Based on the research of bionics theory, combined with the characteristics of automobile gear meshing transmission, and based on the model test, the bionic micro wear-resistant shape on the surface of the ring block sample is optimized, and the concave bionic wear-resistant gear is designed and processed; At the same time, the numerical simulation of the contact between the ring sample and the actual gear is carried out by using the finite element analysis software ANSYS, and the wear resistance and wear mechanism of the concave bionic gear are deeply studied. The main research contents are as follows:
- According to the characteristics of gear meshing transmission, the transmission of gear is simplified into the motion form of two cylinder surfaces with relatively small sliding and meshing rolling. The concave bionic shape on the surface of the ring block sample is optimized and designed. Nine different types of concave bionic shapes are formed on the surface of the ring block sample by using the laser graphic engraving technology. The wear resistance of the ring block sample with smooth and concave bionic shape is compared by using the M-200 friction and wear testing machine to simulate the gear meshing transmission. Using the orthogonal experimental design, the range analysis of the wear amount and wear rate of the ring sample with the pit bionic shape is carried out, and the pit bionic micro shape with the best wear resistance is obtained.
- Based on the finite element analysis method of contact problem, using ANSYS finite element analysis software, the three-dimensional finite element numerical simulation of contact problem between smooth ring block sample and 9 kinds of pit bionic ring block samples is carried out under the condition of no lubrication. Under the same simulation parameters, the contact stress of smooth and concave bionic ring samples is solved. Using post-processing tools, the contact equivalent stress nephogram, contact stress nephogram and contact permeability nephogram of 10 ring samples are displayed. The relationship between various stresses of smooth ring block sample and concave bionic ring block sample is compared, and the law of stress condition is obtained.
- Using the gear fatigue wear testing machine and laser graphic engraving technology, the optimized concave bionic wear-resistant shape is formed in the meshing area of the gear, and the actual wear-resistant performance of smooth and concave bionic shape gears is compared. At the same time, using 3000-4qc gear precision measuring instrument, the tooth direction error and tooth shape error values of the two types of gears before and after the test are measured, the trend of the error value curve before and after the test is compared, and the wear resistance of the two types of gears is qualitatively analyzed; By comparing the relative changes of the error values before and after the test, the relationship between the wear of the two types of gears is quantitatively analyzed.
- Using CAXA electronic drawing board, the two-dimensional contour model of large and small gear contact is established, and the line body model is imported into ANSYS. Using the function of generating surface from line in Boolean operation, the two-dimensional solid model of gear contact is formed, and the two-dimensional contact finite element analysis models of smooth and concave bionic gear are established respectively. Using the finite element analysis software ANSYS, under the same parameter setting, the two-dimensional numerical simulation of the contact between smooth and concave bionic gears is carried out, the contact equivalent stress nephogram and contact stress nephogram of smooth and concave bionic gears are obtained, and the two types of equivalent stress and contact stress are compared and analyzed.
- The three-dimensional contact solid models of large and small gears are established by CATIA, the solid model is imported into ANSYS, a certain pit bionic shape is generated in the contact area of gear contact surface by Boolean operation, and the three-dimensional contact finite element analysis models of smooth and pit gears are established respectively. Using the finite element analysis software ANSYS, under the same parameter setting, the three-dimensional contact numerical simulation of smooth and concave bionic gear is carried out, the cloud diagram of equivalent stress and contact stress distribution of smooth and concave bionic gear is obtained, and the comparative analysis of contact equivalent stress and contact stress of two types of gears is carried out.
- According to the Reynolds basic equation of gear steady-state Isothermal Elastohydrodynamic Lubrication Theory, the basic equations of elastohydrodynamic lubrication of smooth and concave bionic gears in lubrication state are deduced, the numerical calculation of elastohydrodynamic lubrication of smooth and concave bionic gears is carried out, and the relationship between oil film thickness and oil film pressure of the two kinds of gears is obtained.