基于实测接触轮廓线的精密锥面摩擦联接接触性能有限元分析方法

为使精密锥面联接接触性能仿真分析与实际接触情况相一致,并精确评估其传动性能及指导设计,在建立压紧套接触面正压力与轴向预紧力理论关系式的基础上,提出一种基于三坐标测量机精确测量锥面接触轮廓与有限元数字仿真分析相结合的精密锥面摩擦联接接触性能分析方法。运用Bezier曲线拟合三坐标实测接触轮廓数据,通过Matlab输出实测接触轮廓APDL命令构建有限元实测模型,使实测接触轮廓数据和仿真模型得到耦合。实验测试与仿真分析表明,理论计算结果较低估计了锥面摩擦联接传动性能指标,实测模型由于接触轮廓的不规则性导致各零件只在局部接触充分,与理想模型仿真结果差异较大。因此,精密锥面摩擦联接件设计需同时考虑零件弹性变形与实际接触表面的不规则性,特别是后者对传动效率的影响,以提高精密锥面摩擦联接的设计质量。

Contact Performance Analysis of Accurate Conical Friction Coupling Based on Measured Contact Contours

Aiming at making the contact performance analysis of accurate conical friction coupling agree with actual conditions to precisely evaluate performance and guide design process, a theoretical formula about the relation between normal pressure of contact surface and axial pretightening load was given. A method combing experimental measurement technique with finite element simulation analysis was then proposed. In this method, the measured real contact contours of the coupling were fitted by Bezier curve. According to the fitting Bezier contact contours, finite element measured model was constructed by APDL command stream which was outputted by a Matlab program. Thus, the measured data and simulation model were coalesced. The frictional behaviors simulation results were compared to analytical solution, which demonstrated that the analytical solution underestimates the maximum torque and axial force of conical friction coupling. Furthermore, the irregularity of the measured contact contours leads to incomplete contact on interfaces of coupling. Stress distribution and maximum stress of the measured model differ remarkably from that of the ideal model. Therefore, elastic deformation and effect on transmission efficiency caused by the compatibility of interfaces of coupling have to be taken into account simultaneously in accurate conical friction coupling design process.