螺旋伞齿轮磨削残余应力分布规律及仿真分析

螺旋伞齿轮作为重型车辆传动系统的关键零部件，其表面完整性对整车机动性和可靠性起着关键作用。磨削作为齿轮最后一步加工工序，磨削过程产生的残余应力将直接影响齿轮疲劳性能。若残余应力控制不当，将导致齿轮在使用过程中过早发生疲劳失效，产生齿面疲劳点蚀和根部疲劳断裂等问题。针对重型车辆螺旋伞齿轮设计磨削试验，研究不同磨削参数下螺旋伞齿轮残余应力的分布规律；结合磨削前后齿轮残余应力的状态，获得实际磨削过程残余应力；基于力热耦合有限元仿真法计算螺旋伞齿轮磨削残余应力。研究结果表明：齿轮凸面平行磨削方向残余压应力最小，磨削过程使齿面产生拉应力而亚表层产生压应力，力热耦合有限元仿真法能有效用于螺旋伞齿轮磨削残余应力的预测和分析。

Distribution Characteristic and Simulation Analysis on Grinding Residual Stress of Spiral Bevel Gears

The spiral bevel gear is the key part of the transmission component of the heavy duty vehicles. Its surface integrity plays a key role in the maneuverability and reliability. As the last step of gear machining, grinding residual stress is one of the important factor of surface integrity. It leads to the early fatigue failure if the residual stress doesn't meet the requirements. The distribute characteristic of the gear's residual stress in different grinding parameters are investigated by grinding experiments. The effective residual stress caused by grinding is calculated according to the residual stress of the original gear. It also is calculated by the finite element method basing on thermo-mechanical coupling. The results show that, the residual stress of gear convexity parallel to the grinding direction is the smallest; the residual tensile stress is generated by the grinding process in the gear surface, while in the gear subsurface residual compressive stress is produced. The values of residual stress calculated by the finite element model are accordant with those calculated by the experiment, which shows that it is promising to analyse and predict the residual stress of spiral bevel gear by finite element method.