Simulation of the fatigue-wear coupling mechanism of an aviation gear
Simulation of the fatigue-wear coupling mechanism of an aviation gear
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DOI：
10.1007/s40544-020-0447-3
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发表时间：
2020-12
期刊：
影响因子：
6.8
通讯作者：
Boyu Zhang;Huaiju Liu;Cai-chao Zhu;Y. Ge
中科院分区：
文献类型：
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作者：
Boyu Zhang;Huaiju Liu;Cai-chao Zhu;Y. Ge
随着对重载、高功率密度齿轮的要求越来越高，航空齿轮的接触疲劳问题日益突出。同时，齿面接触疲劳损伤和齿面磨损的并存，导致了表面破坏和亚表面破坏之间复杂的竞争机制。针对这一问题，基于弹塑性有限元方法，建立了航空齿轮副的疲劳-磨损耦合模型。考虑了齿面粗糙度的影响，利用Archard磨损公式模拟了齿面粗糙度在重复啮合过程中的演变过程。采用Brown-Miller-Morrow多轴疲劳准则计算了接触表面上和接触下材料点的疲劳损伤累积。通过引入损伤变量来更新损伤材料点的弹塑性本构行为。描述了节点附近磨损深度和疲劳损伤的变化，并讨论了表面粗糙度对疲劳寿命的影响。结果表明，疲劳破坏最初发生在表面还是亚表面，取决于表面粗糙度的大小。与未磨损的结果相比，表面粗糙度的轻微磨损可以缓解局部应力集中，延长表面疲劳寿命。
The contact fatigue of aviation gears has become more prominent with greater demands for heavy-duty and high-power density gears. Meanwhile, the coexistence of tooth contact fatigue damage and tooth profile wear leads to a complicated competitive mechanism between surface-initiated failure and subsurface-initiated contact fatigue failures. To address this issue, a fatigue-wear coupling model of an aviation gear pair was developed based on the elastic-plastic finite element method. The tooth profile surface roughness was considered, and its evolution during repeated meshing was simulated using the Archard wear formula. The fatigue damage accumulation of material points on and underneath the contact surface was captured using the Brown-Miller-Morrow multiaxial fatigue criterion. The elastic-plastic constitutive behavior of damaged material points was updated by incorporating the damage variable. Variations in the wear depth and fatigue damage around the pitch point are described, and the effect of surface roughness on the fatigue life is addressed. The results reveal that whether fatigue failure occurs initially on the surface or sub-surface depends on the level of surface roughness. Mild wear on the asperity level alleviates the local stress concentration and leads to a longer surface fatigue life compared with the result without wear.