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Article(id=1217472618303767015, tenantId=1146029695717560320, journalId=1146123166801305609, issueId=1149780466032669506, articleNumber=null, orderNo=null, doi=10.12404/j.issn.1671-1815.2405713, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1722268800000, receivedDateStr=2024-07-30, revisedDate=1737043200000, revisedDateStr=2025-01-17, acceptedDate=null, acceptedDateStr=null, onlineDate=1768197691751, onlineDateStr=2026-01-12, pubDate=1744041600000, pubDateStr=2025-04-08, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1768197691751, onlineIssueDateStr=2026-01-12, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1768197691751, creator=13701087609, updateTime=1768197691751, updator=13701087609, issue=Issue{id=1149780466032669506, tenantId=1146029695717560320, journalId=1146123166801305609, year='2025', volume='25', issue='10', pageStart='3969', pageEnd='4395', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=0, createTime=1752058624990, creator=13701087609, updateTime=1768456644259, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1218558743898411553, tenantId=1146029695717560320, journalId=1146123166801305609, issueId=1149780466032669506, language=EN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1218558743898411554, tenantId=1146029695717560320, journalId=1146123166801305609, issueId=1149780466032669506, language=CN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=4086, endPage=4092, ext={EN=ArticleExt(id=1217472618672865769, articleId=1217472618303767015, tenantId=1146029695717560320, journalId=1146123166801305609, language=EN, title=Cause Analysis of Damage of Coiled Tubing Injection Head Chain Drive System, columnId=1156262729003422020, journalTitle=Science Technology and Engineering, columnName=Papers·Petroleum and Natural Gas Industry, runingTitle=null, highlight=null, articleAbstract=

The injection head is the key equipment to drive the coiled tubing in the coiled tubing operation machine. A fault occurred during the operation of a LG450 injection head, and it was found that the chain drive system was seriously damaged after disassembly. The macro and micro morphology analysis of the chain drive system shows that there are arc-shaped scratches on the outer side of the gear teeth and inclined scratches on the tooth surface. The chemical composition test, hardness test and metallographic test were carried out on the sprocket teeth, and the results showed that the material met the process requirements. The finite element simulation of the meshing process of the sprocket and the chain is carried out. The results show that the contact pressure distribution is consistent with the friction marks on the tooth surface and side of the failed sprocket. It is revealed that the failure reason of the chain drive system of the injection head is the spatial intersection of the chain roller and the sprocket axis, and the abnormal meshing of the roller and the gear teeth. This study shows that the motion state of the sprocket chain will have an important impact on the safety of the injection head, which is of great significance to guide the design and processing of the injection head.

, correspAuthors=Ting YANG, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, authorCompany=null, fund=null, authors=null, authorsList=Xiao-feng RAN, Yu-si LIU, Ting YANG, Wei ZHENG, Chuan-xin RUAN, Shao-hu LIU), CN=ArticleExt(id=1217472622489682489, articleId=1217472618303767015, tenantId=1146029695717560320, journalId=1146123166801305609, language=CN, title=连续油管注入头链传动系统损伤原因分析, columnId=1156262729603207500, journalTitle=科学技术与工程, columnName=论文·石油、天然气工业, runingTitle=null, highlight=null, articleAbstract=

注入头是连续油管作业机中驱动连续油管上提下放的关键设备。LG450型注入头作业期间发生故障,拆解后发现链传动系统损伤严重。对链传动系统进行宏微观形貌分析,发现轮齿外侧有弧形刮痕,齿面存在倾斜擦痕。对链轮轮齿进行化学成分检测、硬度试验及金相试验,结果显示材料达到工艺要求。对链轮和链条的啮合过程进行有限元仿真,结果显示接触压力分布与失效链轮齿面及侧面摩擦痕迹一致。揭示了该注入头链传动系统失效原因为链条滚子与链轮轴线空间交叉,滚子与轮齿非正常啮合。研究表明链轮链条的运动状态会对注入头工作安全性产生重要影响,对指导注入头设计和加工有重要意义。

, correspAuthors=阳婷, authorNote=null, correspAuthorsNote=
* 阳婷(1988—),女,汉族,湖北公安人,博士研究生,讲师。研究方向:石油机械。E-mail:。
, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=YaIv8Uutc6ThTmKkmyN/iQ==, magXml=DlfS1GyvxZloKMN10q+5iA==, pdfUrl=null, pdf=flqxrL8NdOsijIlj3zvRVA==, pdfFileSize=26475004, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=mdtYopFgFjd1lftY3Q67lA==, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=zkNY+wtd6FEcjLREQZJ+Iw==, mapNumber=null, authorCompany=null, fund=null, authors=

冉小丰(1983—),男,汉族,湖北松滋人,博士,副教授。研究方向:石油装备失效分析。E-mail:。

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冉小丰(1983—),男,汉族,湖北松滋人,博士,副教授。研究方向:石油装备失效分析。E-mail:。

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冉小丰(1983—),男,汉族,湖北松滋人,博士,副教授。研究方向:石油装备失效分析。E-mail:。

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tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, language=CN, orderNo=4, keyword=有限元仿真), Keyword(id=1218525104292675620, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, language=CN, orderNo=5, keyword=磨损)], refs=[Reference(id=1218525109615248010, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, doi=null, pmid=null, pmcid=null, year=2023, volume=46, issue=7, pageStart=29, pageEnd=37, url=null, language=null, rfNumber=[1], rfOrder=0, authorNames=刘寿军, journalName=焊管, refType=null, unstructuredReference=刘寿军. 国产连续管作业机的研究现状及应用[J]. 焊管, 2023, 46(7): 29-37., articleTitle=国产连续管作业机的研究现状及应用, refAbstract=null), Reference(id=1218525109711717014, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, doi=null, pmid=null, pmcid=null, year=2023, volume=46, issue=7, pageStart=29, pageEnd=37, url=null, language=null, rfNumber=[1], 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caption=The deformation torsion diagram of the box body, figureFileSmall=Ee+Aso7dDC+3Q5mgn4e6OA==, figureFileBig=tONOAEwhKDBrSIGVejHICw==, tableContent=null), ArticleFig(id=1218525107950109151, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, language=CN, label=图14, caption=箱体变形扭转示意图, figureFileSmall=Ee+Aso7dDC+3Q5mgn4e6OA==, figureFileBig=tONOAEwhKDBrSIGVejHICw==, tableContent=null), ArticleFig(id=1218525108067549673, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, language=EN, label=Table 1, caption=

Sprocket size parameters

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链轮
参数		 节距/
mm		 滚子外径/
mm		 齿数 齿厚/
mm		 量柱测
量距/mm
标准值 63.5 39.68 15 35.2 343.427
误差范围 ±0.1 ±0.1 0 -0.2 -0.36
测量值 63.5 39.7 15 35.1 343.3
), ArticleFig(id=1218525108176601586, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, language=CN, label=表1, caption=

链轮尺寸参数

, figureFileSmall=null, figureFileBig=null, tableContent=
链轮
参数		 节距/
mm		 滚子外径/
mm		 齿数 齿厚/
mm		 量柱测
量距/mm
标准值 63.5 39.68 15 35.2 343.427
误差范围 ±0.1 ±0.1 0 -0.2 -0.36
测量值 63.5 39.7 15 35.1 343.3
), ArticleFig(id=1218525108260487676, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, language=EN, label=Table 2, caption=

Chemical composition analysis results of sprocket teeth

, figureFileSmall=null, figureFileBig=null, tableContent=
元素 质量分数/%
轮齿样品 GB/T 3077—2015
C 0.43 0.38~0.45
Si 0.24 0.17~0.37
Mn 0.79 0.5~0.8
P 0.015 ≤0.035
S 0.011 ≤0.035
Cr 1.20 0.9~1.2
Ni 0.036 ≤0.3
Mo 0.19 0.15~0.25
Cu 0.041 ≤0.3
), ArticleFig(id=1218525108344373766, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, language=CN, label=表2, caption=

链轮轮齿的化学成分检测结果

, figureFileSmall=null, figureFileBig=null, tableContent=
元素 质量分数/%
轮齿样品 GB/T 3077—2015
C 0.43 0.38~0.45
Si 0.24 0.17~0.37
Mn 0.79 0.5~0.8
P 0.015 ≤0.035
S 0.011 ≤0.035
Cr 1.20 0.9~1.2
Ni 0.036 ≤0.3
Mo 0.19 0.15~0.25
Cu 0.041 ≤0.3
), ArticleFig(id=1218525108461814289, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, language=EN, label=Table 3, caption=

Rockwell hardness of sprocket teeth (HRC)

, figureFileSmall=null, figureFileBig=null, tableContent=
测试位置 1 2 3 4 5 平均值
1号样品 29 30 31 31.5 31 30.5
2号样品 29 31 32 30 31.5 30.7
), ArticleFig(id=1218525108612809247, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, language=CN, label=表3, caption=

链轮轮齿的洛氏硬度(HRC)

, figureFileSmall=null, figureFileBig=null, tableContent=
测试位置 1 2 3 4 5 平均值
1号样品 29 30 31 31.5 31 30.5
2号样品 29 31 32 30 31.5 30.7
), ArticleFig(id=1218525108772192820, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, language=EN, label=Table 4, caption=

Material performance parameters

, figureFileSmall=null, figureFileBig=null, tableContent=
材料名称 密度/
(g·cm-3)		 弹性
模量/
MPa		 泊松比 屈服
强度/
MPa		 抗拉
强度/
MPa
20CrNiMo(链条) 7.89 2.07×105 0.3 785 980
42CrMo(链轮) 7.87 2.08×105 0.295 930 1 080
), ArticleFig(id=1218525108918993468, tenantId=1146029695717560320, journalId=1146123166801305609, articleId=1217472618303767015, language=CN, label=表4, caption=

材料性能参数

, figureFileSmall=null, figureFileBig=null, tableContent=
材料名称 密度/
(g·cm-3)		 弹性
模量/
MPa		 泊松比 屈服
强度/
MPa		 抗拉
强度/
MPa
20CrNiMo(链条) 7.89 2.07×105 0.3 785 980
42CrMo(链轮) 7.87 2.08×105 0.295 930 1 080
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连续油管注入头链传动系统损伤原因分析
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冉小丰 1 , 刘宇思 1 , 阳婷 1, * , 郑伟 2 , 阮传信 3 , 刘少胡 1
科学技术与工程 | 论文·石油、天然气工业 2025,25(10): 4086-4092
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科学技术与工程 | 论文·石油、天然气工业 2025, 25(10): 4086-4092
连续油管注入头链传动系统损伤原因分析
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冉小丰1 , 刘宇思1, 阳婷1, * , 郑伟2, 阮传信3, 刘少胡1
作者信息
  • 1 长江大学机械工程学院, 荆州 434023
  • 2 中石化四机石油机械有限公司, 荆州 434000
  • 3 武汉齐达康能源装备有限公司, 武汉 431400

    • 冉小丰(1983—),男,汉族,湖北松滋人,博士,副教授。研究方向:石油装备失效分析。E-mail:。

通讯作者:

* 阳婷(1988—),女,汉族,湖北公安人,博士研究生,讲师。研究方向:石油机械。E-mail:。
Cause Analysis of Damage of Coiled Tubing Injection Head Chain Drive System
Xiao-feng RAN1 , Yu-si LIU1, Ting YANG1, * , Wei ZHENG2, Chuan-xin RUAN3, Shao-hu LIU1
Affiliations
  • 1 School of Mechanical Engineering, Yangtze University, Jingzhou 434023, China
  • 2 Sinopec Four Machinery Petroleum Machinery Co., Ltd., Jingzhou 434000, China
  • 3 Wuhan Qidakang Energy Equipment Co., Ltd., Wuhan 431400, China
出版时间: 2025-04-08 doi: 10.12404/j.issn.1671-1815.2405713
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摘要
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注入头是连续油管作业机中驱动连续油管上提下放的关键设备。LG450型注入头作业期间发生故障,拆解后发现链传动系统损伤严重。对链传动系统进行宏微观形貌分析,发现轮齿外侧有弧形刮痕,齿面存在倾斜擦痕。对链轮轮齿进行化学成分检测、硬度试验及金相试验,结果显示材料达到工艺要求。对链轮和链条的啮合过程进行有限元仿真,结果显示接触压力分布与失效链轮齿面及侧面摩擦痕迹一致。揭示了该注入头链传动系统失效原因为链条滚子与链轮轴线空间交叉,滚子与轮齿非正常啮合。研究表明链轮链条的运动状态会对注入头工作安全性产生重要影响,对指导注入头设计和加工有重要意义。

注入头  /  链轮  /  失效分析  /  有限元仿真  /  磨损

The injection head is the key equipment to drive the coiled tubing in the coiled tubing operation machine. A fault occurred during the operation of a LG450 injection head, and it was found that the chain drive system was seriously damaged after disassembly. The macro and micro morphology analysis of the chain drive system shows that there are arc-shaped scratches on the outer side of the gear teeth and inclined scratches on the tooth surface. The chemical composition test, hardness test and metallographic test were carried out on the sprocket teeth, and the results showed that the material met the process requirements. The finite element simulation of the meshing process of the sprocket and the chain is carried out. The results show that the contact pressure distribution is consistent with the friction marks on the tooth surface and side of the failed sprocket. It is revealed that the failure reason of the chain drive system of the injection head is the spatial intersection of the chain roller and the sprocket axis, and the abnormal meshing of the roller and the gear teeth. This study shows that the motion state of the sprocket chain will have an important impact on the safety of the injection head, which is of great significance to guide the design and processing of the injection head.

injection head  /  sprocket  /  failure analysis  /  finite element simulation  /  wear
冉小丰, 刘宇思, 阳婷, 郑伟, 阮传信, 刘少胡. 连续油管注入头链传动系统损伤原因分析. 科学技术与工程, 2025 , 25 (10) : 4086 -4092 . DOI: 10.12404/j.issn.1671-1815.2405713
Xiao-feng RAN, Yu-si LIU, Ting YANG, Wei ZHENG, Chuan-xin RUAN, Shao-hu LIU. Cause Analysis of Damage of Coiled Tubing Injection Head Chain Drive System[J]. Science Technology and Engineering, 2025 , 25 (10) : 4086 -4092 . DOI: 10.12404/j.issn.1671-1815.2405713
正文
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注入头是连续油管作业机中将连续油管下入和起出井筒的关键设备。随着中外石油天然气开采技术的发展,连续管作业技术现已广泛应用于油气田中[1-2]。链传动系统作为连续油管注入头结构中的重要组成部分,控制着连续油管上下提放。
磨损是链轮失效的主要形式之一,在链轮与链条发生接触摩擦时易产生[3]。上下链轮共面度、链轮链条的材料、润滑情况等因素会影响链传动的平稳性和链轮的磨损程度[4]。张东阳等[5]借助有限元仿真软件对注入头链轮轮齿进行静强度分析,研究表明轮齿工作时的危险区域集中在轮齿根部附近。胡政等[6]建立了注入头链条与链轮轮齿啮合接触力学模型,研究表明注入头工作载荷对链传动性能有较大影响。王杰之等[7]指出箱体变形会导致链传动系统运行不稳定,造成链轮磨损。许峰[8]提出引发刮板输送机链轮故障的原因有疲劳磨损、过载断裂等。管佳伟等[9]研究了药仓推药链系统滚轮磨损和链轮磨损两种磨损形式下的链传动特性,结果表明磨损会使链传动运动精度和平稳性下降。Li等[10]利用自制的花键联轴器试验台,研究了轴线不对中对花键联轴器齿面磨损的机理。Sun等[11]基于Archard磨损模型等对小模数齿轮的动态磨损问题进行了分析。陈爽等[12]研究发现主从动轮表面粗糙度和硬度参数不匹配导致渐开线齿轮磨损严重。赵富等[13]研究发现重载齿轮在传动中常出现齿轮弯曲疲劳、齿面接触疲劳和齿面磨损3种失效模式。针对链传动系统的损伤问题,当前的研究主要以有限元方法对链轮进行力学分析,对链传动系统提出优化。
经现场调查和查阅文献[14]发现,连续油管注入头在使用过程中链传动系统普遍存在振动、噪音、链轮齿面和链条磨损等现象,影响注入头寿命,而本文研究在连续油管施工现场发现LG450型注入头作业初期出现剧烈振动,发出刺耳卡壳声,1 d后停止运转。拆解该注入头后,通过观察链传动系统的损伤形貌,进行物化检测,结合有限元数值模拟,分析链传动系统损伤原因,并提出改进措施,以消除此类事故风险。
1 注入头链传动系统损伤形貌分析
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故障注入头如图1所示。连续油管两侧共设有两组链轮链条。传动链轮为主动轮,张紧链轮为从动轮,张紧链轮位于传动链轮正下方,现场的链轮链条如图2所示。将链轮安装减速器一侧命名为A端,安装马达一侧为B端。齿轮侧面靠近两端的为外侧,靠近中心的为内侧。从A端看,轮齿左侧齿面为上齿面,右侧齿面为下齿面。宏观形貌观察发现,传动链轮和张紧链轮上存在多种损伤,包括凹坑、碎屑堆积、擦痕以及刮痕等,链条滚子及内链板上也存在磨损和压痕。
1.1 刮痕
传动链轮B端齿轮齿侧形貌如图3所示。如图3(a)所示传动链轮B端轮齿外侧面摩擦光亮,带有弧形沟槽。为链条滚子啮入时,链板内侧与其发生刮擦产生。最深的沟槽是与右侧齿底圆同圆心的逆时针圆弧。划痕最深反映此时载荷最大,判断为上提连续油管过程,并且右侧齿底中的链条滚子已经啮合,左侧齿底中的链条滚子正在啮合。同时可判断出上提连续油管时,该链轮旋转方向为顺时针(从B端看)。
如图3(b)所示轮齿内侧表面无磨损。传动链轮A端和张紧链轮同样发现轮齿外侧磨损严重,内侧无磨损或磨损轻微,判断链条在啮入时轴向偏移严重。
1.2 磨损
在链传动系统运行期间,链轮与链条滚子之间发生相对滑动或滚动,引起接触面材料转移或分离,即链轮表面被磨损。严重的磨损将使齿形失真,齿侧间隙增大,齿顶磨平,影响链轮链条的形状、配合间隙和接触面形貌,从而影响传动精度和链条的稳定性,产生冲击和噪音,甚至发生齿轮折断。注入头链传动系统正常工作时,链条滚子与链轮齿面平行接触,齿面与滚子接触区域摩擦均匀且贯穿于齿面[15]。
齿轮齿面磨损形貌如图4所示,图4(a)为上齿面,图4(b)为下齿面。图4中左侧5组为传动链轮齿面,右侧4组为张紧链轮齿面。可见传动链轮的上齿面损伤重,存在向左倾斜的偏斜擦痕,下齿面可见右侧倾斜啮合痕迹,上下齿面均为偏斜擦痕。传动链轮齿顶右侧棱边出存在摩擦痕迹如图5所示。张紧链轮的齿面上也存在摩擦痕迹,损伤轻于传动链轮,上齿面的摩擦光亮区域集中在两侧,下齿面整条贯穿。分析链条滚子与传动链轮轴线严重倾斜,偏斜啮合。链条滚子与张紧链轮轴线略微倾斜,但链条滚子左右振动较大。
对传动链轮的轮齿上齿面进行取样,如图6所示。利用扫描电镜进行观察6个位置,各处微观形貌如图7所示。4号位置摩擦痕迹不明显,其他位置存在明显的犁沟状磨削痕迹,以及大小不一的磨削颗粒,为磨粒磨损的典型特征。犁沟痕迹倾斜,表明链条滚子与传动链轮上齿面啮合时倾斜接触,局部接触应力过大,发生磨粒磨损。
此外,链条上的链板内侧也出现局部严重磨损,如图8所示,磨损量为0.5 mm。表明链轮齿在链条中居中程度很差,啮合时端部接触,发生严重刮擦。此磨损形貌与图3(a)中的刮痕为同时产生。
2 链轮轮齿理化检测分析
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2.1 尺寸测量
对现场链轮尺寸进行测量,测量结果如表1所示,测得链轮表面粗糙度为3.2 μm,链轮尺寸和粗糙度均在误差范围内,均符合工艺设计要求。
2.2 化学成分检测
对注入头链轮轮齿取样进行化学成分检测,利用直读光谱仪检测其化学成分,结果如表2所示。结果表明,该链轮轮齿的化学成分分析结果符合国家标准GB/T 3077—2015中42CrMo的化学成分要求。
2.3 硬度试验
分别取链轮上的两个轮齿作为1号样品和2号样品,使用洛氏硬度计对样品近表面处的5个位置进行硬度测试,如图9所示。工艺要求调质硬度为28~32 HRC。测试结果如表3所示,显示该样品材料硬度符合工艺设计要求。
2.4 金相试验
在链轮轮齿上取样,进行金相分析。金相组织形貌如图10所示,基体组织为回火索氏体和少量铁素体,组织分布均匀,回火索氏体为主,铁素体呈块状及针状分布。依据GB/T13320—2007 《钢质模锻件金相组织评级图及评定方法》,试样金相组织符合调质钢调质组织500倍下4级标准,表明该轮齿材料组织及热处理工艺符合要求。
3 分析与讨论
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3.1 接触仿真分析
根据失效形貌分析和检测结果初步判断,造成链轮磨损的主要原因是链条与链轮偏斜啮合。运用有限元方法对链条和链轮啮合过程进行模拟仿真,建立链轮链条倾斜接触模型,研究倾斜啮合对链传动系统的影响。
简化链轮链条模型,取3个轮齿与一个链节作为研究对象。滚子长度为38.5 mm,链轮厚度为35.2 mm,内链板与链轮侧面存在缝隙,为模拟链条偏斜啮入链轮的过程,建模时将链节向一侧偏移,如图11(a)所示。滚子外径为39.86 mm,链轮外径为168.42 mm。
采用ABAQUS有限元仿真软件对其进行分析,采用六面体单元C3D8R对链条进行网格划分,大小为1 mm,链轮采用大小为2 mm的C3D10四面体单元进行网格划分,如图11(b)所示。链条的材料为20CrNiMo,链轮的材料为42CrMo,材料性能参数如表4所示。将整个链节与参考点RP1耦合,两个滚子分别与参考点RP2和RP3耦合。模型采用通用接触,摩擦系数设置为0.15。
对链轮施加固定约束,共创建两个动力显示分析步。第一个分析步给RP1施加一个绕基准坐标系X轴旋转的载荷,使滚子轴线偏移,内链板与链轮侧面接触。第二个分析步施加载荷使左侧滚子绕中心RP2的X轴向下旋转,模拟滚子啮入链轮的过程。载荷施加如图11(c)所示。
仿真分析结果如图12所示。可以看出滚子和齿轮在相对运动时,链轮齿面上所受应力集中分布于齿轮根部右侧,最大应力分布于链轮侧面,大小为2 025 MPa,远超过材料的抗拉强度。齿轮根部的最大接触压力为6 856 MPa,位于链轮齿侧,同时链轮齿面也存在接触压力集中。仿真结果显示链节偏斜啮入时,滚子与齿面倾斜接触,齿面右侧相较于齿面左侧磨损更严重。内链板与链轮齿侧发生刮擦,应力超过抗拉强度,材料产生破坏。仿真结果与传动链轮实物上的损伤形貌一致,齿面偏磨,内链板磨损,链轮齿侧产生刮痕。
3.2 损伤原因分析
失效链轮的损伤形貌研究发现轮齿外侧均存在严重的刮擦弧线,部分链条内链板磨损后局部厚度减薄。主动链轮齿底圆面(非主啮合面)有不同方向的摩擦纹路、齿顶棱角处(非啮合面)发生磨损;从动轮上也存在类似的磨损痕迹,程度相对较轻。在齿轮与链条啮合时,存在着相对滑动,在载荷的作用下,接触面上的灰尘,碎屑等引起磨粒磨损。结合有限元仿真分析结果,接触压力分布区域与实际发生磨损位置一致,实验分析与数值模拟结果均表明链条与链轮偏进入啮合,链条滚子与链轮轴线空间交叉。
进一步测量注入头箱体各处空间位置,发现箱体存在明显变形如图13所示。图13中矩形框上部4个顶点代表箱体法兰面位置,下部顶点代表箱体安装张紧链轮位置。虚线为标准箱体位置,实线为实测位置。可见箱体下部向A侧偏离基准达3 mm,箱体上部向B侧偏离达6.44 mm。箱体上部与下部的相对偏差为9.44 mm。同时箱体上部的前端和后端侧偏程度不同,说明箱体还存在扭转,如图14所示,扭转在俯视情况下为逆时针方向。而箱体变形会导致链轮轴偏离标准位置,造成链轮链条的偏载、偏移,使链传动系统无法平稳运行。
综合所述,该注入头箱体变形过大是该注入头链传动系统发生磨损失效的主要原因。该注入头箱体变形过大引起主从动链轮轴错位,导致链条偏斜进入啮合,轮齿外侧与链条内链板刮擦,形成刮痕;链轮齿面与滚子倾斜接触,发生偏载,形成偏磨。链轮轮齿齿面的磨损机理主要为磨粒磨损。
4 结论与建议
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4.1 结论
(1)链传动系统损伤形貌分析表明,主、从动链轮轴线空间交叉,链条滚子偏斜啮入,且链条滚子左右振动。微观形貌分析发现链轮齿面存在大面积倾斜摩擦痕迹。轮齿表面存在材料缺失,表现为明显的犁皱沟槽,链轮齿面磨损机理为磨粒磨损。
(2)失效样品材料检测结果显示链轮洛氏硬度为28~32 HRC,工件经调质处理后基体组织为回火索氏体和少量铁素体,组织分布均匀,回火索氏体为主,铁素体呈块状及针状分布,理化检测均符合标准要求,表明该注入头链轮轮齿材料和加工工艺符合要求。
(3)对链轮和链条偏斜啮合过程进行有限元接触仿真,其接触应力分布与链轮实物损伤形貌一致。齿面应力集中,导致严重磨损,齿侧接触应力过大造成材料缺失,形成刮痕,影响链传动系统安全。
4.2 建议
装配时必须保证链条滚子和链轮轴线的平行度,滚子和轮齿正常啮合。可选择更耐磨的材料制造注入头链轮链条,以延长注入头链传动系统的磨损寿命。采用合适的热处理工艺适当提高齿面硬度;制造时适当降低齿面粗糙度,通过增加润滑油使润滑充分,减少链轮与链条之间的摩擦,以减轻齿面磨损;可定期检查和校正链传动是否正常啮合,及时做出调整,定期检查和更换链轮链条。
基金
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  • 中油国家油气钻井装备工程技术研究中心开放项目(BOMCO-J118-JKY011-2022)
  • 国家自然科学基金(62273060)
  • 湖北省教育厅科技创新服务项目(F2023003)
文献
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2025年第25卷第10期
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doi: 10.12404/j.issn.1671-1815.2405713
  • 接收时间：2024-07-30
  • 首发时间：2026-01-12
  • 出版时间：2025-04-08
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  • 收稿日期：2024-07-30
  • 修回日期：2025-01-17
基金
中油国家油气钻井装备工程技术研究中心开放项目(BOMCO-J118-JKY011-2022)
国家自然科学基金(62273060)
湖北省教育厅科技创新服务项目(F2023003)
作者信息
    1 长江大学机械工程学院, 荆州 434023
    2 中石化四机石油机械有限公司, 荆州 434000
    3 武汉齐达康能源装备有限公司, 武汉 431400

通讯作者:

* 阳婷(1988—),女,汉族,湖北公安人,博士研究生,讲师。研究方向:石油机械。E-mail:。
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2种不同金属材料的力学参数
科
Family		 属数
Number of
genus		 种数
Number of
species		 占总种数比例
Percentage of
total species (%)		 属
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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