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齿轮疲劳试验Back-to-back_gear_testing

'齿轮疲劳试验Back-to-back_gear_testing'
1 Back-to-Back Gear Testing Jishan Zhang Design Unit, Newcastle University 2 Typical Gear Failure Modes ? Pitting (macropitting) ? Micropitting ? Case crushing ? Bending ? Scuffing 3 Typical Failure Modes Macropitting or ? Close to real application, equal pitch line speed ? Avoid the resonance zone of the rig ? To be economic, around 50 Hz motor speed ? Be aware of the different rotation speed between pinion and wheel 18 Test Methodology ? Torque direction determines which gear flank is to be loaded. For example, A direction: left flank; B direction: right flank ? The combination of motor rotation and torque direction determines which gear is driving which gear is driven How to set motor rotation direction and torque direction? 19 Test Methodology How to set oil temperature? ? Set to higher than designed oil temperature to accelerate the test, or ? Set it close to real application 20 Test Methodology How to set oil flow rate? ? 12 litter/minute/MW by default 21 Test Methodology Differences Between Two test gearboxes: ? Driving or Driven ? Speed increasing or speed reducing 22 Test Methodology How many data points can be obtained in one test? ? One test gearbox: one data ? Two test gearboxes: two data Note: ? Normally testing one gear set (pinion and wheel) in one flank generates one data point ? Slave gears are needed if one set of gear fails first 23 Test Methodology How many data points can be obtained in one pair of gear? ? Maximum 2 (1 for left flank; 1 for right flank) 24 Inspection Techniques Before Test ? Metrology (profile, lead and pitch), 4 teeth, 3 locations ? Surface roughness, 4 teeth, 3 locations ? Gear tapered bore dimensional measurement ? Hardness profile ? Residual stress profile ? Micro-structure ? Grinding burn/defects Before mounting gears on the rig, the following items should be checked: ? Backlash ? Contact pattern After mounting gears on the rig, the following items should be checked: 25 Inspection Techniques During Test Test rig needs to be stopped at regular intervals in order to carry out the following inspections: ?Taking photos ? Taking replicas ? Microscopic check on replicas ? On-site surface roughness measurement ? Profile check by taking gears off ? Gear flank temperature measurement ? Sketching gear surface condition 26 Inspection Techniques Example -Sketching gear surface condition 775Nm (925MPa) 1100Nm (1097MPa) 2275Nm (1473MPa) 4400Nm (1924MPa) PinionWheel Progression of micropitting 27 Inspection Techniques After Test ?Sectioning and sampling ? Microscopic studies 28 Inspection Techniques Example –sectioning and sampling 29 Inspection Techniques Example –microscopic studies 30 Failure Criteria Macropitting Case hardened gears: ? 4 % in one flank or 1% in all flanks ? run out: 1×108 at pinion Through-hardened gears: ? 2 % in all flanks ? run out: 5×107at pinion 31 Failure Criteria Micropitting Micropitting is found to be progressive and profile deviation is more than 20μm in either pinion or wheel Run out cyc
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齿轮 疲劳 试验 Back to back_gear_testing
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