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The gearbox of wind turbine is in the complex environment such as random wind load for a long time, and the gear contact fatigue becomes a key factor limiting the stability and reliability of wind turbine equipment. The research on the gear contact damage evolution mechanism is faced with difficulties such as complex stress states, damage anisotropy and failure modeling. Material configurational force theory can describe the effect of defect configurational change on the free energy of materials and can be used to predict the damage and failure behavior of materials. A wind turbine gear contact damage model was constructed based on this theory. The gear contact interface stress field simulation analysis was carried out for the key bearing area of gear contact, and the gear contact damage evolution process under contact load was simulated. The results show that the configurational force theory damage model can effectively simulate the contact damage phenomenon of gear and explain the pitting and spalling of gear surfaces. It has significance to predict contact fatigue life of gears accurately.

, correspAuthors=null, authorNote=null, correspAuthorsNote=
WANG Rong, E-mail:
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风电机组齿轮箱长期处在随机风载等复杂环境下,其齿轮接触疲劳成为限制风电机组装备稳定性与可靠性的关键因素,进行齿轮接触损伤演化机制研究面临着应力状态复杂、损伤各向异性及失效建模困难等难点。材料构型力理论可以描述缺陷构型变化对材料自由能的影响,可用来预测材料的损伤和失效行为。基于构型力理论建立齿轮接触损伤模型,选取齿轮接触承载关键区域进行齿轮接触界面应力场仿真分析,模拟在接触载荷作用下齿轮接触损伤演化过程。结果表明,构型力理论损伤模型可以有效模拟齿轮接触损伤现象,解释齿面点蚀和剥落,对准确预测齿轮接触疲劳寿命具有指导意义。

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王荣,女,1988年生,山西临汾人,副教授,硕士研究生导师;主要研究方向为机电装备可靠性分析与保质设计、材料损伤与断裂;E-mail:
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叶楠,男,1986年生,内蒙古赤峰人,讲师,硕士研究生导师;主要研究方向为工业机器人及核心零部件可靠性、结构动态力学性能;E-mail:

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叶楠,男,1986年生,内蒙古赤峰人,讲师,硕士研究生导师;主要研究方向为工业机器人及核心零部件可靠性、结构动态力学性能;E-mail:

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叶楠,男,1986年生,内蒙古赤峰人,讲师,硕士研究生导师;主要研究方向为工业机器人及核心零部件可靠性、结构动态力学性能;E-mail:

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Intermediate gear parameters

, figureFileSmall=null, figureFileBig=null, tableContent=
项目
Project
齿轮轴
Gear shaft
中间级齿轮
Intermediate gear
齿数Number of teeth3083
法向模数Normal module/mm12.2012.20
压力角Pressure angle/(°)25.0025.00
螺旋角Helix angle/(°)11.3511.35
中心距Center distance/mm685.00685.00
齿宽Face width/mm203.00203.00
弹性模量Elasticity modulus/GPa2.072.07
泊松比Poisson ratio0.300.30
密度Density/(kg/m3)7 8007 800
), ArticleFig(id=1241699561777975767, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241699539866931824, language=CN, label=表1, caption=

中间级齿轮参数

, figureFileSmall=null, figureFileBig=null, tableContent=
项目
Project
齿轮轴
Gear shaft
中间级齿轮
Intermediate gear
齿数Number of teeth3083
法向模数Normal module/mm12.2012.20
压力角Pressure angle/(°)25.0025.00
螺旋角Helix angle/(°)11.3511.35
中心距Center distance/mm685.00685.00
齿宽Face width/mm203.00203.00
弹性模量Elasticity modulus/GPa2.072.07
泊松比Poisson ratio0.300.30
密度Density/(kg/m3)7 8007 800
), ArticleFig(id=1241699561866056155, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241699539866931824, language=EN, label=Tab. 2, caption=

Input torque of the gearbox

, figureFileSmall=null, figureFileBig=null, tableContent=
工况Condition转矩Torque/(kN·m)
设计工况Designed condition4 013.3
额定工况Rated condition5 250.0
极限工况Extreme condition8 800.0
), ArticleFig(id=1241699561966719455, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241699539866931824, language=CN, label=表2, caption=

齿轮箱输入转矩

, figureFileSmall=null, figureFileBig=null, tableContent=
工况Condition转矩Torque/(kN·m)
设计工况Designed condition4 013.3
额定工况Rated condition5 250.0
极限工况Extreme condition8 800.0
), ArticleFig(id=1241699562063188451, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241699539866931824, language=EN, label=Tab. 3, caption=

Half width of contact line and maximum contact pressure under each working condition

, figureFileSmall=null, figureFileBig=null, tableContent=
工况
Condition
接触线半宽
Half width of the contact line/mm
最大接触压力
Maximum contact pressure/MPa
设计工况
Designed condition
0.73687.58
额定工况
Rated condition
0.80818.33
极限工况
Extreme condition
1.081 059.45
), ArticleFig(id=1241699562138685925, tenantId=1146029695717560320, journalId=1227999626482147330, articleId=1241699539866931824, language=CN, label=表3, caption=

各工况下接触线半宽及最大接触压力

, figureFileSmall=null, figureFileBig=null, tableContent=
工况
Condition
接触线半宽
Half width of the contact line/mm
最大接触压力
Maximum contact pressure/MPa
设计工况
Designed condition
0.73687.58
额定工况
Rated condition
0.80818.33
极限工况
Extreme condition
1.081 059.45
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基于构型力理论的风电齿轮接触损伤研究
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叶楠 1, 2 , 张雁辉 1, 2 , 王荣 1, 2, 3 , 刘冉 3, 4 , 张传棻 1, 2 , 欧阳衡 1, 2 , 段书用 1, 2
机械强度 | ·疲劳·损伤·断裂·失效分析· 2025,47(4): 39-46
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机械强度 | ·疲劳·损伤·断裂·失效分析· 2025, 47(4): 39-46
基于构型力理论的风电齿轮接触损伤研究
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叶楠1, 2 , 张雁辉1, 2, 王荣1, 2, 3 , 刘冉3, 4, 张传棻1, 2, 欧阳衡1, 2, 段书用1, 2
作者信息
  • 1.河北工业大学 省部共建电工装备可靠性与智能化国家重点实验室,天津 300401
  • 2.河北工业大学 机械工程学院,天津 300401
  • 3.西安交通大学 机械结构强度与振动国家重点实验室,西安 710049
  • 4.西安交通大学 航天航空学院,西安 710049
  • 叶楠,男,1986年生,内蒙古赤峰人,讲师,硕士研究生导师;主要研究方向为工业机器人及核心零部件可靠性、结构动态力学性能;E-mail:

通讯作者:

王荣,女,1988年生,山西临汾人,副教授,硕士研究生导师;主要研究方向为机电装备可靠性分析与保质设计、材料损伤与断裂;E-mail:
Study on contact damage of wind power gear based on configurational force theory
Nan YE1, 2 , Yanhui ZHANG1, 2, Rong WANG1, 2, 3 , Ran LIU3, 4, Chuanfen ZHANG1, 2, Heng OUYANG1, 2, Shuyong DUAN1, 2
Affiliations
  • 1.State Key Laboratory of Reliability and Intelligence of Electrical Equipment, Hebei University of Technology, Tianjin 300401, China
  • 2.School of Mechanical Engineering, Hebei University of Technology, Tianjin 300401, China
  • 3.State Key Laboratory for Strength and Vibration of Mechanical Structures, Xi’an Jiaotong University, Xi’an 710049, China
  • 4.School of Aerospace Engineering, Xi’an Jiaotong University, Xi’an 710049, China
出版时间: 2025-04-15 doi: 10.16579/j.issn.1001.9669.2025.04.005
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风电机组齿轮箱长期处在随机风载等复杂环境下,其齿轮接触疲劳成为限制风电机组装备稳定性与可靠性的关键因素,进行齿轮接触损伤演化机制研究面临着应力状态复杂、损伤各向异性及失效建模困难等难点。材料构型力理论可以描述缺陷构型变化对材料自由能的影响,可用来预测材料的损伤和失效行为。基于构型力理论建立齿轮接触损伤模型,选取齿轮接触承载关键区域进行齿轮接触界面应力场仿真分析,模拟在接触载荷作用下齿轮接触损伤演化过程。结果表明,构型力理论损伤模型可以有效模拟齿轮接触损伤现象,解释齿面点蚀和剥落,对准确预测齿轮接触疲劳寿命具有指导意义。

风电齿轮  /  齿轮接触  /  构型力  /  界面应力  /  损伤演化

The gearbox of wind turbine is in the complex environment such as random wind load for a long time, and the gear contact fatigue becomes a key factor limiting the stability and reliability of wind turbine equipment. The research on the gear contact damage evolution mechanism is faced with difficulties such as complex stress states, damage anisotropy and failure modeling. Material configurational force theory can describe the effect of defect configurational change on the free energy of materials and can be used to predict the damage and failure behavior of materials. A wind turbine gear contact damage model was constructed based on this theory. The gear contact interface stress field simulation analysis was carried out for the key bearing area of gear contact, and the gear contact damage evolution process under contact load was simulated. The results show that the configurational force theory damage model can effectively simulate the contact damage phenomenon of gear and explain the pitting and spalling of gear surfaces. It has significance to predict contact fatigue life of gears accurately.

Wind turbine gear  /  Gear contact  /  Configurational force  /  Interfacial stress  /  Damage evolution
叶楠, 张雁辉, 王荣, 刘冉, 张传棻, 欧阳衡, 段书用. 基于构型力理论的风电齿轮接触损伤研究. 机械强度, 2025 , 47 (4) : 39 -46 . DOI: 10.16579/j.issn.1001.9669.2025.04.005
Nan YE, Yanhui ZHANG, Rong WANG, Ran LIU, Chuanfen ZHANG, Heng OUYANG, Shuyong DUAN. Study on contact damage of wind power gear based on configurational force theory[J]. Journal of Mechanical Strength, 2025 , 47 (4) : 39 -46 . DOI: 10.16579/j.issn.1001.9669.2025.04.005
在我国低碳发展战略转型的背景下,风电机组发展已经呈现出快速增长的趋势。然而,在复杂多变的运行环境中,风电机组的实际使用寿命常常低于设计的20年使用寿命。齿轮箱作为风电机组的核心部件之一,其内部齿轮是承受高速旋转和交变载荷的关键零部件,其性能的优劣直接影响风电机组的运行效率以及可靠性。在工程实际中,风电机组传动链齿轮虽然经过强度校核,但仍常出现接触疲劳失效。其中,齿轮接触损伤为齿轮失效的关键因素之一,严重影响整个风电机组的运行安全。因此,开展齿轮接触损伤失效行为研究是亟待解决的关键问题。
近年来,齿轮接触损伤失效行为逐渐受到了学者们的关注。韩存仓等[1]分析了齿轮表层下疲劳失效形式和转化机制,提出一种基于局部屈服强度值方法的判定准则,进行了疲劳失效形式和疲劳裂纹源预测。唐东红等[2]建立了实测载荷谱下的齿轮疲劳寿命的流程,通过测定齿轮表层不同深度处的硬度和残余应力,计算得到齿轮沿深度方向的接触疲劳极限分布,从而构造出零件的P-S-N曲线,进行齿轮的接触疲劳寿命预测研究。由于齿轮疲劳寿命问题属于高周疲劳,其没有明显的宏观塑性形变,往往应力水平较低,采取以往的传统S-N寿命曲线预测需要进行复杂的修正。徐鹤鸣等[3]在损伤本构模型的基础上结合Lemaitre-Chaboche塑性损伤理论,建立了一种新的齿轮材料疲劳损伤模型,分析了材料属性与应力水平对齿轮疲劳寿命的影响。在众多影响齿轮接触失效问题的因素中,材料方面的重要作用已被工程实践所证实。除了已经广为熟知的硬度、强度等因素外,影响齿轮接触疲劳性能的材料因素还包括材料晶体特征、夹杂和相成分等。WANG等[4-5]为揭示大型重载风电齿轮接触疲劳失效机制,建立了一种多因素耦合齿轮接触疲劳失效分析模型,该模型包含材料晶体、相成分、夹杂物和硬度梯度等宏微观材料特征,从微观尺度上研究了齿轮的损伤演化过程。然而,此微观组织的模型没有考虑晶粒尺寸的梯度特征和力学性能。基于齿轮从外部到核心的力学性能以及微观组织的梯度特征,WEI等[6]提出了一种综合两者的数值模型,详细研究了风电齿轮的接触损伤行为。评估齿轮接触疲劳行为时,需要考虑微观结构中晶体各向异性问题。ZHOU等[7]为了更准确地描述此行为,建立了考虑齿轮材料微观拓扑及晶体弹性各向异性的数值模型,研究了大型风力发电机齿轮的接触疲劳行为。齿轮在载荷传递过程中材料沿齿廓方向会经历一个复杂的应力应变响应。少有研究考虑齿轮啮合过程中微观组织对齿轮材料疲劳行为的影响。针对此问题,LIU等[8]提出了一种考虑齿轮材料微观结构的各向异性和硬度梯度,建立了渗碳齿轮滚动接触疲劳(Rolling Contact Fatigue, RCF)性能评价数值模型。由于齿轮接触失效形式的多样性,且失效机制大多复杂,影响因素众多,在齿轮服役过程中,可能会产生多种失效形式同时发生或相继发生的现象。例如,齿面接触损伤与磨损效应同时存在,并且两者之间存在复杂的竞争机制。关于齿轮接触疲劳-磨损竞争现象,ZHANG等[9]建立了基于弹塑性有限元法齿轮疲劳磨损耦合模型,采用多轴疲劳准则捕捉了接触面疲劳损伤累积,通过引入损伤变量更新了材料损伤本构行为,研究了多源因素耦合导致的失效竞争机制。但是齿轮失效是既包含宏观力学因素,也涉及微观力学范畴的一个极其复杂过程。少有从介观尺度下研究风电齿轮动态特性中的滚动接触效应。针对此问题,张建宇等[10]907-919以风电齿轮为研究对象,利用Voronoi图与多晶体组织的几何相似性,建立了介观尺度下无限大板问题的齿面仿真模型,研究通过内聚力单元模拟晶界对基体的割裂作用,并引入“表面移动载荷”模拟风电齿轮实际运转过程中的滚动接触效应,研究了齿轮损伤演化过程。以上成果均为对常规意义上齿轮损伤问题进行的研究,主要集中在材料、工况、结构等因素,并且在一定程度上解决了齿轮接触损伤建模的问题。但值得注意的是,风电机组齿轮接触状态复杂,传统的断裂力学和损伤力学在预测复杂缺陷的临界失效载荷以及评估结构完整性时面临挑战[11]
近年来研究发现,当材料缺陷的构型(位置、大小等)发生变化时,材料总势能会发生变化,该构型驱动力被定义为构型力。构型力的概念最早由ESHELBY[12]在晶格缺陷的研究中提出,其相关工作为之后材料构型力学的建立奠定了基础。构型力理论在材料损伤表征等领域有很多进展。例如,材料的裂纹和夹杂干涉问题[13-14]、医学领域中生物可降解镁合金椎体支架降解问题[15]等。当损伤演化过程发生时,真实材料表现出不连续特性,导致系统中总能量变化。从物理观点来看,这种空间上的不连续性就会使材料处于某应力状态时,材料物理空间点的势能发生相当大的变化。同时,可以将势能梯度看作反映任何物质点上不连续性或奇点的有效特征量。因此认为,势能梯度可能是损伤演化的驱动力[16]712-718
综上所述,本文基于材料构型力理论,从势能的角度引入构型力作为内部损伤变量,构建齿轮接触损伤模型;对提出的损伤模型进行数值实现,选取齿轮接触承载关键区域进行齿轮接触界面应力场仿真分析,模拟在接触载荷作用下齿轮接触损伤演化过程。
某4.55 MW型齿轮箱由复合行星轮系组合而成。在齿轮箱传动系统运行中,中间级齿轮轴最易发生失效,齿面经常出现点蚀、剥落现象,如图1所示。表1表2所示分别为该型号齿轮箱中间级齿轮参数以及齿轮箱输入转矩。表2中,设计工况定义为齿轮箱正常运转的某一工况条件,额定工况定义为齿轮箱运转处于额定功率条件,极限工况定义为风电齿轮箱运转处于承受的最大功率条件。
齿轮轴和中间级齿轮结构复杂,在进行整体接触分析时将会浪费大量计算资源。本文重点关注齿轮啮合时接触承载区域接触损伤情况,因此对齿轮模型做适当的简化。根据赫兹接触理论,将齿轮在啮合时的接触简化为两个圆柱接触,如图2所示。其中,R1R2分别为齿轮轴、中间级齿轮在啮合位置齿面的曲率半径。同时,由于接触宽度远小于齿面曲率半径,因此,采用平面应变假设原理[10]907-919,齿面啮合过程可进一步等效为一个半无限大的平板问题,模型加载的实际载荷条件是齿面啮合时的接触载荷。
接触位置的法向压力分布px)计算式为
式中,FN为接触位置处单位宽度的力载荷;a为接触位置的半宽,其计算式为
式中,E1ν1分别为下侧齿轮轴的弹性模量和泊松比;E2ν2分别为上侧中间级齿轮的弹性模量和泊松比。
根据该型号齿轮箱各工况的转矩,计算出对应的接触线半宽以及最大接触压力,如表3所示。
本文重点关注齿轮在啮合时接触承载区域的接触损伤情况。选取齿轮副某一时刻的啮合状态,其接触承载区域的选取如图3所示。然后根据半无限大平板问题,建立模拟齿轮工作损伤的有限元模型,如图4所示。该模型在宽度方向(x方向)上的长度为20 mm,在深度方向(y方向)上的长度为10 mm。为保证模拟结果的准确性,将接触承载区域的网格进行了细化。在有限元接触仿真过程中,接触载荷分布中心位置从-3a移动到3a,利用移动加载方式,模拟齿轮对啮入和啮出整个过程的滚动效应。
考虑齿间摩擦因数,接触区内的切向应力为
式中,Qx)为切向应力分布函数;μ为摩擦因数。其中,摩擦因数可能受到许多因素的影响,如润滑条件、表面粗糙度和温度等。在良好的润滑条件下,齿轮间的动摩擦因数为0.05[16]712-718。因此,本文选取的摩擦因数μ为0.05。
在损伤力学中,利用连续介质热力学的唯象法可建立内部变量表征材料局部损伤的发展和演化过程,着重研究对材料力学性质的影响。为了估计损伤程度,通过建立损伤本构方程,从势能的角度引入构型力并将其作为内部损伤变量。这些损伤变量可以描述微缺陷的演变,用于结构损伤计算,以预测损伤分布和结构的承载能力。与传统的应力、应变等损伤变量相比,构型力从能量的概念出发,形式简单,物理意义明确。
对于空间中的任意一点(x1x2 ),拉格朗日能量密度函数L
式中,W为弹性应变能密度,为位置坐标xk和位移梯度uij的函数;V为外力势能密度,为位置坐标xk和位移ui的函数。因此,根据求导法则可以得到
不考虑惯性项时,应力平衡方程为
因此,由式(4)~式(6)可得
图5所示为任意两个相邻的材料空间点DD*DD'在二维空间中的距离分别为Δx1和Δx2。当材料中存在损伤时,从无穷小的材料空间点D到与其相邻的无穷小的材料空间点D*的势能差可以表示为
式中,为拉格朗日能量密度函数L对位置坐标xk的显式导数。因此,从无穷小的材料空间点DD*,所有场变量的变化可以表示为
从能量梯度的角度,推导得到了描述材料损伤演化的驱动力Jk积分,详细的推导过程见文献[17],即
式中,δ为Kronecker函数;σij为应力场;uik为位移梯度;ΩD为曲面上单元D任意相邻材料空间点。
材料在逐渐损伤过程中,其真实应力σ会随着损伤变量演化退化。当材料处于准静态加载状态时,材料的应力-应变本构关系可描述为
式中,ω为损伤变量;σ为材料的有效应力张量;E为材料的初始弹性模量。
为了描述齿轮结构中材料的损伤,利用Jk积分建立损伤演化模型,损伤变量ωJk参量的函数。当ω=0时,材料处于未损伤状态;当ω=1时,材料处于完全受损状态,即该处发生断裂。则损伤变量函数ω定义为
式中,Js为损伤演变过程开始时的临界值,定义为损伤开始阈值;Je为发生断裂时的临界值,定义为损伤结束阈值;S1S2均为与材料宏观损伤现象相关的材料参数;α为模型的修正系数。因此可将材料损伤过程分为3个状态,即未损伤状态、损伤状态和最终失效状态。损伤函数可表示为
齿轮接触界面应力实际上是啮合接触时所产生的力学效应。然而,由于力的相互作用,过大或不均匀分布的齿面接触力可导致齿面损伤失效。尤其发生机械故障后,啮合齿轮界面产生显著的应力响应。齿轮接触界面应力分析是研究整个齿轮副啮合的关键因素之一。同时它也直接影响整个传动系统的寿命和运行状况,因此进行齿轮接触界面应力分析至关重要。
借助有限元分析软件Ansys,建立齿轮接触有限元模型,进行齿轮接触界面应力场仿真分析。当接触载荷作用在原点位置时,齿面接触承载区域等效应力分布如图6所示。
图6可知,当接触载荷作用在原点位置时,设计工况下最大等效应力为729.697 MPa,额定工况下最大接触应力为873.874 MPa,极限工况下最大接触应力为962. 127 MPa。由这3个典型工况结果可见,随着接触载荷的不断增加,等效应力的分布逐渐沿深度和水平方向同时扩展,同时在靠近齿轮接触界面处伴随着较明显的应力集中现象。分析极限工况、额定工况和设计工况下齿轮接触界面应力变化及界面能量分布等接触特性,为下一步研究齿轮接触损伤提供了指导。
基于齿轮接触损伤模型开发有限元程序,根据应力状态的演化定律计算损伤增量。图7显示了该程序的主要任务,即在损伤过程中完成损伤变量计算。首先,读取损伤模型,得到每个单元材料参数在初始分析步骤中的数值。然后,根据构型力二次开发计算程序计算节点位移、应力、数量并存储损伤变量。最后,通过损伤演化方程迭代求出材料的损伤,并通过更新材料单元属性实现材料损伤的数值模拟。
齿轮传动系统中,齿轮接触处于复杂工况条件,导致齿轮接触面积不均匀,进而使得齿轮受力不均匀,影响齿轮接触界面能量(势能梯度)分布,使得用于描述能量分布的构型力发生改变。表征齿轮接触损伤的构型损伤模型,通过更新材料本构方程,能够准确描述齿轮接触损伤演化规律。
在有限元接触仿真过程中,接触载荷分布中心位置从-3a移动到3a,并以离散的步骤从左向右移动进行模拟,本文将一个循环载荷过程分解为13个离散载荷步。选取了齿轮接触过程中具有代表性的4个损伤演化阶段,即图8所示的第4个循环载荷、第5个循环载荷、第7个循环载荷以及第10个循环载荷作用下齿轮接触损伤结果。
当完成第4个循环载荷时,其对应载荷加载次数为52,此时次表面产生一段条形损伤带,损伤程度不明显;当完成第5个循环载荷时,对应载荷加载次数为65,对比52次载荷加载次数,可以看出损伤区域的损伤程度加重,部分区域的损伤值ω甚至接近1;随着载荷加载次数进一步增加,在完成第7个循环载荷时,即对应载荷加载次数为91,损伤区域沿深度方向和齿轮接触表面方向扩展;当完成第10个循环载荷时,对应载荷加载次数为130,此时损伤面积不断增大,造成该区域完全损伤。
对比数值模拟齿轮损伤演化结果与实际齿轮失效形貌,如图9所示。在接触载荷加载次数较少时,齿面表现出小面积损伤。随着载荷加载次数的增加,齿面上有着较明显的材料剥落现象。
为进一步研究齿轮接触承载区不同位置处的损伤演化情况,在齿轮接触区域选取不同位置进行分析:①啮入点位置;②啮入点下方次表面位置;③次表面位置;④原点表面位置;⑤原点次表面位置。接触承载区不同位置示意图如图10所示。
不同工况下次表面损伤演化如图11所示。结果表明,不同工况下次表面的损伤程度不同,随着载荷加载次数的增加,损伤呈现出增大的趋势,损伤出现累积。当处于极限工况条件下,载荷加载次数达到60左右时,极限工况的次表面损伤值接近完全损伤。对比其他两种工况条件下次表面损伤情况,说明恶劣极限工况对齿轮接触损伤影响最大,其次是额定工况,对齿轮接触损伤影响最小的是设计工况。
不同工况下不同位置处的齿轮接触损伤演化结果如图12所示。由图12(c)可得,在极限工况中,接触载荷加载开始阶段时,次表面位置发生损伤较快,其次是啮入点次表面位置和原点次表面位置。随着载荷加载次数的增加,损伤逐渐累积,其总体趋势是位于齿轮接触表面下方的次表面的各位置(②、③、⑤)比其余位置(①、④)的损伤发展快。
综合图12,对接触承载区域的深度位置和宽度位置两种情况分别进行分析。对于同一深度、不同宽度位置对比(②、③、⑤),在极限工况中次表面位置发生损伤相对较快,其次是啮入点次表面,原点次表面位置发生损伤较为缓慢。但在设计工况与额定工况中,次表面位置与原点次表面位置出现损伤比啮入点位置快。说明随着接触载荷以及切向力的增加,次表面位置损伤速度加快。
对同一宽度、不同深度的位置进行分析,对比①啮入点位置与②啮入点下方次表面位置以及④原点表面位置与⑤原点次表面位置这两种情况,3个典型工况下的总体趋势均为:啮入点下方次表面位置比啮入点位置发生损伤快,原点次表面位置比原点表面位置发生损伤快。说明位于齿轮接触表面下方的次表面位置比齿轮接触表面位置出现损伤早。
综上所述,齿轮在发生接触损伤时,次表面首先发生损伤,随后扩展到表面位置致使最终失效。同时满足损伤趋势:在齿轮接触表面下方形成条形损伤带,损伤区域向深度方向和齿轮接触表面方向扩展,最终损伤区域贯穿整个损伤带,与真实材料发生失效对比,该部分材料发生了剥落,形成凹陷。
针对风电齿轮接触损伤问题,引入了表征材料构型变化的构型力理论,构建了齿轮接触损伤模型,并对所提出的损伤模型开发了相应的用户子程序进行了数值实现,选取齿轮接触承载关键区域,进行了齿轮接触界面应力场仿真分析,模拟了在接触载荷作用下齿轮接触损伤演化过程。得出的主要结论如下:
1)在齿轮接触表面下方产生了一段条形的损伤带,随着载荷加载次数增加,齿面失效区域向深度方向和齿轮接触表面方向扩展。
2)齿轮接触承载区域不同位置的损伤程度不同,在发生接触损伤失效时,齿轮次表面首先发生损伤失效,随后扩展到表面位置直至齿面达到完全损伤。
3)通过与实际情况对比,齿面表现出的失效形式是齿面点蚀或剥落。说明基于表征材料构型变化的构型损伤模型可以有效模拟齿轮接触损伤现象,解释了齿面点蚀和剥落,对今后准确预测齿轮接触疲劳寿命具有指导意义。
  • 国家自然科学基金项目(52205259)
  • 河北省自然科学基金项目(A2021202006)
  • 河北省自然科学基金创新群体项目(E2020202142)
  • 机械结构强度与振动国家重点实验室开放课题(SV2021-KF-15)
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2025年第47卷第4期
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doi: 10.16579/j.issn.1001.9669.2025.04.005
  • 接收时间:2023-08-18
  • 首发时间:2026-03-20
  • 出版时间:2025-04-15
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  • 收稿日期:2023-08-18
  • 修回日期:2023-09-28
基金
National Natural Science Foundation of China(52205259)
国家自然科学基金项目(52205259)
Natural Science Foundation of Hebei Province(A2021202006)
河北省自然科学基金项目(A2021202006)
Innovative Group Project of Natural Science Foundation of Hebei Province(E2020202142)
河北省自然科学基金创新群体项目(E2020202142)
Open Topic From the State Key Laboratory for Strength and Vibration of Mechanical Structures(SV2021-KF-15)
机械结构强度与振动国家重点实验室开放课题(SV2021-KF-15)
作者信息
    1.河北工业大学 省部共建电工装备可靠性与智能化国家重点实验室,天津 300401
    2.河北工业大学 机械工程学院,天津 300401
    3.西安交通大学 机械结构强度与振动国家重点实验室,西安 710049
    4.西安交通大学 航天航空学院,西安 710049

通讯作者:

王荣,女,1988年生,山西临汾人,副教授,硕士研究生导师;主要研究方向为机电装备可靠性分析与保质设计、材料损伤与断裂;E-mail:
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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