基于分形理论的双渐开线齿轮接触应力研究

综合考虑接触面粗糙度、材料特性等因素对齿轮接触应力的影响，基于分形理论和经典Hertz接触理论建立双渐开线齿轮分形接触模型. 该模型中，影响载荷和实际接触面积的主要因素包括分形维数、粗糙度幅值和材料特性参数. 理论分析表明:分形维数一定时，真实接触面积随着载荷的增大而增大；载荷一定时，接触面积随着粗糙度幅值的增大而减小；随着材料特性参数值的增加，在一定程度上加强了软材料轮齿承载能力，同时会使得微凸体由弹性变形到塑性变形的临界面积减小. 对比分形接触模型和有限元模型两种计算双渐开线齿轮轮齿接触应力方法，结果证明了分形接触模型计算双渐开线齿轮接触应力的有效性.      

内啮合直齿轮的三维接触应力分析

本文运用三维弹性接触问题的有限元局部网格密化技术有有限元－线性规划法计算了内啮合直齿轮副在啮合过程中不同接触位置的接触应力分布，对此分析了系统静载和动载作用下的齿轮接触应力，揭示了内啮合直齿轮在啮合过程接触应力的变化规律。从而为内啮合直齿轮的接触强度及其可靠性分析奠定基础。     

双渐开线齿轮传动的油膜刚度研究

在齿轮传动系统中，齿轮啮合刚度对振动、冲击、齿轮动力学特性分析以及接触应力计算有重要影响. 根据双渐开线齿轮齿廓啮合特点，基于弹流润滑理论，建立了双渐开线齿轮传动油膜刚度计算模型，研究双渐开线齿轮传动油膜刚度变化规律. 采用对比法分析了双渐开线齿轮与同参数普通渐开线齿轮传动油膜刚度差异，并研究双渐开线齿轮齿廓参数和工况条件对油膜刚度的影响. 分析表明:双渐开线齿轮由于轮齿分阶的影响，与同参数渐开线齿轮传动油膜刚度相比有较大差异；双渐开线齿轮传动油膜刚度随齿腰高度系数的增大而减小，齿腰切向变位系数变化时，油膜刚度基本不变；工况条件变化时，双渐开线齿轮传动油膜刚度随转速的增大而减小，随载荷增量因子的增大而增大.      

内啮合直齿轮的三维接触应力分析

本文运用三维弹性接触问题的有限元局部网格密化技术和有限元－线性规划法计算了内啮合直齿轮副在啮合过程中不同接触位置的接触应力分布。对比分析了在系统静载和动载作用下的齿轮接触应力，揭示了内啮合直齿轮在啮合过程中接触应力的变化规律。从而为内啮合直齿轮的接触强度及其可靠性分析奠定基础。     

齿轮接触有限元分析

通过接触仿真分析研究了通用接触单元在轮齿变形和接触应力计算中的应用。建立了一对齿轮接触仿真分析的模型，并使用新的接触单元法计算了轮齿变形和接触应力，与赫兹理论比较，同时也计算了摩擦力对接触应力的影响。计算分析了单元离散、几何、边界范围与加载或约束处理方式的误差，建立了一个计算轮齿变形和接触应力的标准，说明了新的接触单元法的精确法、有效性和可靠性。     

某差速器齿轮的动态接触仿真与疲劳分析

为分析差速器齿轮的疲劳寿命,运用动态有限元与试验相结合的方法,研究了锥齿轮在啮合过程中的应力分布以及疲劳强度。首先基于CATIA软件对差速器的半轴齿轮、行星齿轮进行了参数化建模,并采用动态有限元法模拟了齿轮副在最大扭矩工况下的动态接触;再根据有限元强度分析结果,将最大接触应力作为静载输入,运用疲劳分析软件对齿轮副的接触疲劳性能进行计算;最后进行了差速器齿轮副的台架试验,并将仿真结果与台架试验进行了对比。结果表明:齿面最大接触应力产生于节圆附近,齿轮间的最大接触应力为1309MPa;半轴齿轮在90%存活率下的疲劳寿命为3.394×106;仿真结果与台架试验具有较好的一致性,齿轮满足疲劳寿命要求。将动态有限元和疲劳寿命分析方法相结合可以有效预测差速器齿轮疲劳寿命。     

斜齿轮弹流润滑下的接触疲劳寿命计算

经典齿轮接触疲劳强度理论是基于光滑表面赫兹干接触理论,而实际齿面具有粗糙度,且啮合轮齿多数处于混合润滑状态.本文基于齿轮润滑接触分析建立了渐开线斜齿轮的接触疲劳寿命计算模型.模型由齿轮润滑接触分析模型和基于次表面应力分布的疲劳寿命模型组成.首先将斜齿圆柱齿轮一对齿的瞬时啮合等效为两反向圆锥的接触问题,建立了齿轮的有限长弹流润滑计算模型,考虑了齿轮啮合周期内瞬时载荷、接触线长、卷吸速度等因素的影响,基于统一雷诺方程方法求得啮合齿对间的润滑压力和油膜厚度分布;在此基础上,计算轮齿接触区次表面的米歇斯应力分布,根据Zaretsky接触疲劳寿命计算模型,对齿轮组的接触疲劳寿命进行模拟预测.针对不同工况参数下接触疲劳寿命计算表明:润滑油黏度、轮齿表面粗糙度等因素对齿面接触疲劳寿命均有显著的影响.     

应用边界元方法的正齿轮接触应力分析

本文应用边界元方法,采用在齿廓上按赫兹分布的载荷,直接计算了在接触区附近齿表面和齿体内的真实接触应力。并通过计算定量地分析了各齿轮参数及齿面摩擦对接触应力的影响。为高精度的齿轮设计、寿命预测和渗碳层厚度选择提供了可靠的依据。     

渐开线斜齿轮非稳态弹流润滑数值模拟研究

建立了渐开线斜齿轮啮合的弹流润滑计算模型,将斜齿圆柱齿轮啮合的齿面接触等效为有限长线接触的弹流润滑问题.考虑斜齿轮啮合的实际因素,将斜齿轮啮合过程中的等效曲率半径和齿面载荷的变化反映到弹流润滑计算模型中,应用统一Reynolds方程方法求得轮齿在1个完整啮合周期内的瞬时弹流润滑数值解.结果表明：斜齿轮啮合线上各点处的膜厚、压力均有较大不同,各接触点处的油膜厚度受综合曲率半径的影响较大;斜齿轮传动非稳态效应相对较弱;小齿轮齿根附近和节点位置处润滑状态较差;适当增大压力角可以改善齿轮的润滑.     

基于热弹流润滑的双渐开线齿轮温度场研究

针对现有双渐开线齿轮温度场计算模型不考虑油膜润滑影响的问题,根据双渐开线齿轮啮合特点,提出采用“分段法”建立适合双渐开线齿轮的热弹流润滑模型,综合有限元法和热弹流润滑方法对其本体温度进行研究,并以润滑油膜为热源对其瞬时温升进行研究,最后分析了齿腰分阶参数对双渐开线齿轮温度场影响以及与普通渐开线齿轮温度场差异. 结果表明:双渐开线齿轮本体温度沿齿宽方向呈非对称分布,主动轮最高本体温度偏向齿根啮入端,从动轮偏向齿顶啮出端;啮合齿面间的油膜瞬时温升明显高于两齿轮界面温升,且主动轮界面瞬时温升高于从动轮;齿腰分阶参数变化对双渐开线齿轮温度场影响较小;双渐开线齿轮与普通渐开线齿轮的本体温度及齿面瞬时温升区别不大.      

Contact friction analysis and stress oscilation suppression with a simple interface element

A simple interface element for analyzing contact friction problems is developed. Taking nodal displacements and contact stresses as unknowns, this element can simulate frictional slippage, decoupling and re-bonding of two bodies initially mating or having gaps at a common inteface. The method is based on the Finite Element Method and load incremental theory. The geometric and static constrait conditions on contact surfaces are treated as additional conditions and are included in stiffness equations. This simple element has the advantages of easy implementation into standard finite element programs and fast speed for convergence as well as high accuracy for stress distribution in interface. Undesirable stress oscillations are also investigated whenever large stress gradients exist over the contact surfaces. Exact integration or the conventional Gauss integration scheme used to evaluate the interpolation function matrix of the interface element is found to be the source of the oscillations. Eigenmode analysis demonstrates that the stress behavior of an interface element can be improved by using the Newton-Cotes integration scheme. Finally, the test example of a strip footing problem is presented.     

Linear and Nonlinear Algorithms for Stress Separation in Photoelasticity

An experimental-numerical hybrid method for the stress separation in photoelasticity is proposed in this study. In the proposed method, boundary conditions for a local finite element model, that is, tractions along boundaries are inversely determined from photoelastic fringes. Two algorithms are proposed for determining the boundary condition. One is a linear algorithm in which the tractions are obtained by the method of linear least-squares from both principal stress difference and principal direction. Another is the nonlinear algorithm in which the tractions are determined only from the principal stress difference. After determining the boundary conditions for the local finite element model, the stresses can be obtained by finite element direct analysis. The effectiveness is demonstrated by applying the proposed method to a perforated plate under tension and contact problems. Results show that the boundary conditions of the local finite element model can be determined from the photoelastic fringes and then the individual stresses can be obtained by the proposed method. Furthermore, the stresses can be evaluated even if the boundary condition is complicated such as at the contact surface. It is expected that the proposed method can be powerful tool for stress analysis.     

Local contact characteristics of threaded surfaces in a planetary roller screw mechanism

Abstract

This study investigates the local contact characteristics of the threaded surface meshing of a planetary roller screw mechanism (PRSM). First, according to the threaded surface structure and threaded surface meshing characteristics, expressions for the principal curvature and principal direction of the contact ellipse at a contact point are derived based on the differential geometry theory. Next, based on a force analysis and threaded surface equations, an analytical model is established to calculate the dimensions and principal vector direction of contact ellipses on threaded surfaces. The elastic deformation and maximum contact stress are determined using Hertz elastic contact theory. Then, finite element (FE) numerical models for a single pair of threads at the screw–roller interface and the roller–nut interface are developed to calculate the contact area and maximum contact stress. The results are compared with those of the analytical model to demonstrate the validity of the analytical model. Finally, based on the analytical model proposed in this article, the local contact characteristics of threaded surfaces with various thread pitches, flank angles, and profile radii of roller threads are analyzed in detail.     

Study of milling stability with Hertz contact stiffness of ball bearings

This present work examines the stability and nonlinear responses of a spindle milling system supported by ball bearings. A shaft finite element based on Timoshenko beam theory is employed to model the spindle, and modal reduction method is therefore adopted for saving the numerical calculating time. The issues of evaluating the effects of the ball bearing Hertz contact stiffness are consequently addressed. It is found that suitable constant bearing stiffness can be adopted to replace the nonlinear nonsmooth Hertz stiffness in prediction of the critical cutting depth of the milling system in certain bearing configuration conditions. For the constant bearing stiffness can be obtained by experiment, this replacement will undoubtedly simplify the spindle-bearing milling system. But with the increase in the bearing clearance, the spindle milling system will present obvious nonlinear behaviors, and the nonlinear Hertz contact bearing stiffness will take over. Isolated islands of chatter vibration, which are induced by the nonlinear nonsmooth bearing Hertz stiffness, can be found exist in milling processes in large bearing clearance conditions.     

基于三维各向异性分形理论的固定机械结合面法向接触刚度建模研究

摘要：将结合面微凸体拓展为椭球体,基于KE有限元模型,类比球形微凸体在弹塑性接触变形阶段法向载荷、接触面积以及变形量之间的关系,根据椭球体的弹性接触理论,采用代入法得到了表征椭球形微凸体弹塑性接触变形机制的对应关系式。结合三维各向异性分形几何理论得到了结合面接触点离心率的有效区间为[0,0.7374],在此基础上,假设结合面接触点离心率分布在有效区间内,在该区间上服从指数分布,且与接触点面积分布相互独立,根据概率论以及接触点的面积大小分布函数,获得了关于结合面接触点面积与离心率的二维联合分布密度函数,进而建立了包含椭球形微凸体完全弹性、弹塑性以及完全塑性三种变形机制的结合面法向接触刚度分形模型。所建模型理论刚度与实验数据的对比结果,表明了模型的正确性及有效性,能较好的预测固定结合面在轻载状态下的法向接触刚度。     

打捆机驱动轮系统接触三维有限元分析

应用ANSYS软件对打捆机驱动轮系统进行了三维接触非线性有限元分析，得出了接触应力的分布规律，并将其最大接触应力与应用简化方法进行了比较，两相吻合的结果表明，有限元分析结果可为系统的进一步精确分析提供依据．     

Single-strand strainwire technique: Comparison with existing methods and a proposed photostrain technique

This paper is the third of three papers evaluating a refined internal strainwire technique. This final paper evaluates the technique by comparing it with two elastic solutions, with a photoelastic solution, and with a new proposed photostrain technique. The problem chosen as the basis of comparison was a plane-stress problem of a plate with a circular hole under uniform tension. The proposed technique is experimental in nature and combines parts of the results of a photoelastic solution with those yielded by a three-wire internal strain-gage-rosette analysis to completely fix the state of stress in the model. The scientific techniques used to compare the three-wire strain technique and photostrain technique are as follows: two elastic solutions, one evaluated at a point and one arrived at by integrating the stress functions over a finite length; a finite-element solution; a photoelastic analysis using the shear-difference technique to separate the principal stresses; and a three-wire-rosette analysis. A comparison is made of the values of principal stresses yielded by these methods.     

Measurement of Orthogonal Stress Gradients Due to Impact Load on a Transparent Sheet using Digital Gradient Sensing Method

A full-field optical method called Digital Gradient Sensing (DGS) for measuring stress gradients due to an impact load on a planar transparent sheet is presented. The technique is based on the elasto-optic effect exhibited by transparent solids due to an imposed stress field causing angular deflections of light rays quantified using 2D digital image correlation method. The measured angular deflections are proportional to the in-plane gradients of stresses under plane stress conditions. The method is relatively simple to implement and is capable of measuring stress gradients in two orthogonal directions simultaneously. The feasibility of this method to study material failure/damage is demonstrated on transparent planar sheets of PMMA subjected to both quasi-static and dynamic line load acting on an edge. In the latter case, ultra high-speed digital photography is used to perform time-resolved measurements. The quasi-static measurements are successfully compared with those based on the Flamant solution for a line-load acting on a half-space in regions where plane stress conditions prevail. The dynamic measurements, prior to material failure, are also successfully compared with finite element computations. The measured stress gradients near the impact point after damage initiation are also presented and failure behavior is discussed.     

Frictional contact of two rotating elastic disks

We study the problem of constrained uniform rotation of two precompressed elastic disks made of different materials with friction forces in the contact region taken into account. The exact solution of the problem is obtained by the Wiener-Hopf method.An important stage in the study of rolling of elastic bodies is the Hertz theory [1] of contact interaction of elastic bodies with smoothly varying curvature in the contact region under normal compression. Friction in the contact region is assumed to be negligible. If there are tangential forces and the friction in the contact region is taken into account, then the picture of contact interaction of elastic bodies changes significantly. Although the normal contact stress distribution strictly follows the Hertz theory for bodies with identical elastic properties and apparently slightly differs from the Hertz diagram for bodies made of different materials, the presence of tangential stresses results in the splitting of the contact region into the adhesion region and the slip region. This phenomenon was first established by Reynolds [2], who experimentally discovered slip regions near points of material entry in and exit from the contact region under constrained rolling of an aluminum cylinder on a rubber base. The theoretical justification of the partial slip phenomenon in the contact region, discovered by Reynolds [2], can be found in Carter [3] and Fromm [4]. Moreover, Fromm presents a complete solution of the problem of constrained uniform rotation of two identical disks. Apparently, Fromm was the first to consider the so-called “clamped” strain and postulated that slip is absent at the point at which the disk materials enter the contact region.Ishlinskii [5, 6] gave an engineering solution of the problem on slip in the contact region under rolling friction. Considering the problem on a rigid disk rolling on an elastic half-plane, we model this problem by an infinite set of elastic vertical rods using Winkler-Zimmermann type hypotheses. Numerous papers of other authors are surveyed in Johnson’s monograph [7].The exact solution of the problem on the constrained uniform rotation of precompressed rigid and elastic disks under the assumptions of Fromm’s theory is contained in the papers [8, 9]. In the present paper, we generalize the solution obtained in [8, 9] to the case of two elastic disks made of different materials.