王长健.高速齿轮轴断齿原因分析[J].表面技术,2016,45(6):192-197.
WANG Chang-jian.Failure Analysis of High-speed Gear Shaft[J].Surface Technology,2016,45(6):192-197 |
| 高速齿轮轴断齿原因分析 |
| Failure Analysis of High-speed Gear Shaft |
| 投稿时间：2016-01-18 修订日期：2016-06-20 |
| DOI：10.16490/j.cnki.issn.1001-3660.2016.06.029 |
| 中文关键词: 风电齿轮箱 高速齿轮轴 有效硬化层深度 疲劳断裂 表面渗碳热处理 马氏体脆性 |
| 英文关键词:wind power generation speed-up gearbox high speed gear shaft effective hardening layer depth fatigue fracture surface carburizing heat treatment Martensite brittleness |
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| 中文摘要: |
| 目的 材质为 17Cr2Ni2MoA 的风电齿轮箱高速齿轮轴，同炉号共生产 5 件，在安装装配后进行试车试验时其中 4 件均发现有断齿现象，导致高速齿轮轴报废，同时导致整个风电齿轮箱的安装调试工作停滞。故对该高速齿轮轴断齿原因进行分析，以区分质量事故责任。 方法 通过化学成分分析、齿面宏观外貌观察分析、宏观断口、宏观金相、微观金相、有效硬化层深度测试、扫描电镜试验分析等一系列的理化试验，对该高速齿轮轴断齿原因进行分析。 结果 该高速齿轮轴材质正常，化学成分合格。齿轮轴齿部断口上有疲劳贝壳纹线，齿轮断口为疲劳断口，疲劳源在齿根。齿轮轴齿部表面渗碳热处理层组织正常，晶粒度级别为 7 级，合格；齿轮轴齿根、齿面、齿顶表面渗碳热处理层的有效硬化层深度均过深，不符合产品技术要求。齿轮轴断口微观形态呈疲劳辉纹，未见明显的冶金缺陷。结论 该高速齿轮轴断齿性质为快速疲劳断裂，其形成原因是齿根渗碳层深度过深所致。 |
| 英文摘要: |
| Objective Among the five pieces of 17Cr2Ni2Mo high-speed gear shaft of wind power generation speed-up gearbox, 4 pieces were found to have teeth broken phenomenon after assembling, leading to out of service of the high-speed gear shaft, and meanwhile resulted in stopping of installation and debugging. This work aimed to analyze the failure cause for the high-speed gear shaft, in order to identify the quality accident liability. Methods In this paper, comparative analysis was carried on the gear shaft to analyze the failure cause, including metallographic analysis, macrofractography, observation analysis of tooth surface, macroscopic examination, chemical analysis, effective hardening layer depth testing ,SEM, and so forth. Results The high speed gear shaft’s material was normal and its chemical composition was qualified. There were many fatigue shell ridges on the high speed gear shaft’s fracture, indicating that the gear fracture was fatigue fracture, and the fatigue source originated from the root. The metallurgical structure for the surface carburizing heat treatment layer of the gear shaft was normal, and the grain size was Grade 7, which was also qualified. The effective hardening layer depth of carburizing layer at the root of tooth, tooth surface, tooth top was all too deep, which did not meet the technical requirements of the product. The micro morphology of the fracture surface of the gear shaft was fatigue striation, and no obvious metallurgical defects were found. Conclusion The results showed that the failure type of the high-speed gear shaft was quick fatigue fracture, and its formation was caused by the excessive depth of carburizing layer at the root of tooth. |
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