Bending Fatigue Life Prediction of Transmission Gear of Urban Rail Train under Two-stage Load
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摘要: 齿轮弯曲疲劳对列车安全运营具有重要影响。本文针对城轨列车载荷特点,建立一种适用于城轨列车的齿轮疲劳寿命预测模型。通过分析城轨列车实际运行过程的齿轮载荷特点,并结合主动齿轮累积受载频次,确定两级载荷大小,以两级应力比作为损伤参量,对城轨列车齿轮弯曲疲劳进行试验研究与寿命预测。研究结果表明:齿轮在两级载荷作用下疲劳寿命明显低于单一载荷作用下的疲劳寿命。通过将本文提出的疲劳寿命预测模型预测结果与试验数据进行对比发现,本文建立的疲劳寿命预测模型可以较为准确的预测齿轮的疲劳寿命。Abstract: Gear bending fatigue has an important impact on the safe operation of urban railway vehicles. According to the load characteristics of urban railway vehicles, this paper establishes a gear fatigue life prediction model suitable for urban railway vehicles. By analyzing the gear load characteristics of the actual operation condition of urban rail vehicles, and combining the cumulative load frequency of the driving gear, the two-stage load is determined; using the two-level stress ratio as the damage parameter, the bending fatigue test and life prediction of urban rail train gears are carried out. The research results show that the fatigue life of the gear under two-stage load is significantly lower than that under a single load. By comparing the prediction results of the fatigue life prediction model proposed in this paper with the test data, it is found that the fatigue life prediction model established in this paper can predict the bending fatigue life of gears more accurately.
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Key words:
- urban railway vehicle /
- spur gear /
- bending fatigue /
- two-stage load /
- fatigue life prediction
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表 1 齿轮参数
齿轮 模数/mm 齿数 齿宽/mm 材料 大齿轮 5 22 70 18CrNiMo7-6 小齿轮 5 133 60 18CrNiMo7-6 表 2 材料参数
密度/(g·cm−3) 弹性模量/MPa 泊松比 7.85 235 000 0.3 表 3 牵引工况的边界与载荷条件
牵引工况 小齿轮转速/ (rad·s−1) 大齿轮阻力矩/Nm 恒转矩阶段 62 18 800 恒功率阶段 128 14 500 自然特性阶段 204 8 400 表 4 不同工况下齿根应力
工况 σF/MPa 牵引 恒转矩阶段 430.61 恒功率阶段 376.52 自然特性阶段 212.63 惰行 −20.10 制动 −144.12 表 5 不同牵引阶段下齿轮齿根弯曲应力及循环次数
牵引阶段 列车速度/
(km·h−1)齿根弯曲应力
均值/MPa循环次数/
cyc恒转矩牵引 0~40 430.61 31 000 恒功率牵引 40~45 401.14 7 000 45~50 388.12 10 200 50~55 370.04 12 800 55~60 355.55 15 800 表 6 两级弯曲应力及加载载荷
σ2/σ1 弯曲应力 加载载荷 σ1/MPa σ2/MPa F1/kN F2/kN 0.95 416.75 395.91 10.49 9.97 0.90 423.15 380.84 10.66 9.59 0.85 430.61 365.87 10.84 9.21 0.80 457.63 366.10 11.52 9.22 0.75 462.33 346.75 11.64 8.73 表 7 试件弯曲疲劳寿命
σ2/σ1 $N_{D}^{\prime} /{\rm{cyc}}$ ND/cyc Pd /% 0.95 1 929 204 6 861 310 71.9 0.90 1 409 567 79.5 0.85 994 967 85.5 0.80 509 093 92.6 0.75 423 600 93.8 表 8 裂纹萌生寿命及萌生寿命占比
σ2/σ1 Ni /cyc I /% 0.95 1 737 800 90.1 0.90 1 158 036 82.2 0.85 753 786 75.8 0.80 437 820 86.0 0.75 368 532 87.0 表 9 裂纹扩展长度与循环次数的关系
σ2/σ1 aNuc/
mmNNuc/
cycaMac/
mmNMac/
cycaS-exp
/mmNS-exp/
cyc0.95 0.42 100 523 1.32 112 436 2.67 104 951 0.38 134 260 1.15 120 243 2.23 131 348 0.59 136 521 1.36 75 621 2.54 188 076 0.90 0.91 58 531 2.03 37 941 3.98 45 458 0.42 85 316 0.99 137 561 1.66 124 649 0.77 64 725 1.23 74 682 2.03 74 287 0.85 0.85 36 852 1.57 50 236 4.06 31 441 1.03 29 836 2.06 64 103 4.12 23 815 0.91 21 365 2.01 39 684 4.11 15 518 0.80 0.96 11 074 2.45 23 416 4.92 11 042 1.10 14 614 2.02 18 942 3.36 17 806 0.85 24 526 2.47 15 174 3.23 37 715 0.75 0.81 14 682 1.86 16 716 3.77 23 864 0.53 9 621 1.69 16 852 3.82 25 437 0.73 12 357 1.91 17 532 4.05 23 455 表 10 寿命预测模型验证
σ2/σ1 试验均值寿命/cyc 预测寿命/cyc 误差/% 0.95 1 929 204 1 857 820 3.7 0.90 1 158 036 1 097 820 5.2 0.85 753 786 676 146 10.3 0.80 437 820 404 545 7.6 0.75 368 532 344 580 6.5 -
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