航空齿轮胶合承载能力试验与材料-工艺-滑油抗胶合设计方法
收稿日期: 2024-06-03
修回日期: 2024-06-26
录用日期: 2024-07-24
网络出版日期: 2024-08-26
基金资助
国家自然科学基金(U2141247)
Experiment and anti-scuffing design for aviation gear scuffing based on material, surface treatment and lubricant combinations
Received date: 2024-06-03
Revised date: 2024-06-26
Accepted date: 2024-07-24
Online published: 2024-08-26
Supported by
National Natural Science Foundation of China(U2141247)
高温、高速、重载下发生的齿轮胶合会严重影响航空发动机等装备的服役性能。目前面向我国材料-工艺-滑油环境的航空齿轮胶合承载能力试验基础数据缺失，综合考虑材料-工艺-滑油组合的抗胶合主动设计方法不足。开展了21组不同材料-工艺-滑油组合的齿轮胶合承载能力试验，包含9310、18Cr2Ni4WA、16Cr3NiWMoVNbE等材料，磨削、喷丸、微粒喷丸、二次喷丸、光整、二次喷丸+光整等工艺及4450、555、4106、4010、2197、387、560、Mobil jet oil Ⅱ等润滑油。基于PVT极限（齿轮接触压力P、滑动速度V、滑油温度T）计算了不同组合下的齿轮胶合承载能力，探究了材料、工艺、润滑等因素对齿轮胶合承载能力的影响规律。结果表明16Cr3NiWMoVNbE光整齿轮与555滑油组合具有最高的抗胶合性能，其胶合承载能力达39 721 MPa·（m/s）0.51·℃0.45。添加剂类型、润滑剂黏度、表面粗糙度为影响齿轮胶合承载能力的3个主要因素，其对胶合承载能力的贡献度分别占比28.7%、23.6%、14.9%。通过OLS（Ordinary Least Squares）线性回归方法拟合了航空齿轮胶合承载能力预测公式，与试验结果对比的平均误差仅为4.99%，为齿轮抗胶合主动设计提供了理论支撑。
陈进筱 , 魏沛堂 , 李炎军 , 刘怀举 , 朱才朝 . 航空齿轮胶合承载能力试验与材料-工艺-滑油抗胶合设计方法[J]. 航空学报, 2025 , 46(4) : 430777 -430777 . DOI: 10.7527/S1000-6893.2024.30777
Gear scuffing occurring under high-temperature， high-speed， and heavy-load can significantly impair the performance of aviation engines. However， there is a lack of test data on the gear scuffing load-carrying capacity， and insufficient anti-scuffing design under the combined influences of materials， surface treatment and lubricants. This study investigates the effects of different combinations of materials （9310， 18Cr2Ni4WA， 16Cr3NiWMoVNbE）， surface treatments （grinding， shot peening， Micro-shot peening， dual shot peening， barrel finishing， dual shot peening + barrel finishing） and lubricants （4450， 555， 4106， 4010， 2197， 387， 560， Mobil jet oil Ⅱ） on the scuffing load-carrying capacity， and proposes an evaluation method based on the PVT limit （involving gear contact pressure P， sliding velocity V， and lubricant temperature T）. The results indicate that the tribological system composed of 16Cr3NiWMoVNbE， barrel finishing treatment， and 555 lubricant （containing high-performance EP additives） exhibits relatively superior anti-scuffing performance， and its PVT limit is 39 721 MPa·（m/s）0.51·℃0.45. Additive type， lubricant viscosity， and surface roughness are identified as three main factors affecting gear scuffing within the parameter framework， accounting for 28.7%， 23.6%， and 14.9%， respectively. An anti-scuffing design formula was fitted using the Ordinary Least-Squares （OLS） model， with an average error of only 4.99% compared to experimental results， providing a theoretical support for gear anti-scuffing design.
Key words： aviation gear; scuffing test; PVT limit; anti-scuffing design; surface treatment
| 1 | CHEN T M， WEI P T， ZHU C C， et al. Experimental investigation of gear scuffing for various tooth surface treatments［J］. Tribology Transactions， 2023， 66（1）： 35-46. |
| 2 | KRANTZ T L， KAHRAMAN A. An experimental investigation of the influence of the lubricant viscosity and additives on gear wear［J］. Tribology Transactions， 2004， 47（1）： 138-148. |
| 3 | WU J Z， WEI P T， LIU G Q， et al. A comprehensive evaluation of DLC coating on gear bending fatigue， contact fatigue， and scuffing performance［J］. Wear， 2024， 536-537： 205177. |
| 4 | RIGGS M R， MURTHY N K， BERKEBILE S P. Scuffing resistance and starved lubrication behavior in helicopter gear contacts： Dependence on material， surface finish， and novel lubricants［J］. Tribology Transactions， 2017， 60（5）： 932-941. |
| 5 | CHEN T M， ZHU C C， CHEN J X， et al. A review on gear scuffing studies： theories， experiments and design［J］. Tribology International， 2024， 196： 109741. |
| 6 | WOJCIECHOWSKI L， KUBIAK K J， MATHIA T G. Roughness and wettability of surfaces in boundary lubricated scuffing wear［J］. Tribology International， 2016， 93： 593-601. |
| 7 | DROZDOV Y N， GAVRIKOV Y A. Friction and scoring under the conditions of Simultaneous rolling and sliding of bodies［J］. Wear， 1968， 11（4）： 291-302. |
| 8 | CHEN J X， ZHU C C， WEI P T， et al. Experimental study on high-speed aviation gear scuffing based on tooth profile and surface treatment improvements［J］. Tribology Transactions， 2024， 67（2）： 280-293. |
| 9 | WU J Z， WEI P T， ZHU C C， et al. Development and application of high strength gears［J］. The International Journal of Advanced Manufacturing Technology， 2024， 132（7）： 3123-3148. |
| 10 | 陈国定， 李东紫. 动力传输齿轮表面闪温的部分弹流热分析［J］. 航空学报， 1992， 13（8）： 444-447. |
| CHEN G D， LI D Z. Thermo-pehl analysis for the surface flashtemperature of power transmission gears ［J］. Acta Aeronautica et Astronautica Sinica，1992， 13（8）：444-447 （in Chinese）. | |
| 11 | 潘升材， 吴林丰， 钟穗香， 等. 采用积分温度准则预测航空锥齿轮胶合失效［J］. 航空学报， 1987， 8（8）： 370-376. |
| PANG S C， WU L F， ZHONG H X， et al. Using integral temperature criterion topredict scuffing failure of bevel gears for aircraft ［J］ Acta Aeronautica et Astronautica Sinica， 1987， 8（8）： 370-376 （in Chinese）. | |
| 12 | ZHANG B Y， LIU H J， ZHU C C， et al. Simulation of the fatigue-wear coupling mechanism of an aviation gear［J］. Friction， 2021， 9（6）： 1616-1634. |
| 13 | CARPER H J， KU P M， ANDERSON E L. Effect of some material and operating variables on scuffing［J］. Mechanism and Machine Theory， 1973， 8（2）： 209-225. |
| 14 | WU J Z， CHEN K W， ZHANG P， et al. Effects of peening velocity and coverage on peen forming［J］. Proceedings of the Institution of Mechanical Engineers， Part E： Journal of Process Mechanical Engineering， 2023， DOI： 10.1177/09544089231207086 . |
| 15 | WU J Z， WEI P T， GUAGLIANO M， et al. A study of the effect of dual shot peening on the surface integrity of carburized steel： Combined experiments with dislocation density-based simulations［J］. Archives of Civil and Mechanical Engineering， 2024， 24（2）： 83. |
| 16 | 王绪虎， 王东飞， 吕泮功， 等. 基于齿面磷化的齿轮抗胶合性能试验［J］. 机械传动， 2020， 44（11）： 134-138. |
| WANG X H， WANG D F， Lü P G， et al. Study on the anti scuffing performance of gear based on tooth flank phosphate［J］. Journal of Mechanical Transmission， 2020， 44（11）： 134-138 （in Chinese）. | |
| 17 | ZHANG J W， LI W， WANG H Q， et al. A comparison of the effects of traditional shot peening and micro-shot peening on the scuffing resistance of carburized and quenched gear steel［J］. Wear， 2016， 368-369： 253-257. |
| 18 | KOENIG J， KOLLER P， TOBIE T， et al. Correlation of relevant case properties and the flank load carrying capacity of case-hardened gears［C］∥ASME 2015 Power Transmission and Gearing Conference； 23rd Reliability， Stress Analysis， and Failure Prevention Conference. New York：American Society of Mechanical Engineers， 2015， 57205： V010T11A006. |
| 19 | TUSZYNSKI W， SZCZEREK M， MICHALCZEWSKI R， et al. The potential of the application of biodegradable and non-toxic base oils for the formulation of gear oils—Model and component scuffing tests［J］. Lubrication Science， 2014， 26（5）： 327-346. |
| 20 | BRAND?O J A， MEHEUX M， VILLE F， et al. Comparative overview of five gear oils in mixed and boundary film lubrication［J］. Tribology International， 2012， 47： 50-61. |
| 21 | MURTHY N， BERKEBILE S， RAI A K， et al. Effects of ionic liquid additive concentration on scuffing and wear in oil-starved EHL contacts［J］. Tribology Transactions， 2018， 61（6）： 1117-1130. |
| 22 | KOTIA A， GHOSH G K， SRIVASTAVA I， et al. Mechanism for improvement of friction/wear by using Al2O3 and SiO2/Gear oil nanolubricants［J］. Journal of Alloys and Compounds， 2019， 782： 592-599. |
| 23 | International Organization for Standardization. ISO 14635-1 Gears- test procedures-Part 1： FZG test method A/8.3/90 for relative scuffing load-carrying capacity of oils［S］. Geneva： International Organization for Standardization， 2023： 1-17. |
| 24 | AmericanSociety of Testing Materials. Standardpractice for calculating viscosity index from kinematicviscosity at 40 ℃ and 100 ℃ ［S］. West Conshohocken： ASTM International， 2016. |
| 25 | Department of Defense. performance specification lubricating oil aircraft turbine engine， synthetic base ［S］. Washington， D.C.： DOD， 2014. |
| 26 | CHEN T M， ZHU C C， LIU H J， et al. Simulation and experiment of carburized gear scuffing under oil jet lubrication［J］. Engineering Failure Analysis， 2022， 139： 106406. |
| 27 | YADAV P S， PUROHIT R， KOTHARI A. Study of friction and wear behaviour of epoxy/nano SiO2 based polymer matrix composites-A review［J］. Materials Today： Proceedings， 2019， 18： 5530-5539. |
| 28 | WEI S Z， ZHU J H， XU L. Research on wear resistance of high speed steel with high vanadium content［J］. Materials Science and Engineering： A， 2005， 404（1-2）： 138-145. |
| 29 | PARENAGO O P， KUZ’MINA G N， ZAIMOVSKAYA T A. Sulfur-containing molybdenum compounds as high-performance lubricant additives （Review）［J］. Petroleum Chemistry， 2017， 57（8）： 631-642. |
| 30 | ALMEN J O. Dimensional value of LUBRICANTS in GEAR DESIGN［C］∥SAE Technical Paper Series. Warrendale： SAE International， 1942： 373-380. |
| 31 | PROKHORENKOVA L， GUSEV G， VOROBEV A， et al. CatBoost： unbiased boosting with categorical features［DB/OL］. arXiv preprint： 1706.09516， 2017. |
| 32 | FRIEDMAN J H. Stochastic gradient boosting ［J］. Computational Statistics & Data Analysis， （4）： 367-378. |
| 33 | LIU H L， LIU H J， ZHU C C， et al. Effects of lubrication on gear performance： A review［J］. Mechanism and Machine Theory， 2020， 145： 103701. |
| 34 | MICHAELIS K， HOEHN B R， OSTER P. Influence of lubricant on gear failures—Test methods and application to gearboxes in practice［J］. Tribotest， 2004， 11（1）： 43-56. |
| 35 | YAMAMOTO Y， HIRANO F. Relation between scuffing resistance and the increase in surface hardness during tests under conditions of rolling/sliding［J］. Wear， 1980， 63（1）： 165-173. |
| 36 | GAO Q H， SUN W J， ZHANG J Z. Thermo-elasto-hydrodynamic analysis of a specific multi-layer gas foil thrust bearing under thermal-fluid-solid coupling［J］. Chinese Journal of Aeronautics， 2023， 36（12）： 231-246. |
/
| 〈 |
|
〉 |
CJA