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

doi:10.7527/S1000-6893.2024.30777

Abstract

Abstract:

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

CLC Number:

V216.3

Jinxiao CHEN, Peitang WEI, Yanjun LI, Huaiju LIU, Caichao ZHU. Experiment and anti-scuffing design for aviation gear scuffing based on material, surface treatment and lubricant combinations[J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(4): 430777.

Figures/Tables 16

Table 1

Fig.1

Table 2

Material characteristics for 16Cr3NiWMoVNbE， 18Cr2Ni4WA， and 9310 gear steels

参数	16Cr3NiWMoVNbE	18Cr2Ni4WA	9310
热导率 $λ M$ /（W·（m·K）^-1）	38	47	25
密度 $ρ M$ /（kg·m^-3）	7 850	7 910	7 700
比热容 $C M$ /（J·（kg·K）^-1）	450	460	460
弹性模量E/（N·mm^-1）	210	202	206
热膨胀系数v/（10^-5 ℃）	1.15	1.24	1.00

Table 2

Table 3

Table 4

Fig.2

Fig.3

Fig.4

Fig.5

Fig.6

Table 5

Table 6

Fig.7

Fig.8

Fig.9

Fig.10

References 36

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	BRANDÃO 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.

参数	CQU M/38.3/74	FZG A/8.3/90
小齿轮转速/（r·min^-1）	10 000	2 183
对应节圆线速度/（m·s^-1）	38.3	8.3
载荷级	16级Ryder载荷	13级FZG载荷
运行时间/min	10	15
齿数比	16/24	16/24
加载方式	扭矩盘逐级加载	砝码杆逐级加载
润滑方式	喷油润滑	油浴润滑
润滑油温/℃	74	90
失效判定	总损伤面积相加大于齿面总面积的30%	失效损伤总面积相加大于1个齿

材料	工艺	表面硬度（HV）	表面残余应力/MPa	表面粗糙度/μm
16Cr3NiWMoVNbE	磨削	738	-532	0.39
	二次喷丸	786	-1 166	0.41
	二次喷丸+光整	800	-1 386	0.20
	喷丸	761	-1 479	0.51
9310	磨削	645	-509	0.62
	微粒喷丸	714	-1 328	0.70
	光整	660	-1 450	0.28
18Cr2Ni4WA	磨削	628	-631	0.60

参数	测试温度/℃	4010	4106	555	4450	2197	Mobil jet oil Ⅱ	387	560
运动黏度/ （mm²·s^-1）	40	13.40	24.40	26.50	61	26.96	27.60	25.92	26.70
运动黏度/ （mm²·s^-1）	100	3.31	5.02	5.20	9.55	5.28	5.10	5.20	5.21
滑油类型		STD	STD	HTS+	HTS	HTS	STD	HTS	HTS
黏度指数		120	136	128	130	131	114	135	129

序号	材料	齿形	工艺	滑油	试验测量油温/ ℃	小齿轮转速/（r·min^-1）	线速度/（m·s^-1）	失效扭矩/ （N·m）
1	16Cr3NiWMoVNbE	FZG-A	二次喷丸	4106	130	2 175	8.3	239.3
2			二次喷丸+光整	4106	130	2 175	8.3	183.4
3			喷丸	4106	140	2 175	8.3	183.4
4			磨削	4106	130	2 175	8.3	302.0
5			磨削	4010	130	2 175	8.3	302.0
6	18Cr2Ni4WA	FZG-A	磨削	4106	130	2 175	8.3	183.4
7				4010	130	2 175	8.3	135.3
8				555	140	2 175	8.3	629.7
9				4450	140	2 175	8.3	450.1
10	9310	FZG-A	磨削	4106	130	2 175	8.3	135.3
11				4010	130	2 175	8.3	135.3
12				555	140	2 175	8.3	730.5
13				4450	140	2 175	8.3	450.1
14	9310	M-20	磨削	2197	80	10 000	38.3	123.0
15			光整	2197	80	10 000	38.3	140.0
16			微粒喷丸	2197	80	10 000	38.3	88.0
17			磨削	Mobil jet oil Ⅱ	80	10 000	38.3	105.0
18			光整	Mobil jet oil Ⅱ	80	10 000	38.3	140.0
19			微粒喷丸	Mobil jet oil Ⅱ	80	10 000	38.3	123.0
20			磨削	560	80	10 000	38.3	158.0
21			磨削	387	80	10 000	38.3	123.0
22	9310	M-25	磨削	Mobil jet oil Ⅱ	80	10 000	38.3	175.0
23			光整	Mobil Jet oil Ⅱ	80	10 000	38.3	228.0
24			喷丸	Mobil Jet oil Ⅱ	80	10 000	38.3	105.0
25	18CrNiMo7-6	FZG-A	磨削	4106	40	2 175	8.3	534.5
26			磨削	4106	65	2 175	8.3	302.0
27			磨削	4106	75	2 175	8.3	302.0
28			喷丸	4106	80	2 175	8.3	239.3
29			光整	4106	80	2 175	8.3	302.0

序号	材料	齿形	工艺	滑油	S_PVT/（MPa∙（m·s^-1）^-0.51·℃^0.45）
1	16Cr3NiWMoVNbE	FZG-A	二次喷丸	4106	21 989
2			二次喷丸+光整	4106	20 711
3			喷丸	4106	19 250
4			磨削	4106	24 702
5			磨削	4010	24 702
6	18Cr2Ni4WA	FZG-A	磨削	4106	18 758
7				4010	16 534
8				555	36 879
9				4450	31 180
10	9310	FZG-A	磨削	4106	16 534
11				4010	16 534
12				555	39 721
13				4450	31 180
14	9310	M-20	磨削	2197	19 144
15			光整	2197	21 698
16			微粒喷丸	2197	19 144
17			磨削	Mobil jet oil Ⅱ	19 144
18			光整	Mobil jet oil Ⅱ	21 698
19			微粒喷丸	Mobil jet oil Ⅱ	19 144
20			磨削	560	20 424
21			磨削	387	19 144
22	9310	M-25	磨削	Mobil jet oil Ⅱ	19 754
23			光整	Mobil Jet oil Ⅱ	22 257
24			喷丸	Mobil Jet oil Ⅱ	15 091
25	18CrNiMo7-6	FZG-A	磨削	4106	15 751
26			磨削	4106	14 731
27			磨削	4106	15 711
28			喷丸	4106	14 397
29			光整	4106	16 174

Experiment and anti-scuffing design for aviation gear scuffing based on material, surface treatment and lubricant combinations

RichHTML

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 16

References 36

Related Articles 1

Recommended Articles

Metrics

Comments