含Ni量、渗氮层深度及喷丸强化对42CrMo齿轮弯曲疲劳性能影响研究

doi:10.3969/j.issn.1004-132X.2024.03.002

摘要/Abstract

摘要： 针对不同含Ni量、渗氮层深度和喷丸强化组合的42CrMo齿轮开展弯曲疲劳试验，探究了不同工艺组合的齿轮弯曲疲劳极限提升效果，为齿轮抗疲劳制造提供工艺指导。基于随机森林算法分析了不同工艺组合齿轮的表面硬度、渗氮层深度、表面残余应力和含Ni量对弯曲疲劳极限的贡献度，采用多元回归建立了考虑表面硬度、渗氮层深度、表面残余应力和含Ni量的齿轮弯曲疲劳极限预测公式。预测值与试验值相比，最大误差可以控制在7.80%以内，为工程应用中快速、低成本评估齿轮弯曲疲劳极限提供了理论依据。

关键词: 弯曲疲劳, 含镍量, 渗氮层深度, 喷丸, 疲劳极限预测

Abstract: Single tooth bending fatigue tests were conducted on 42CrMo gears with different combinations of Ni content, nitriding hardening depth, and shot peening. The effectiveness of different process combinations on improving the bending fatigue limit of gears was investigated, providing process guidance for gear fatigue resistance manufacturing. Additionally, the contribution of surface hardness, nitriding hardening depth, surface residual stress, and Ni content to the bending fatigue limit of gears with different process combinations was analyzed using the random forest algorithm. A multiple regression model considering surface hardness, nitriding hardening depth, surface residual stress, and Ni content was established to predict the bending fatigue limit of gears. Comparing the predicted values with experimental values, the maximum error is controlled within 7.80%, providing a theoretical basis for the rapid and low-cost assessment of gear bending fatigue limit in engineering applications.

Key words: bending fatigue, Ni content, nitriding hardening depth, shot peening, fatigue limit prediction

中图分类号:

TH114

武忠睿, 陈地发, 吴吉展, 杨玉典, 刘怀举. 含Ni量、渗氮层深度及喷丸强化对42CrMo齿轮弯曲疲劳性能影响研究[J]. 中国机械工程, 2024, 35(03): 394-404.

WU Zhongrui, CHEN Difa, WU Jizhan, YANG Yudian, LIU Huaiju. Study on Influences of Ni Content, Nitriding Hardening Depth, and Shot Peening on Bending Fatigue Performance of 42CrMo Gears[J]. China Mechanical Engineering, 2024, 35(03): 394-404.

参考文献

［1］吴吉展, 魏沛堂, 刘怀举, 等. 航空齿轮钢表面完整性与滚动接触疲劳性能关联规律研究［J/OL］. 机械工程学报, 2023:1-12.(2023-08-29). https:∥kns.cnki.net/kcms/detail/11.2187.TH.20230828.1041.010.html.
WU Jizhan, WEI Peitang, LIU Huaiju, et al. Study on the Correlation between Surface Integrity and Rolling Contact Fatigue Performance of Aviation Gear Steel［J/OL］. Journal of Mechanical Engineering, 2023:1-12.(2023-08-29). https:∥kns.cnki.net/kcms/detail/11.2187.TH.20230828.1041.010.html.
［2］毛天雨, 刘怀举, 王宝宾, 等. 基于分层贝叶斯模型的齿轮弯曲疲劳试验分析［J］. 中国机械工程, 2021, 32(24):3008-3015.
MAO Tianyu, LIU Huaiju, WANG Baobin, et al. Analysis of Gear Bending Fatigue Test Based on Hierarchical Bayesian Model［J］. China Mechanical Engineering, 2021, 32(24):3008-3015.
［3］武忠睿, 刘怀举, 陈地发, 等.基于最小次序统计量的脉动型与运转型齿轮弯曲疲劳试验转化方法研究［J］.中国科学:技术科学, 2023, 53(12):2066-2078.
WU Zhongrui, LIU Huaiju, CHEN Difa, et al. Research on Transformation Method of Bending Fatigue Test for Single Tooth Bending Fatigue and Running Gear Based on Minimum Order Statistics［J］. Scientia Sinica(Technologica), 2023, 53(12):2066-2078.
［4］董瀚, 廉心桐, 胡春东, 等. 钢的高性能化理论与技术进展［J］. 金属学报, 2020, 56(4):558-582.
DONG Han, LIAN Xintong, HU Chundong, et al. High Performance Steels:the Scenario of Theory and Technology［J］. Acta Metallurgica Sinica, 2020, 56(4):558-582.
［5］FENG Jian, YE Bing, ZUO Lijie, et al. Effects of Ni Content on Low Cycle Fatigue and Mechanical Properties of Al-12Si-0.9Cu-0.8Mg-xNi at 350 ℃［J］. Materials Science and Engineering:A, 2017, 706:27-37.
［6］YOKOYAMA Y, FUKAURA K, INOUE A. Effect of Ni Addition on Fatigue Properties of Bulk Glassy Zr50Cu40Al10 Alloys［J］. Materials Transactions, 2004, 45(5):1672-1678.
［7］梁梦斐, 王海燕, 王超, 等. 合金元素Ni对Fe-Cu合金析出过程的影响［J］. 稀有金属, 2021, 45(1):117-122.
LIANG Mengfei, WANG Haiyan, WANG Chao, et al. Precipitation Process of Copper-containing Steel with Addition of Ni［J］. Chinese Journal of Rare Metals, 2021, 45(1):117-122.
［8］李彩云, 邢志国, 赵向伟, 等. 强化方法对重载齿轮弯曲疲劳强度影响的研究现状与建议［J］. 材料导报, 2020, 34(21):21146-21154.
LI Caiyun, XING Zhiguo, ZHAO Xiangwei, et al. Research Status and Suggestions on Influence of Strengthening Methods on Bending Fatigue Strength of Heavy-duty Gear［J］. Materials Reports, 2020, 34(21):21146-21154.
［9］GENEL K, DEMIRKOL M, APA M. Effect of Ion Nitriding on Fatigue Behaviour of AISI 4140 Steel［J］. Materials Science and Engineering:A, 2000, 279(1/2):207-216.
［10］TERRES M A, BEN M S, SIDHOM H. Influence of Ion Nitriding on Fatigue Strength of Low-alloy(42CrMo4) Steel:Experimental Characterization and Predictive Approach［J］. International Journal of Fatigue, 2010, 32(11):1795-1804.
［11］SITZMANN A, HOJA S, SCHURER S, et al. Deep Nitriding—Contact and Bending Strength of Gears with Increased Nitriding Hardening Depth［J］. Forschung Im Ingenieurwesen, 2022, 86(3):649-659.
［12］SAVARIA V, BRIDIER F, BOCHER P. Predicting the Effects of Material Properties Gradient and Residual Stresses on the Bending Fatigue Strength of Induction Hardened Aeronautical Gears［J］. International Journal of Fatigue, 2016, 85:70-84.
［13］吴少杰, 刘怀举, 张仁华, 等. 基于正交实验和数据驱动的喷丸表面完整性参数预测［J］. 表面技术, 2021, 50(4):86-95.
WU Shaojie, LIU Huaiju, ZHANG Renhua, et al. Prediction of Surface Integrity Parameters of Shot Peening Based on Orthogonal Experiment and Data-driven［J］. Surface Technology, 2021, 50(4):86-95.
［14］WU Jizhan, LIU Huaiju, WEI Peitang, et al. Effect of Shot Peening Coverage on Residual Stress and Surface Roughness of 18CrNiMo7-6 Steel［J］. International Journal of Mechanical Sciences, 2020, 183:105785.
［15］WU Jizhan, LIU Huaiju, WEI Peitang, et al. Effect of Shot Peening Coverage on Hardness, Residual Stress and Surface Morphology of Carburized Rollers［J］. Surface and Coatings Technology, 2020, 384:125273.
［16］WU Jizhan, WEI Peitang, LIU Huaiju, et al. Effect of Shot Peening Intensity on Surface Integrity of 18CrNiMo7-6 Steel［J］. Surface and Coatings Technology, 2021, 421:127194.
［17］CHEN Difa, ZHU Jiazan, LIU Huaiju, et al. Experimental Investigation of the Relation between the Surface Integrity and Bending Fatigue Strength of Carburized Gears［J］. Science China Technological Sciences, 2023, 66(1):33-46.
［18］ZHANG Xiuhua, LIU Huaiju, WU Shaojie, et al. Experimental Investigation on the Effect of Barrel Finishing Processes on Surface Integrity of 18CrNiMo7-6 Carburized Rollers［J］. Proceedings of the Institution of Mechanical Engineers, Part E:Journal of Process Mechanical Engineering, 2022, 236(5):2095-2105.
［19］YAN Huan, WEI Peitang, SU Lihong, et al. Rolling-sliding Contact Fatigue Failure and Associated Evolutions of Microstructure, Crystallographic Orientation and Residual Stress of AISI 9310 Gear Steel［J］. International Journal of Fatigue, 2023, 170:107511.
［20］TANAKA K. The cosα Method for X-ray Residual Stress Measurement Using Two-dimensional Detector［J］. Mechanical Engineering Reviews, 2019, 6(1):18-378-18-00378.
［21］LEE S Y, LING Jinjing, WANG Shenghe, et al. Precision and Accuracy of Stress Measurement with a Portable X-ray Machine Using an Area Detector［J］. Journal of Applied Crystallography, 2017, 50(1):131-144.
［22］ZHANG Boyu, LIU Huaiju, BAI Houyi, et al. Ratchetting–multiaxial Fatigue Damage Analysis in Gear Rolling Contact Considering Tooth Surface Roughness［J］. Wear, 2019, 428/429:137-146.
［23］李萍, 闫英, 周平. 白光干涉测量法中蝠翼效应的模拟分析［J］. 中国测试, 2022, 48(1):1-8.
LI Ping, YAN Ying, ZHOU Ping. Research of Batwing Effect in White-light Interferometry［J］. China Measurement & Test, 2022, 48(1):1-8.
［24］BENEDETTI M, FONTANARI V, HHN B R, et al. Influence of Shot Peening on Bending Tooth Fatigue Limit of Case Hardened Gears［J］. International Journal of Fatigue, 2002, 24(11):1127-1136.
［25］BONAITI L, BAYOUMI A B M, CONCLI F, et al. Gear Root Bending Strength:a Comparison between Single Tooth Bending Fatigue Tests and Meshing Gears［J］. Journal of Mechanical Design, 2021, 143(10):103402.
［26］DOBLER A, HERGESELL M, TOBIE T, et al. Increased Tooth Bending Strength and Pitting Load Capacity of Fine Module Gears［J］. Gear technology, 2016, 33(7):48-53.
［27］MCPHERSON D R, RAO S B. Methodology for Translating Single-tooth Bending Fatigue Data to Be Comparable to Running Gear Data［J］. Gear Technology, 2008, 6:42-51.
［28］VUCˇKOVIC＇ K, GALIC＇ I, BOIC＇ , et al. Effect of Friction in a Single-tooth Fatigue Test［J］. International Journal of Fatigue, 2018, 114:148-158.
［29］HONG I J, KAHRAMAN A, ANDERSON N. A Rotating Gear Test Methodology for Evaluation of High-cycle Tooth Bending Fatigue Lives under Fully Reversed and Fully Released Loading Conditions［J］. International Journal of Fatigue, 2020, 133:105432.
［30］RAO S B, MCPHERSON D R. Experimental Characterization of Bending Fatigue Strength in Gear Teeth［J］. Gear Technology, 2003, 20(1):25-32.
［31］SPICE J J, MATLOCK D K, FETT G. Optimized Carburized Steel Fatigue Performance as Assessed with Gear and Modified Brugger Fatigue Tests［C］∥SAE Technical Paper Series. 400 Commonwealth Drive, Warrendale, 2002:589-597.
［32］VILELA C L, CORRA de O D, WALLACE D, et al. Bending Fatigue in Low-pressure Carbonitriding of Steel Alloys with Boron and Niobium Additions［J］. Journal of Materials Engineering and Performance, 2020, 29(6):3593-3602.
［33］MAO Tianyu, LIU Huaiju, WEI Peitang, et al. An Improved Estimation Method of Gear Fatigue Strength Based on Sample Expansion and Standard Deviation Correction［J］. International Journal of Fatigue, 2022, 161:106887.
［34］陈地发, 刘怀举, 朱加赞, 等. 低碳合金钢
18CrNiMo7-6齿轮弯曲疲劳试验研究与误差分析［J］. 重庆大学学报, 2023, 46(1):1-15.
CHEN Difa, LIU Huaiju, ZHU Jiazan, et al. Experimental Study and Error Analysis on Bending Fatigue of Low-carbon Alloy Steel 18CrNiMo7-6 Gear［J］. Journal of Chongqing University, 2023, 46(1):1-15.
［35］武忠睿, 魏沛堂, 陈地发, 等. 铸锭工艺对齿轮弯曲疲劳性能影响的试验研究［J］. 机械传动, 2023, 47(4):98-107.
WU Zhongrui, WEI Peitang, CHEN Difa, et al. Experimental Investigation on Effect of Ingot Processing on Gear Bending Fatigue Performance［J］. Journal of Mechanical Transmission, 2023, 47(4):98-107.
［36］MLLER C, WCHTER M, MASENDORF R, et al. Accuracy of Fatigue Limits Estimated by the Staircase Method Using Different Evaluation Techniques［J］. International Journal of Fatigue, 2017, 100:296-307.
［37］LI Yang, WEI Peitang, XIANG Ge, et al. Gear Contact Fatigue Life Prediction Based on Transfer Learning［J］. International Journal of Fatigue, 2023, 173:107686.
［38］ZHANG Xiuhua, WEI Peitang, PARKER R G, et al. Study on the Relation between Surface Integrity and Contact Fatigue of Carburized Gears［J］. International Journal of Fatigue, 2022, 165:107203.

[1]	毛天雨, 刘怀举, 王宝宾, 侯圣文, 陈地发. 基于分层贝叶斯模型的齿轮弯曲疲劳试验分析[J]. 中国机械工程, 2021, 32(24): 3008-3015，3023.
[2]	林棻1；唐洁1；赵又群1；李剑垒1；臧利国2；陈宇珂1. 基于修正L-P模型的轮毂轴承载荷分布与弯曲疲劳寿命分析[J]. 中国机械工程, 2020, 31(08): 898-906.
[3]	胡建军1, 2, 张根保1, 许洪斌3, 李小波2. 不同精加工齿面的电子束处理齿轮弯曲疲劳性能[J]. 中国机械工程, 2013, 24(3): 380-385.
[4]	史学刚, 鲁世红, 张炜. 铝合金超声波喷丸成形制件表面完整性研究[J]. 中国机械工程, 2013, 24(22): 3100-3104.
[5]	胡建军1, 2, 许洪斌2, 祖世华2, 高孝旺2. 服从正态分布随机载荷作用下齿轮弯曲疲劳试验研究[J]. 中国机械工程, 2013, 24(12): 1572-1576.
[6]	邹世坤, 曹子文, 杨贺来. 激光冲击处理发动机叶片的固有频率测试 [J]. 中国机械工程, 2010, 21(06): 648-651.