| 涂层强化齿轮传动抗胶合机理分析与试验 |
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| 引用本文： | 肖洋轶,贾鲁敏,曾炳中,雷宗霖,高艺平,万强.涂层强化齿轮传动抗胶合机理分析与试验[J].农业工程学报,2023,39(23):45-54. |
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| 作者姓名： | 肖洋轶 贾鲁敏 曾炳中 雷宗霖 高艺平 万强 |
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| 作者单位： | 华中农业大学工学院, 武汉 430070;华中科技大学机械科学与工程学院, 武汉 430074 |
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| 基金项目： | 国家自然科学基金项目（51905204），湖北省自然科学基金项目（2023AFB871），华中科技大学自主创新研究基金项目（2022XCZX001） |
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| 摘 要： | 为提高农机装备传动齿轮于润滑条件恶劣、变速、重载工况下的抗胶合承载性能，该研究将表面涂层强化技术应用于啮合齿面。首先，基于齿轮啮合原理、摩擦学、热力学等理论，建立涂层与齿轮接触特性、胶合承载能力关系数学模型，分析不同膜基弹性模量比下系统应力场的分布特点，阐明齿面摩擦系数对油膜厚度、瞬时接触温度的影响规律，为择取齿面抗胶合涂层提供理论参考。由此进一步对标准钢球表面分别沉积含钨ta-C和a-C:H碳膜，通过四球法评价涂层材料摩擦学性能，并在FZG(Forschungsstelle für Zahnr?der und Getriebesysteme)传动试验台上对两种涂层齿轮进行耐胶合试验。结果表明：与无涂层齿轮相比，碳膜摩擦副跑合性更好，其中a-C:H涂层的sp2 C-C键含量高于ta-C，具有更低的摩擦系数(0.055～0.058);ta-C涂层齿轮抗胶合承载能力提高了2个FZG载荷级，a-C:H涂层齿轮至少提升了4个载荷级；ta-C齿面展现为涂层剥落后的磨粒磨损和黏着磨损；且无涂层齿面与ta-C齿面均显示出热胶合与微点蚀损伤竞争性关系，并兼存齿面塑性变形；而a-C...
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| 关 键 词： | 涂层 齿轮传动 胶合 接触特性 摩擦磨损 承载能力 |
| 收稿时间： | 2023/7/6 0:00:00 |
| 修稿时间： | 2023/11/7 0:00:00 |
Scuffing resistance mechanism for coating strengthened gear transmission |
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| XIAO Yangyi,JIA Lumin,ZENG Bingzhong,LEI Zonglin,GAO Yiping,WAN Qiang.Scuffing resistance mechanism for coating strengthened gear transmission[J].Transactions of the Chinese Society of Agricultural Engineering,2023,39(23):45-54. |
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| Authors: | XIAO Yangyi JIA Lumin ZENG Bingzhong LEI Zonglin GAO Yiping WAN Qiang |
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| Institution: | College of Engineering, Huazhong Agricultural University, Wuhan 430070, China;School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China |
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| Abstract: | Scuffing is one of the most typical damage forms in the gear transmission of agricultural machinery. The fast bursting speed and serious damage degree should be strictly avoided in the conditions of the low lubrication and extreme loading during the gear service. This study aims to improve the scuffing resistance load carrying performance in the transmission gears of agricultural machinery under severe lubrication, variable speed, and heavy-duty conditions. The surface coating strengthening was applied to the meshed tooth surface. A mathematical model was established for the relationship between the contact properties of coatings and gears, as well as the scuffing load capacity. The gear meshing, tribology, and thermodynamics were also utilized in this case. The finite element model of plane strain was selected to explore the influence of elastic modulus ratio between coating and substrate on the stress field distribution. Anti-scuffing gear coatings were achieved to clarify the effect of tooth surface frictional coefficient on oil film thickness and transient contact temperature, according to the calculation in ISO/TS 6336-22. Then, the carbon films were prepared by low-temperature plasma enhanced chemical vapor deposition technology. Surfaces of standard steel balls were coated with the tungsten containing ta-C and a-C:H coatings. Tribological properties of coating materials were evaluated using the four-ball method. A series of experiments of scuffing resistance were performed on the two coated gears in the FZG (Forschungsstelle für Zahnräder und Getriebesysteme) transmission test rig. The results showed that the carbon film friction pairs had the better running-in performance, compared with the uncoated components. The a-C:H coating presented the higher sp2 C-C bond content than ta-C, resulting in a lower frictional coefficient. Also, the scuffing resistance capacity increased by 2 FZG loading stages in the ta-C coating, while at least 4 loading stages were found in the a-C:H coating one. In the process of engagement, the ta-C coating was peeled off, and then the peeled coating particles were pressed into, adhered to the contact surface, or discharged from the scratched surface, thus forming abrasive wear between the tooth surfaces, and finally the gear steel substrate was completely exposed. Furthermore, the failure mode was changed from abrasive wear to adhesive wear with the increase of frictional temperature. The surface material was subject to adhesive tearing. Moreover, both uncoated and ta-C coated tooth surfaces showed the significant competitive relationship between the thermal scuffing and micro pitting damage, which was mainly determined by the oil film thickness and contact temperature. In addition, the concave plastic deformation near the driving wheel pitch line was found on both surfaces. The a-C:H coating showed the conventional fatigue wear with the smooth and flat wear trace, where the tooth surface coating had the high integrity without outstanding damage. Theoretical analysis and experimental data were combined to enhance the gear scuffing resistance capacity. Although the frictional coefficient was low, the ta-C coating was more prone to the coating peeling and interface damage, due to the high elastic modulus ratio between coating and substrate. By contrast, a-C:H coating shared the relatively low elastic modulus ratio. The interface stress was smaller and more difficult to peeling, and the frictional coefficient was smaller, resulting in a relatively thicker oil film thickness and lower transient contact temperature on the tooth surface. The achievements demonstrated that the a-C:H coating exhibited the excellent scuffing resistance load carrying performance suitable for gear transmission. The finding can lay the foundation for the application of coating strengthening technology in the high-performance agricultural machinery gears, even the other transmission systems with harsh service conditions. |
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| Keywords: | coating gear transmission scuffing contact characteristics friction and wear load carrying capacity |
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