog for T, wherein R1, R2Radius of curvature for two Gear Contact positions;(b) it represents torque of transmission etc.
The contact force of two circle of effect, wherein F represent the size of contact force;(c) represent that the contact by two circles is equivalent to a rigidity circle and one
The contact in a semo-infinite face;(d) it represents contact force being equivalent to surface distribution pressure, wherein px represents distribution pressure.
The gear pair contact analysis model of foundation is
R=R1R2/(R1+R2)(1)
In formula (1) and formula (2), R1, R2For the radius of curvature of two Gear Contact positions, " AGMAinformation
sheet908-B89,1989.“Geometry factors for determining the pitting resistance
And bending strength of spur, helical and herringbone gear teeth " " (U.S.'s gear marks
Accurate 1989 " judgement spur gear, helical gear, the pitting corrosion resistant performance of the double helical spurgear gear teeth and the geometry of bending strength influence because
Son ") at the 5-7 pages describe R1, R2, R is composite curve radius, E1, E2For the elasticity modulus of two gears, E is Equivalent Elasticity mould
Amount, υ1, υ2Poisson's ratio for two gears.
Step 2, the contact analysis model according to step 1 apply the normal load for generating plastic deformation, soft by finite element
The numerical simulation of part ABAQUS obtains the surface pressure distribution under the load, which is to do standard to solve gear crack germinating
It is standby.
Normal load is the load that can generate plastic deformation, that is to say that surface pressing is no longer complies with Hertzian pressure point
Cloth, therefore can just obtain true surface pressure distribution using finite element software simulation.
Fig. 2 is gear being distributed as the contact obtained by finite element software calculates under twice of specified normal load, horizontal
Coordinate is to the distance at contact center, and ordinate is pressure.The pressure is fitted using numerical analysis software-MATLAB to be distributed to obtain
Following fit equation:
px=1000* (- 0.67x6+0.58x4-0.42x2+1.3)(3)
In formula (3), pxDistribution pressure is represented, x represents surface arbitrary point to the distance at the center of contact.
Since the pressure distribution under different loads differs, for different loads situation, it is required for remeasuring,
The fitting function is only one embodiment.
Step 3 solves the material constant related with crack initiation life.
The derivation of material damage equation and the solution of the related material constant of crack initiation life are referring to " Effects of
plasticity on subsurface initiated spalling in rolling contact fatigue.”
Warhadpande A,Sadeghi F,Kotzalas Michael N,et al.International Journal of
Fatigue,2012,36(1):80-95. (" plasticity peels off subsurface the influence to be formed in rolling contact fatigue ",
Warhadpande A, Sadeghi F, Kotzalas Michael N etc., international fatigue magazine, the 80-95 pages, 2012).
Crack initiation is that elastic damage caused by the Plastic Damage as caused by plastic deformation and shear stress amplitude is jointly caused, therefore,
Total damage ratio can be expressed as:
In formula (4), first item represents elastic damage rate on the right of equation, and Section 2 represents Plastic Damage rate, and N is represented
The number of revolutions of gear operation.The calculation formula of elastic damage rate is as follows:
In formula (5), σRWithmIt is material constant, D is damage variable, and Δ τ represents gear and revolves any point on the gear teeth that turn around
Shear stress amplitude.
The calculation formula of Plastic Damage rate is as follows:
In formula (6), S and q represent material constant, and E is elasticity modulus, σM,maxIt represents gear and revolves any point on the gear teeth that turn around
Maximum Mises stress, p represents gear rotation and turns around the accumulated plastic strain rate of any point on the gear teeth.
According to " Adiscrete damage mechanics model for high cycle fatigue in
polycrystalline materials subject to rolling contact.”Raje N,Slack T,Sadeghi
(" one kind rolls for polycrystalline material high week by F, International Journal of Fatigue, pp346-360,2009.
The discrete damage mechanics model of contact fatigue " Raje N, Slack T and Sadeghi F, international fatigue magazine, 346-360
Page, 2009) and " A Voronoi FE Fatigue Damage Model for Life Scatter in Rolling
Contacts. " Jalalahmadi B, Sadeghi F.Journal of Tribology, 2010 (" one for being in rolling contact
The crystal finite element Fatigue Damage Model in service life ", Jalalahmadi B and Sadeghi F, rub magazine, 2010), 4 materials
Material constant can be obtained by complete torsional fatigue S-N (S-L) curve.
(1), according to Basquin ' s rules, complete torsional fatigue S-N curves can be expressed as:
A in formula (7), B are material constants, can be determined according to experiment.NfIt is corresponding tired when shear stress width is Δ τ
The labor service life.Due to having under pure torsion state:
Wherein, τmaxFor maximum shear stress
So formula is also referred to as:
(2), formula (5) and (6) are integrated and can obtained:
(3), the variation of above-mentioned equation
In formula (12), (13), Δ εpFor the equivalent plastic strain increment in a load cycle period.
(4), compare formula (7) and formula (12), material constant σ can be acquiredRAnd m, compare formula (9) and formula (13),
Can acquire material constant S andq。
Step 4, based on continuum damage mechanics theory, judge whether subsurface cracked, and builds using Critical Damage amount
The Gear Contact Elastic-plastic Constitutive equation of vertical Coupling Damage;
Continuum damage mechanics describe the process of crack initiation using damaging parameter D, and value range is 0~1, as D=
0, representing material does not have any damage, when damage variable reaches critical value DcWhen=1, then represent material and damage completely, so as to go out
Existing crackle, therefore the process of the contemporary surface check germinating of evolutionary process of damage variable.Due to will be plastically deformed under heavy duty,
Accordingly, it is considered to the Mises yield criterions of damage are represented by:
F=J2In-k (14) formula (14), f represents yield function, and k represents the radius of yield surface, J2It represents and considers material damage
With the Mises equivalent stress of bauschinger effect, can be expressed as:
In formula (15), α is back stress tensor, and S is deviatoric stress tensor.
Due to being plastically deformed, overall strain can be decomposed into:
ε=εe+εp(16) in formula (16), εeRepresent elastic strain tensor, εpRepresent plastic strain tensor.
So the gear constitutive equation containing damage variable represents as follows:
σ=(1-D) C:(ε-εp) in (17) formula (17), σ represents stress tensor, and C represents quadravalence elasticity tensor.
Step 5 calculates crack initiation life and obtains the position of crack initiation.
The calculating of crack initiation life, gear crack germinates iterative algorithm flow according to Fig. 4, includes the following steps:
In step S101, the geometric parameter and material parameter of gear are obtained;
The geometric parameter of gear is the number of teeth, modulus;Material parameter is elasticity modulus, yield limit, hardening modulus, surface shifting
Dynamic pressure peak.
In step s 102, the simplification finite element model at arbitrary meshing point is obtained according to the geometric parameter of gear;
ABAQUS softwares by gear material grid division, form finite element model automatically.
In step s 103, the material constant of (i.e. initial time) when not damaged according to material parameter input gear, simultaneously
The amount of damage for setting all units is 0;Dj i=0, wherein i are gear operation number, and it is finite element grid list to have i=0, j at this time
Member number.
In step S104, apply mobile pressure, the movement pressure as obtained from numerical simulation for finite element model and lead to
The subprogram DLOAD crossed in ABAQUS finite element softwares applies.
In step S105, it is complete mobile in experience one that entire model is calculated by using ABAQUS finite element softwares
Stress-strain field after pressure loading
In step s 106, since gear life is up to million times or more, " Continuum damage are referred to
mechanics combined with the extended finite element method for the total life
Prediction of a metallic component " Zhan Z, Hu W, Li B, et al, International
Journal of Mechanical Sciences, the 2017 (" gold based on continuum damage mechanics with extension finite element method
Metal elements entire life is predicted ", Zhan Zhixin defends equality recklessly, international machine science magazine, 2017) using the method for load block, note
Computer simulation CYCLIC LOADING once represents actual motion Δ n times.So according to the stress-strain field that step S105 is obtained, meter
Calculate damage ratio and damage increment at this time.It is hit by a bullet, and Plastic Damage amount is calculated by formula (5) and (6), total damage ratio
It is added to obtain by the two, damage increment is obtained according to equation below:
In step s 107, accumulated damage amount is updated according to the damage increment acquired, while updates global cycle number.Accumulation
Amount of damage and global cycle number are calculated according to equation below:
In step S108, judge whether cumulative maximum amount of damage is less than 1, if so, entering step S109;Otherwise, generation
Table has reached crack initiation life at this time, enters step S110.
In step S109, by accumulated damage amount, material constant is updated, then and enters step S104.Wherein, material
Constant more new formula is as follows:
In formula, E is elasticity modulus, and H is hardening modulus, σYFor the initial yield limit.
Step S110 representatives reach crack initiation life, and calculating terminates.
Embodiment
As shown in figure 5, sample tooth is the intergrade gear pair of 2MW wind turbine high-speed overload gear-boxes, in actual use should
The contact fatigue failure as caused by subsurface crackle often occurs for gear pair.
The major parameter of gear pair is as follows:
According to embodiment gear second parameter, by gear path of contact at node for result, can step by step calculation go out gear pair
Contact crack initiation life and crackle position.
Step 1, according to formula (2), obtain R1=248.2mm, R2=49.2mm, so gear pair composite curve radius R=
40.91mm;Equivalent elastic modulus E=1.15 × 1011Pa。
Step 2, according to nominal input torque, obtaining nominal force load is:1263N/mm considers fully loaded transportation condition, by load
Change is twice, and it is as shown in Figure 2 then to obtain distribution pressure according to finite element modelling.Wherein maximum contact pressure is 1300MPa, is connect
It is 1.2mm. to touch half-breadth
Step 3, with reference to " Lubrication and contact fatigue models for roller and gear
Contacts. " Li S.PhD Thesis, Ohio The Ohio State University, 2009 (" roller and Gear Contacts
Lubrication and contact fatigue model ", Li Sheng, doctoral thesis, Ohio, Ohio State University, 2009) shown in page 277
Complete torsion S-N curves, obtaining its corresponding material constant is:
A=2783, B=-0.097
So it is as follows to obtain equation:
It is hereby achieved that material constant is as follows
M=10.3, q=5.15, τR=3512MPa, S=42MPa.
Step 4 brings damage variable in the Elastic-plastic Constitutive equation of kinematic hardening into, obtains the Gear Contact of Coupling Damage
Elastic-plastic Constitutive equation:σ=(1-D) C:(ε-εp)。
Step 5 carries out numerical simulation in finite element software ABAQUS, as shown in figure 4, wherein bringing initial parameter into such as
Under:
Yield limit 640MPa, elasticity modulus 115GPa, hardening modulus 5.75GPa, canine tooth tooth number 115, pinion gear teeth
Number 24, two module 11mm, surface movement pressure spike 1300MPa, Δ N are set as Δ N=105。
Obtained result is shown in Fig. 6 and Fig. 7.As shown in fig. 6, when gear rotates 2.6*106When secondary, the amount of damage of gear reaches
1, that is to say, that the crack initiation life of gear is 2.6*106It is secondary.As shown in fig. 7, when reaching crack initiation life, away from
Amount of damage at about 0.5 times of contact half-breadth (0.63mm) of gear surface is maximum, that is to say, that the position of gear subsurface crack initiation
It puts at about 0.5 times away from gear surface contact half-breadth.
With reference to " Study on initiation and propagation angles of subsurface cracks
in GCr15bearing steel under rolling contact.”Chen,L.,Q.Chen,and E.Shao,Wear,
Pp 205-218,1989 (" GCr15 bearing steels are in rolling contact the germinating of next surface layer crackle and extended corner research " Chen, L.,
Q.Chen and E.Shao, abrasion, the 205-218 page, 1989) also obtained its result of the position of subsurface crack initiation with
The result that the present invention obtains is basically identical, thus demonstrates the practicability and reliability of present method invention.
Claims (7)
1. a kind of Forecasting Methodology of heavy-duty gear subsurface crack initiation, it is characterized in that, include the following steps:
Step 1, based on Hertzian contact theory, gear pair contact is simplified, and according to the geometry motion calculating position of engagement
Parameter establishes contact analysis model;
Step 2, the normal load being plastically deformed based on gear pair contact analysis model, application generation, pass through finite element software
Numerical simulation obtains surface contact pressure distribution of the analysis model under fully loaded transportation condition;
Step 3 solves the material constant related with crack initiation life;
Step 4, based on continuum damage mechanics theory, judge whether subsurface cracked, and establishes coupling using Critical Damage amount
Close the Gear Contact Elastic-plastic Constitutive equation of damage;
Step 5 calculates crack initiation life and obtains the position of crack initiation.
2. the Forecasting Methodology of heavy-duty gear subsurface crack initiation according to claim 1, it is characterized in that, in step 1,
The contact analysis model is:
R=R1R2/(R1+R2)
In formula, R1, R2For the radius of curvature of two Gear Contact positions, R is composite curve radius, E1, E2Springform for two gears
Amount, E are equivalent elastic modulus, υ1, υ2Poisson's ratio for two gears.
3. the Forecasting Methodology of heavy-duty gear subsurface crack initiation according to claim 2, it is characterized in that, in step 3,
Material constant σR, m, S andqIt can be obtained by comparing equation below:
With
With
In formula, Δ τ and σM,maxThe turn around shear stress amplitude of any point and maximum Mises on the gear teeth of gear rotation is represented respectively to answer
Power, A and B are material constants, and E is elasticity modulus, Δ εpFor the equivalent plastic strain increment in a load cycle period, NfFor
The corresponding fatigue life when shear stress width is Δ τ.
4. the Forecasting Methodology of heavy-duty gear subsurface crack initiation according to claim 3, it is characterized in that, in step 4,
The gear Elastic-plastic Constitutive equation of Coupling Damage is:
σ=(1-D) C:(ε-εp)
D represents amount of damage, and σ represents stress tensor, and C represents quadravalence elasticity tensor, and ε represents overall strain tensor, εpRepresent plastic strain
Tensor.
5. the Forecasting Methodology of heavy-duty gear subsurface crack initiation according to claim 4, it is characterized in that, in steps of 5,
The step of gear crack germinating iterative algorithm, includes:
Step (1), geometry and material parameter according to gear, the finite element model being simplified and material when not damaging are normal
Number;
Step (2), the mobile pressure obtained to finite element model application by numerical simulation;
Step (3) calculates stress-strain field;
Step (4), according to ess-strain field computation damage ratio and damage increment;
Step (5) calculates accumulated damage amount;
Step (6) judges whether accumulated damage amount is less than 1, if so, updating material constant according to amount of damage, and returns to (2),
Crack initiation life is reached at this time if it is not, then representing, has stopped calculating.
6. the Forecasting Methodology of heavy-duty gear subsurface crack initiation according to claim 5, it is characterized in that, in step (5)
In, accumulated damage amount is:
In formula, i is gear operation number, and j is finite element grid element number;Δ N finite element modelling CYCLIC LOADINGs primary institute's generation
The actual motion number of table;D is amount of damage, and N represents the number of revolutions of gear operation;Δ D is damage increment, and dD/dN is damage
Hinder rate.
7. the Forecasting Methodology of heavy-duty gear subsurface crack initiation according to claim 6, it is characterized in that, in step (6)
In, material constant is updated to:
In formula, E is elasticity modulus, and H is hardening modulus, σYFor the initial yield limit.
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CN109271711A (en) * | 2018-09-25 | 2019-01-25 | 重庆大学 | A kind of comentation hardening gear finite element modeling method considering uneven characteristic |
CN109299559A (en) * | 2018-10-08 | 2019-02-01 | 重庆大学 | A kind of Surface hardened layer gear wear and fatigue failure competition mechanism analysis method |
CN109885868A (en) * | 2019-01-09 | 2019-06-14 | 昆明理工大学 | A kind of inside configuration crack propagation modeling method for finite element analysis |
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