Simulation analysis of locomotive gear wear under internal and external excitations
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摘要: 通过Archard磨损公式和Hertz接触模型，建立了考虑动态磨损系数的机车齿轮磨损数值仿真模型，计算了理想情况下齿面磨损分布情况；利用ABAQUS二次开发UMESHMOTION子程序，结合ALE自适应网格，建立了齿轮磨损有限元模型，在仿真后通过MATLAB提取齿面磨损信息，并将有限元计算结果与数值仿真结果进行了对比；通过改变模型参数，研究了摩擦因数和中心距误差对齿面磨损的影响；基于多体动力学软件SIMPACK建模仿真得到了轮轨激励下从动齿轮垂向振动位移，并将其加载到有限元模型进行齿面磨损仿真计算。计算结果表明：2种计算方法得出的齿轮磨损分布情况较为一致，即主、从动齿轮最大磨损深度均在齿根处，节线处磨损深度为0，且节线两侧单双齿交替区域磨损深度均出现突变，磨损深度总量随摩擦因数的增大而增加，且均位于以节线为界靠近齿根处，当摩擦因数最大值取0.25时，磨损深度总量为3.104×10-6 mm，而齿顶处相反；当中心距误差为负时，随着中心距的减少，磨损深度总量呈增大趋势，最大值为3.313×10-6 mm，而当中心距误差为正时，随着中心距的增大，磨损深度总量变化甚微；轮轨外部激励会加剧齿根处磨损，影响齿轮寿命及行车安全。Abstract: Based on the Archard wear formula and Hertz contact model, the numerical simulation model of locomotive gear wear considering dynamic wear coefficient was established, and the wear distribution of tooth surface was calculated under ideal condition. The finite element model of gear wear was established by the secondary development of the UMESHMOTION subroutine in ABAQUS and ALE adaptive mesh. After simulation, the tooth surface wear information was extracted by MATLAB, and the results of finite element calculation were compared with those of numerical simulation. The effects of friction factor and center distance error on tooth surface wear were studied by changing the model parameters. Based on the multi-body dynamics software SIMPACK, the vertical vibration displacement of the driven gear under wheel-rail excitation was obtained and loaded into the finite element model for simulation and calculation of tooth surface wear. Calculation results show that the gear wear distributions obtained by the two calculation methods are consistent, or in other words, the maximum wear depths of the driving and driven gears are at the root of the tooth, and the wear depth of the pitch line is 0. The wear depths of the alternating area of single and double teeth on both sides of the pitch line are abrupt. The total wear depth increases with the increase in friction factor, and all of them are located near the root of the tooth, with the pitch line as the boundary. When the maximum friction factor is 0.25, the total wear depth is 3.104×10-6 mm, while the opposing situation is observed at the tip of the tooth. When the center distance error is negative, the total wear depth increases with the decrease in the center distance, and the maximum value is 3.313×10-6 mm. However, when the center distance error is positive, the total wear depth changes slightly with the increase in the center distance. Wheel-rail external excitation will aggravate wear at the root of the tooth, affecting gear life and driving safety.
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图 7 机车传动齿轮接触有限元模型
Figure 7. Contact finite element model of locomotive transmission gears
图 10 齿面最大接触压力和相对滑动位移分布
Figure 10. Distributions of maximum contact pressure and relative sliding displacement on tooth surface
图 11 有限元计算和理论计算下齿面磨损深度分布
Figure 11. Wear depth distributions of tooth surface under finite element calculation and theoretical calculation
图 12 多循环下主动齿轮齿面磨损深度分布
Figure 12. Wear depth distributions of driving gear tooth surface under multiple cycles
图 13 不同摩擦因数下相对滑动位移差值
Figure 13. Relative sliding displacements differences under different friction factors
图 14 不同摩擦因数下最大接触压力差值
Figure 14. Maximum contact pressure differences under different friction factors
图 15 不同摩擦因数下磨损深度差值
Figure 15. Differences of wear depth under different friction factors
图 16 不同摩擦因数下磨损深度总量
Figure 16. Total amounts of wear depth under different friction factors
图 17 不同中心距误差下相对滑动位移差值
Figure 17. Relative sliding displacement differences under different center distance errors
图 18 不同中心距误差下最大接触压力差值
Figure 18. Maximum contact pressure differences under different center distance errors
图 19 不同中心距误差下磨损深度差值
Figure 19. Wear depth differences under different center distance errors
图 20 不同中心距误差下磨损深度总量
Figure 20. Total amounts of wear depth under different center distance errors
图 24 有、无轮轨激励齿面各差值分布
Figure 24. Distributions of each difference of tooth surface with and without wheel-rail excitation
图 25 多循环下有、无轮轨激励齿面磨损深度差值分布
Figure 25. Distributions of wear depth difference of tooth surface with and without wheel-rail excitation under multiple cycles
图 26 有、无轮轨激励齿面磨损深度总量差值
Figure 26. Total differences of tooth surface wear depth with and without wheel-rail excitation
表 1 某型机车传动齿轮基本参数
Table 1. Basic parameters of transmission gear of a locomotive
参数 主动齿轮 从动齿轮 齿轮材料 18CrNiMo7-6 模数/mm 8 压力角/(°) 20 齿顶高系数 1 顶隙系数 0.25 0.25 变位系数 0.362 0.151 齿宽/mm 140 齿数 23 120 弹性模量/GPa 206 泊松比 0.3 表面粗糙度/μm 0.3 中心距/mm 572 黏度系数/(Pa·s) 6.5×10-3 润滑油黏压因数/(m2·N-1) 1.33×10-8 
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