增速传动螺旋锥齿轮的主动设计、加工控制及啮合性能测试研究

Speed increasing spiral bevel and hypoid gears can be applied in large speed increasing drive systems to change the direction of axis of the transformed rotation and torque, at the same time, increasing the velocity of rotation and reducing the value of torque simultaneously. Unfortunately, the works specifically aimed at the speed increasing spiral bevel and hypoid gears or even referred to the comparison of these two different cases are seldom reported in the literature. The public experience for design, manufacture, and application of spiral bevel and hypoid gears mainly considers the speed reducing case...This project aims to propose a systematic approache for the design and manufacture of speed increasing spiral bevel and hypoid gears...To reduce complexity, an invariant approach for the theory of gearing based on tensor analysis will be proposed. By this approach, the design and manufacture of spiral bevel and hypoid gears will be represented in a compact and clear way...An extended tooth contact analysis and the numerical simulation of meshing will be employed to learn the contact characteristics of spiral bevel and hypoid gears operating in speed increasing and reducing modes. The relations between tooth geometry and contact characteristics will be built which are necessary for the optimization of tooth contact performance...The global synthesis approach proposed by the applicant will be employed to synthesis the contact characteristics of speed increasing spiral bevel and hypoid gears. By this approach, the entire contact point path and the contact characteristics for each point of the entire contact point path can be directly predesigned...The desired tooth surfaces for speed increasing can be produced on dedicated bevel gear cutting machines or 5-axis machining centers. The tool positioning strategies for different tooth forms will be investigated in this project...The proposed ideas will be proven by the manufacturing and test of prototypes of spiral bevel gear drives...All the achievements obtained from this project will be provided for the public through an intelligent design software which will be deployed in the cloud computing environment.

增速传动螺旋锥齿轮能在改变运动和动力传递方向的同时实现增速，具有重要的应用价值，但其设计制造相关的应用基础研究目前尚属空白。两轴之间的齿轮副理论上存在减速正转、减速反转、增速正转和增速反转四种不同的工作模式。螺旋锥齿轮的已有研究几乎都是针对减速正转传动，相关成果不能直接照搬应用于增速传动。将张量分析方法应用于共轭曲面相关的理论研究，建立空间啮合原理基于张量分析的理论研究框架。运用扩展的齿面接触分析方法和齿轮啮合数值仿真方法，揭示不同工作模式下轮齿几何参数对啮合特性的影响规律。基于全局综合法开展增速传动螺旋锥齿轮齿面啮合性能主动设计研究。研究弧齿、摆线齿和一般齿形增速传动螺旋锥齿轮在专用数控机床或加工中心上的加工控制方法。开展数控加工、齿面检测及动态啮合性能测试实验验证研究。通过研究，建立一套增速传动螺旋锥齿轮的主动设计和数控加工控制方法；建设一个基于云计算的螺旋锥齿轮设计加工智能服务平台。

增速传动齿轮是工业增速器、风力发电机、特种车辆、医疗器械及渔具等装置中增速齿轮传动系统中的关键零件。因对增速传动和减速传动齿轮啮合机理差异研究和认识的不足，增速齿轮传动系统的设计和加工主要依据减速传动齿轮的相关标准和经验，常出现过早失效和较高的故障率。.项目以增速传动和减速传动齿轮啮合特性对比分析为核心，从齿轮相关的啮合理论、设计方法、加工控制方法、试验方法和装置以及齿轮智能制造方法这几个方面开展了探索性研究。采用张量分析方法对啮合理论的核心问题进行了阐述，推导了共轭曲面曲率关系的通用公式。针对考虑齿面滑动摩擦力影响的增速传动和减速传动齿轮，采用齿面接触分析方法分析了齿面啮合过程摩擦力的变化规律，并分别采用齿轮弯曲强度计算标准和有限元啮合仿真两种方法，研究了齿轮副啮合过程齿根最大弯曲应力的变化趋势，以及同一轮齿齿根最大弯曲应力在增速传动和减速传动下的变化趋势。基于增速传动和减速传动啮合特性差异，研究了面向增速传动齿轮的设计方法。面向零齿高增速传动齿轮及螺旋锥齿轮等复杂齿轮，研究了主动控制复杂齿面整体啮合性能的主动设计和数控加工方法。针对齿轮的大批量成形制造中对齿轮模具的需求，研究了基于加工中心和通用刀具的齿面刀路规划和误差补偿方法。研究了增速传动和减速传动啮合性能对比试验方法及齿轮的智能制造方法。.通过研究，建立了齿轮啮合理论新的研究框架，发现了增速传动大轮最大齿根弯曲应力提高了27.8%，建立了增速传动齿轮的零齿高设计方法和面向高性能复杂齿轮加工控制的全局综合法，设计了增速传动和减速传动啮合性能对比试验台，开发了齿轮智能制造云服务平台。.研究结果为高性能复杂齿轮的基础理论、设计方法、加工控制方法、试验方法和装置以及齿轮智能制造中关键科学和技术问题提供了有价值的参考。