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Mesh relationship modeling and dynamic characteristic analysis of external spur gears with gear wear

《机械工程前沿（英文）》 2022年 第17卷 第1期   页码 9-9 doi: 10.1007/s11465-021-0665-z

摘要： Gear wear is one of the most common gear failures, which changes the mesh relationship of normal gear. A new mesh relationship caused by gear wear affects meshing excitations, such as mesh stiffness and transmission error, and further increases vibration and noise level. This paper aims to establish the model of mesh relationship and reveal the vibration characteristics of external spur gears with gear wear. A geometric model for a new mesh relationship with gear wear is proposed, which is utilized to evaluate the influence of gear wear on mesh stiffness and unloaded static transmission error (USTE). Based on the mesh stiffness and USTE considering gear wear, a gear dynamic model is established, and the vibration characteristics of gear wear are numerically studied. Comparison with the experimental results verifies the proposed dynamic model based on the new mesh relationship. The numerical and experimental results indicate that gear wear does not change the structure of the spectrum, but it alters the amplitude of the meshing frequencies and their sidebands. Several condition indicators, such as root-mean-square, kurtosis, and first-order meshing frequency amplitude, can be regarded as important bases for judging gear wear state.

关键词： gear wear     mesh relationship     mesh stiffness     transmission error     vibration characteristics    

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High-precision gyro-stabilized control of a gear-driven platform with a floating gear tension device

《机械工程前沿（英文）》 2021年 第16卷 第3期   页码 487-503 doi: 10.1007/s11465-021-0635-5

摘要： This study presents an improved compound control algorithm that substantially enhances the anti-disturbance performance of a gear-drive gyro-stabilized platform with a floating gear tension device. The tension device can provide a self-adjustable preload to eliminate the gap in the meshing process. However, the weaker gear support stiffness and more complex meshing friction are also induced by the tension device, which deteriorates the control accuracy and the ability to keep the aim point of the optical sensors isolated from the platform motion. The modeling and compensation of the induced complex nonlinearities are technically challenging, especially when base motion exists. The aim of this research is to cope with the unmeasured disturbances as well as the uncertainties caused by the base lateral motion. First, the structural properties of the gear transmission and the friction-generating mechanism are analyzed, which classify the disturbances into two categories: Time-invariant and time-varying parts. Then, a proportional-integral controller is designed to eliminate the steady-state error caused by the time-invariant disturbance. A proportional multiple-integral-based state augmented Kalman filter is proposed to estimate and compensate for the time-varying disturbance that can be approximated as a polynomial function. The effectiveness of the proposed compound algorithm is demonstrated by comparative experiments on a gear-drive pointing system with a floating gear tension device, which shows a maximum 76% improvement in stabilization precision.

关键词： inertially stabilized platform     floating gear tension device     nonlinear friction     disturbance compensation     proportional multiple-integral observer    

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齿轮测量技术100年——回顾与展望

石照耀,费业泰,谢华锟

《中国工程科学》 2003年 第5卷 第9期   页码 13-17

摘要：

全面概述了过去100年齿轮测量技术的发展历程，给出了6件标志性事情；着重论述了测量原理的演变、实现测量原理技术方式的发展以及测量结果的表述与利用；介绍了当今CNC齿轮测量中心的原理、组成和特点；结合90年代以来齿轮测量技术领域中几股新潮流，展望了未来齿轮测量技术的一些研究方向。

关键词： 齿轮     齿轮测量     齿轮误差     齿轮测量仪器    

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Gear fault diagnosis using gear meshing stiffness identified by gearbox housing vibration signals

《机械工程前沿（英文）》 2022年 第17卷 第4期 doi: 10.1007/s11465-022-0713-3

摘要： Gearbox fault diagnosis based on vibration sensing has drawn much attention for a long time. For highly integrated complicated mechanical systems, the intercoupling of structure transfer paths results in a great reduction or even change of signal characteristics during the process of original vibration transmission. Therefore, using gearbox housing vibration signal to identify gear meshing excitation signal is of great significance to eliminate the influence of structure transfer paths, but accompanied by huge scientific challenges. This paper establishes an analytical mathematical description of the whole transfer process from gear meshing excitation to housing vibration. The gear meshing stiffness (GMS) identification approach is proposed by using housing vibration signals for two stages of inversion based on the mathematical description. Specifically, the linear system equations of transfer path analysis are first inverted to identify the bearing dynamic forces. Then the dynamic differential equations are inverted to identify the GMS. Numerical simulation and experimental results demonstrate the proposed method can realize gear fault diagnosis better than the original housing vibration signal and has the potential to be generalized to other speeds and loads. Some interesting properties are discovered in the identified GMS spectra, and the results also validate the rationality of using meshing stiffness to describe the actual gear meshing process. The identified GMS has a clear physical meaning and is thus very useful for fault diagnosis of the complicated equipment.

关键词： gearbox fault diagnosis     meshing stiffness     identification     transfer path     signal processing    

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Tool wear mechanisms in the machining of Nickel based super-alloys: A review

Waseem AKHTAR,Jianfei SUN,Pengfei SUN,Wuyi CHEN,Zawar SALEEM

《机械工程前沿（英文）》 2014年 第9卷 第2期   页码 106-119 doi: 10.1007/s11465-014-0301-2

摘要：

Nickel based super-alloys are widely employed in aircraft engines and gas turbines due to their high temperature strength, corrosion resistance and, excellent thermal fatigue properties. Conversely, these alloys are very difficult to machine and cause rapid wear of the cutting tool, frequent tool changes are thus required resulting in low economy of the machining process. This study provides a detailed review of the tool wear mechanism in the machining of nickel based super-alloys. Typical tool wear mechanisms found by different researchers are analyzed in order to find out the most prevalent wear mechanism affecting the tool life. The review of existing works has revealed interesting findings about the tool wear mechanisms in the machining of these alloys. Adhesion wear is found to be the main phenomenon leading to the cutting tool wear in this study.

关键词： tool wear     nickel based super-alloy     wear mechanism    

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Facile synthesis of polyaniline nanorods to simultaneously enhance the mechanical properties and wear

《化学科学与工程前沿（英文）》 2023年 第17卷 第9期   页码 1254-1266 doi: 10.1007/s11705-023-2297-3

摘要： To enhance the mechanical properties and wear resistance of epoxy resin, polyaniline nanorods were first synthesized using a facile route, and then introduced into the epoxy matrix to yield composites via solution mixing. Several measurements were conducted to investigate the phase structures and compositions of polyaniline nanorods, and their positive influences on the mechanical and tribological properties of epoxy resin were also characterized. The results confirmed that the as-synthesized polyaniline exhibited representative rod-like morphologies and dispersed well in the epoxy matrix, leading to significant enhancements in the tensile strength and elastic modulus of epoxy composites. The highest values of 110.33 MPa and 2.04 GPa were obtained by adding 5%–7% polyaniline nanorods, which were 43% and 62% higher than the pure sample, respectively. The wear rate was increased first and then decreased along with polyaniline nanorods, presenting the lowest value of 2.12 × 10−5 mm3·Nm–1 by adding 5% filler, which was markedly reduced by ca. 70% compared to the control sample. Finally, the possible wear mechanism was proposed and discussed in detail. This study tried to broaden the applications of polyaniline nanorods in the field of tribology.

关键词： epoxy resin     polyaniline nanorods     mechanical property     tribological performance     wear mechanism    

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Russian school of the theory and geometry of gearing: Its origin and golden period (1935 --1975)

Dmitry BABICHEV,Sergey LAGUTIN,Natalya BARMINA

《机械工程前沿（英文）》 2016年 第11卷 第1期   页码 44-59 doi: 10.1007/s11465-015-0360-z

摘要：

During the second half of the twentieth century, Soviet scientists were among the world leaders in the theory and geometry of gearing or the theoretical fundamentals of designing gears and gear-cutting tools. The authors of the current paper review works related to the development of the theory of gearing (TG) written in Russian from the mid-1930s to the present. Overall, the review covers more than 400 publications of nearly 200 authors (among more than 1000 studied works). This review involves some works on gear strength and accuracy to attract more experts.

This paper presents a short list of works from the seventeenth century to the nineteenth century and discusses the basic concepts of the TG. This paper also includes a review of more than 160 papers in Russian for the period of 1935–1975, which is the “golden age” of the TG. The main features and achievements during this period are also considered.

The distinctive feature of this review is the use of diagrams that visually present TG experts and the dates and themes of their published works. The diagrams also show the following aspects: 1) The most popular and important themes in a specific period, 2) the most important publications on the themes of interest to readers, and 3) the direction of the works and scope of interests of every researcher.

关键词： theory of gearing (TG)     gear geometry     generating surface     gear synthesis     gear analysis    

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Integrated slipper retainer mechanism to eliminate slipper wear in high-speed axial piston pumps

《机械工程前沿（英文）》 doi: 10.1007/s11465-021-0657-z

摘要： The power density of axial piston pumps can greatly benefit from increasing the speed level. However, traditional slippers in axial piston pumps are exposed to continuous sliding on the swash plate, suffering from serious wear at high rotational speeds. Therefore, this paper presents a new integrated slipper retainer mechanism for high-speed axial piston pumps, which can avoid direct contact between the slippers and the swash plate and thereby eliminate slipper wear under severe operating conditions. A lubrication model was developed for this specific slipper retainer mechanism, and experiments were carried out on a pump prototype operating at high rotational speed up to 10000 r/min. Experimental results qualitatively validated the theoretical model and confirmed the effectiveness of the new slipper design.

关键词： axial piston pump     high speed     slipper wear     slipper design     retainer     lubrication model    

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Fault feature extraction of planet gear in wind turbine gearbox based on spectral kurtosis and time wavelet

Yun KONG, Tianyang WANG, Zheng LI, Fulei CHU

《机械工程前沿（英文）》 2017年 第12卷 第3期   页码 406-419 doi: 10.1007/s11465-017-0419-0

摘要：

Planetary transmission plays a vital role in wind turbine drivetrains, and its fault diagnosis has been an important and challenging issue. Owing to the complicated and coupled vibration source, time-variant vibration transfer path, and heavy background noise masking effect, the vibration signal of planet gear in wind turbine gearboxes exhibits several unique characteristics: Complex frequency components, low signal-to-noise ratio, and weak fault feature. In this sense, the periodic impulsive components induced by a localized defect are hard to extract, and the fault detection of planet gear in wind turbines remains to be a challenging research work. Aiming to extract the fault feature of planet gear effectively, we propose a novel feature extraction method based on spectral kurtosis and time wavelet energy spectrum (SK-TWES) in the paper. Firstly, the spectral kurtosis (SK) and kurtogram of raw vibration signals are computed and exploited to select the optimal filtering parameter for the subsequent band-pass filtering. Then, the band-pass filtering is applied to extrude periodic transient impulses using the optimal frequency band in which the corresponding SK value is maximal. Finally, the time wavelet energy spectrum analysis is performed on the filtered signal, selecting Morlet wavelet as the mother wavelet which possesses a high similarity to the impulsive components. The experimental signals collected from the wind turbine gearbox test rig demonstrate that the proposed method is effective at the feature extraction and fault diagnosis for the planet gear with a localized defect.

关键词： wind turbine     planet gear fault     feature extraction     spectral kurtosis     time wavelet energy spectrum    

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Development of a new wear resistant coating by arc spraying of a steel-based cored wire

Lidong ZHAO, Pia KUTSCHMANN, Binyou FU, Dingyong HE

《机械工程前沿（英文）》 2009年 第4卷 第1期   页码 1-4 doi: 10.1007/s11465-009-0012-2

摘要： In the present study, a cored wire of 304 L stainless steel as sheath material and NiB and WC-12Co as filler materials was designed and deposited to produce a new wear resistant coating containing amorphous phase by arc spraying. The microstructure of the coating was investigated. The porosity and hardness of the coating were determined. The wear performance of the coating was evaluated. The XRD and TEM analyses showed that there are high volume of amorphous phase and very fine crystalline grains in the coating. DTA measurements revealed that the crystallization of the amorphous phase occurred at 579.2°C. Because metallurgical processes for single droplets were non-homogenous during spraying, the lamellae in the coating have different hardness values, which lie between about 700 and 1250 HV . The abrasive wear test showed that the new Fe-based coating was very wear resistant.

关键词： amorphous phase     arc spraying     microstructure     wear     cored wire    

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Experimental investigation of fatigue behavior of spur gear in altered tooth-sum gearing

H. K. SACHIDANANDA, Joseph GONSALVIS, H. R. PRAKASH

《机械工程前沿（英文）》 2012年 第7卷 第3期   页码 268-278 doi: 10.1007/s11465-012-0331-6

摘要：

This paper deals with the contact stress, power loss, and pitting of spur gear tooth in altered tooth-sum gearing for a tooth-sum of 100 teeth when altered by±4% tooth-sum. Analytical and experimental methods were performed to investigate and compare the altered tooth-sum gearing against the standard tooth-sum gearing. The experiments were performed using a power recirculating type test rig. The tooth loads for the experimental investigations were determined considering the surface durability of gears. A clear picture of the surface damage was obtained using a scanning electron microphotograph. The negative alteration in the tooth-sum performed better than the positive alteration in a tooth-sum operating between specified center distances.

关键词： spur gear     power recirculating test rig     altered tooth-sum gearing     scanning electron microscopy (SEM)    

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Effect of wood dust type on mechanical properties, wear behavior, biodegradability, and resistance to

Sawan KUMAR, Ajitanshu VEDRTNAM, S. J. PAWAR

《结构与土木工程前沿（英文）》 2019年 第13卷 第6期   页码 1446-1462 doi: 10.1007/s11709-019-0568-9

摘要： The present work reports the inclusion of different proportions of Mango/Sheesham/Mahogany/Babool dust to polypropylene for improving mechanical, wear behavior and biodegradability of wood-plastic composite (WPC). The wood dust (10%, 15%, 20% by weight) was mixed with polypropylene granules and WPCs were prepared using an injection molding technique. The mechanical, wear, and morphological characterizations of fabricated WPCs were carried out using standard ASTM methods, pin on disk apparatus, and scanning electron microscopy (SEM), respectively. Further, the biodegradability and resistance to natural weathering of WPCs were evaluated following ASTM D5338-11 and ASTM D1435-99, respectively. The WPCs consisting of Babool and Sheesham dust were having superior mechanical properties whereas the WPCs consisting of Mango and Mahogany were more wear resistant. It was found that increasing wood powder proportion results in higher Young’s modulus, lesser wear rate, and decreased stress at break. The WPCs made of Sheesham dust were least biodegradable. It was noticed that the biodegradability corresponds with resistance to natural weathering; more biodegradable WPCs were having the lesser resistance to natural weathering.

关键词： wood-plastic composites     mechanical testing     wear     biodegradability     injection molding     weathering    

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Molybdenum disulfide@nickel phyllosilicate hybrid for improving the flame retardancy and wear resistance

《化学科学与工程前沿（英文）》 2023年 第17卷 第12期   页码 2114-2126 doi: 10.1007/s11705-023-2357-1

摘要： In this study, nickel phyllosilicate was synthesized based on molybdenum disulfide (MoS2@NiPS) by the sol-gel method, and then MoS2@NiPS was used to prepare epoxy composites. The thermal stability, flame retardancy, and frictional performances of epoxy composites were studied. With the addition of 3 wt% MoS2@NiPS, the epoxy composite increased the limiting oxygen index from 23.8% to 26.1% and reduced the vertical burning time from 166 s for epoxy resin to 35 s. The residual char of the epoxy composite increased from 11.8 to 20.2 wt%. MoS2@NiPS promoted the graphitization of the residual char, and facilitated the formation of a dense and continuous char layer, thereby improving the fire safety of epoxy resin. The epoxy composite with 3 wt% MoS2@NiPS had excellent wear resistance property with a wear rate of 2.19 × 10−5 mm3·N–1·m–1, which was 68.8% lower than that of epoxy resin. This study presented a practical approach to improve the frictional and fire resistance of epoxy composites.

关键词： molybdenum disulfide     nickel phyllosilicate     epoxy resin     flame retardancy    

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Mathematical model and manufacture programming of loxodromic-type normal circular-arc spiral bevel gear

Zhenyun DUAN, Houjun CHEN, Zhilan JU, Jian LIU

《机械工程前沿（英文）》 2012年 第7卷 第3期   页码 312-321 doi: 10.1007/s11465-012-0308-5

摘要：

In this paper, loxodromic-type normal circular-arc spiral bevel gear is proposed as a novel application of the circular-arc tooth profile at the gear transmission with intersecting axes. Based on the principle of molding-surface conjugation, the study develops a mathematical model for the tooth alignment curve and the computational flow at the design stage to enable the generation of the tooth surface. Machining of the tooth surface is then carried out to determine the interference-free tool path of the numerical control (NC). Moreover, a pair of loxodromic-type normal circular-arc spiral bevel gears is manufactured on computer numerical control (CNC) machine tools. The proposed theory and method are experimentally investigated, and the obtained results primarily reflect the superior performance of the proposed novel gear.

关键词： loxodrome     circular-arc tooth profile     Wildhaber-Novikov (W-N) gear     spiral bevel gear    

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Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0719-x

摘要： The substitution of biolubricant for mineral cutting fluids in aerospace material grinding is an inevitable development direction, under the requirements of the worldwide carbon emission strategy. However, serious tool wear and workpiece damage in difficult-to-machine material grinding challenges the availability of using biolubricants via minimum quantity lubrication. The primary cause for this condition is the unknown and complex influencing mechanisms of the biolubricant physicochemical properties on grindability. In this review, a comparative assessment of grindability is performed using titanium alloy, nickel-based alloy, and high-strength steel. Firstly, this work considers the physicochemical properties as the main factors, and the antifriction and heat dissipation behaviours of biolubricant in a high temperature and pressure interface are comprehensively analysed. Secondly, the comparative assessment of force, temperature, wheel wear and workpiece surface for titanium alloy, nickel-based alloy, and high-strength steel confirms that biolubricant is a potential replacement of traditional cutting fluids because of its improved lubrication and cooling performance. High-viscosity biolubricant and nano-enhancers with high thermal conductivity are recommended for titanium alloy to solve the burn puzzle of the workpiece. Biolubricant with high viscosity and high fatty acid saturation characteristics should be used to overcome the bottleneck of wheel wear and nickel-based alloy surface burn. The nano-enhancers with high hardness and spherical characteristics are better choices. Furthermore, a different option is available for high-strength steel grinding, which needs low-viscosity biolubricant to address the debris breaking difficulty and wheel clogging. Finally, the current challenges and potential methods are proposed to promote the application of biolubricant.

关键词： grinding     aerospace     difficult-to-machine material     biolubricant     physicochemical property     grindability    

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标题 作者 时间 类型 操作

Mesh relationship modeling and dynamic characteristic analysis of external spur gears with gear wear

期刊论文

High-precision gyro-stabilized control of a gear-driven platform with a floating gear tension device

期刊论文

齿轮测量技术100年——回顾与展望

石照耀,费业泰,谢华锟

期刊论文

Gear fault diagnosis using gear meshing stiffness identified by gearbox housing vibration signals

期刊论文

Tool wear mechanisms in the machining of Nickel based super-alloys: A review

Waseem AKHTAR,Jianfei SUN,Pengfei SUN,Wuyi CHEN,Zawar SALEEM

期刊论文

Facile synthesis of polyaniline nanorods to simultaneously enhance the mechanical properties and wear

期刊论文

Russian school of the theory and geometry of gearing: Its origin and golden period (1935 --1975)

Dmitry BABICHEV,Sergey LAGUTIN,Natalya BARMINA

期刊论文

Integrated slipper retainer mechanism to eliminate slipper wear in high-speed axial piston pumps

期刊论文

Fault feature extraction of planet gear in wind turbine gearbox based on spectral kurtosis and time wavelet

Yun KONG, Tianyang WANG, Zheng LI, Fulei CHU

期刊论文

Development of a new wear resistant coating by arc spraying of a steel-based cored wire

Lidong ZHAO, Pia KUTSCHMANN, Binyou FU, Dingyong HE

期刊论文

Experimental investigation of fatigue behavior of spur gear in altered tooth-sum gearing

H. K. SACHIDANANDA, Joseph GONSALVIS, H. R. PRAKASH

期刊论文

Effect of wood dust type on mechanical properties, wear behavior, biodegradability, and resistance to

Sawan KUMAR, Ajitanshu VEDRTNAM, S. J. PAWAR

期刊论文

Molybdenum disulfide@nickel phyllosilicate hybrid for improving the flame retardancy and wear resistance

期刊论文

Mathematical model and manufacture programming of loxodromic-type normal circular-arc spiral bevel gear

Zhenyun DUAN, Houjun CHEN, Zhilan JU, Jian LIU

期刊论文

Comparative assessment of force, temperature, and wheel wear in sustainable grinding aerospace alloy

期刊论文