低速重载开式齿轮齿条传动副失效模式及低环境负荷润滑研究

Low-speed heavy-duty open rack and pinion drives are the core components for large shiplift and offshore drilling platforms. Three Gorges Shiplift rack and pinion transmission device operates under complex environment and conditions, there is the risk of scuffing failure, and cold scuffing failure mechanism analysis and failure prevention are very challenging. This project will study the failure mode of low speed and heavy rack and pinion drive, the life cycle design method of transmission system and the low environmental load lubrication process, with the large pinion - lubricating media - rack drive system as the object. Firstly, the project analyzes the mechanism and law of lubricating oil physical and chemical properties, meshing surface contact characteristics, service environment and working condition on the failure mode and transmission performance of low-speed heavy-duty rack and pinion drive system. Based on this, the project will further study life cycle design method of pinion - lubrication media - rack lubrication system and low environmental load lubrication process, and finally is the development of transmission performance evaluation and failure mode analysis and forecasting prototype system. The research results of this project can not only solve the failure mode and lubrication problem of the Three Gorges Shiplift rack and pinion transmission system, but also provide the basic methods and basic technical support of large-scale rack and pinion drive system such as Xiangjiaba shiplift and offshore drilling platform. Through the study and application, design methods and standards of large modulus open rack and pinion will come true.

低速重载开式齿轮齿条传动是大型升船机和海洋钻井平台的核心部件。三峡升船机齿轮齿条传动装置运行环境和工况复杂，存在胶合失效的风险，而冷胶合失效机理分析和失效预防极具挑战。本项目将以大型齿轮-润滑介质-齿条传动系统为对象，研究低速重载开式齿轮齿条传动副失效模式、传动系统的全生命周期设计方法及低环境负荷润滑工艺。首先重点研究润滑油物化特性、啮合面接触特征、服役环境及工况对低速重载硬齿面齿轮齿条传动系统失效模式和传动性能的影响机理和规律，再以此为基础研究齿轮-润滑介质-齿条润滑系统全生命周期设计方法和低环境负荷润滑工艺，最后开发传动性能评价和故障模式分析预测原型系统。本项目研究成果不仅可以解决三峡升船机齿轮齿条传动系统的失效模式和润滑问题，而且对向家坝升船机和海洋石油钻井平台升降系统等大模数齿轮齿条传动装置的设计提供基本方法和基础技术支持。通过研究和应用最终形成大模数开式齿轮齿条副设计方法和标准。

低速重载开式齿轮齿条传动机构广泛应用于大型升船机和海洋钻井平台，目前国内外缺乏此类齿轮齿条传动副润滑的试验数据积累和试验方法研究，难以开展对三峡升船机升降系统的大模数、大尺寸齿条进行润滑性能试验。.针对三峡升船机超大模数齿轮-齿条传动润滑设计不完整与过早磨损（或胶合），开展低速重载使役状态下传动系统的润滑特性研究。构建变位齿轮-齿条传动系统瞬态热弹流润滑计算模型，研究结果发现，齿条啮入瞬间的成膜条件差，滑移速度与摩擦力较大，易使齿条顶部发生磨损；齿轮副硬材料表面的润滑性能较差；适当增大变位系数、模数、压力角和黏度可改善润滑性能。.在MJP-30A滚动磨损试验机上进行了18CrNiMo7-6渗碳钢齿轮材料在不同润滑条件下的胶合试验。结果表明干摩擦条件下，出现胶合损伤时的接触应力为1927MPa，出现胶合损伤前，接触界面摩擦因数随接触应力的增加而降低；良好润滑条件下，接触应力达到3047MPa仍未发生胶合，摩擦因数随接触应力的增加有轻微下降趋势；乏油条件下，摩擦因数随着乏油程度的加剧呈明显上升趋势，仅当摩擦因数几乎增大至干摩擦因数水平时才发生胶合损伤。.超大型模数开式齿轮齿条机构的精益润滑设计分为“表征润滑行为，揭示润滑特性”、“减少供油与浪费”和“提高欠润滑条件下的摩擦学性能”三个步骤。对齿面织构设计和最适供油量计算得到减摩效果最佳的织构设计参数方案为：面积率44%，深度7μm，直径12μm。提出了一种能够保证齿面充分润滑的最适供油量的计算方法，计算得到低速重载齿轮齿条一个啮合周期的最适供油量为734.51mL，相比推荐供油量减少了4.13%。在任何供油条件下，表面织构均能减小齿面摩擦系数。.本项目在国内外学术刊物发表SCI收录期刊论文4篇、EI收录期刊论文5篇，国际学术会议论文4篇，授权专利3件，软件著作权1项，参加国际国内外交流研讨会6次。.通过本项目的研究，将对向家坝升船机和海洋石油钻井平台升降系统等大模数齿轮齿条传动装置的设计提供基本方法和基础技术支持，形成相应的设计方法和标准。