齿轮胶合研究综述：机理、计算方法及优化策略

郭栋; 邓文丰; 李明; 辛玉; 方川

doi:10.16490/j.cnki.issn.1001-3660.2025.19.002

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表面技术 ›› 2025, Vol. 54 ›› Issue (19) : 14-15. DOI: 10.16490/j.cnki.issn.1001-3660.2025.19.002

研究综述

齿轮胶合研究综述：机理、计算方法及优化策略

郭栋^a, 邓文丰^a, 李明^a,*, 辛玉^b, 方川^a

作者信息 +

Research Review of Gear Scuffing: Mechanism, Calculation Methods and Optimization Strategies

GUO Dong^a, DENG Wenfeng^a, LI Ming^a,*, XIN Yu^b, FANG Chuan^a

Author information +

文章历史 +

摘要

随着新能源汽车的发展,其减速器中的齿轮常处于高速重载等极端工况,易因润滑不良引发胶合失效,表现为齿面温度急剧上升导致润滑油膜破裂,金属表面粘连并撕裂,严重影响着传动系统的可靠性和使用寿命。综述了现目前有关于齿轮胶合的失效机理,包括闪温理论、弹流润滑理论、PVT极限理论以及绝热剪切不稳定性理论。通过对比ISO 6336-20/21与GB/Z 6413.1/2等标准中的计算方法,揭示了积分温度法与闪温法在复杂工况下的适用性差异,探讨了数值计算方法和机器学习算法在齿轮胶合问题中的应用。总结了影响齿轮胶合的关键因素,包括制造工艺、工作条件、几何参数和润滑条件等。合理设计压力角、模数等宏观参数可改善载荷分布,而微观修形则能优化表面接触状态;极压添加剂和合理的供油方式能有效增强油膜稳定性;表面强化处理和涂层技术则能改善残余应力分布,降低摩擦系数。通过优化齿轮制造工艺、改善齿轮工作和润滑条件、合理设计齿轮几何参数,可有效提高齿轮的抗胶合性能。最后对齿轮胶合的发展趋势进行了展望,未来研究应结合多学科交叉技术,融合先进计算方法与实验手段,提升齿轮胶合预测的精度和适用性。同时应针对现代高性能齿轮在极端工况下的应用需求,优化材料、润滑和制造工艺,开发更具针对性的抗胶合设计策略,为高效可靠的齿轮传动系统提供坚实的技术支撑。

Abstract

With the development of new energy vehicles, the gears in their reducers are often in extreme working conditions such as high speed, heavy load and poor lubrication, which makes the gears prone to scuffing failure during the meshing process. Gear scuffing is mainly manifested in a sharp increase in the local temperature of the tooth surface, rupture of the lubricating oil film, direct contact and adhesion of the metal surfaces, and ultimately tearing of the tooth surface material. This failure mode seriously affects the reliability and service life of the transmission system. Beyond merely reducing service life, scuffing failures in critical components like new energy vehicle reducers often lead to unpredictable breakdowns, resulting in significant economic losses due to downtime and high maintenance costs. Studying the mechanism of gear scuffing and its affecting factors is crucial to improving the durability of the gear. Improving the anti-scuffing performance of the gear is an urgent problem to be solved at present. The work aims to review the current failure mechanisms of gear scuffing, including flash temperature theory, elastohydrodynamic lubrication theory, PVT limit theory and adiabatic shear instability theory. By comparing the calculation methods in standards such as ISO 6336-20/21 and GB/Z 6413.1/2, the differences in the applicability of the integral temperature method and the flash temperature method under complex working conditions are revealed. The application of numerical calculation methods and machine learning algorithms in gear scuffing problems is analyzed. Numerical approaches, such as the finite element method, enable precise simulation of gear temperature fields under various operating conditions, offering detailed insights into thermal behavior. Concurrently, the integration of machine learning algorithms presents a powerful avenue for enhancing prediction accuracy and efficiency, particularly in handling the multifaceted variables and non-linear relationships inherent in gear scuffing problems. The key factors affecting gear scuffing are summarized, including manufacturing process, working conditions, geometric parameters and lubrication conditions. Reasonable design of macro parameters such as pressure angle and modulus can improve load distribution, while micro-modification can optimize surface contact state. Extreme pressure additives and reasonable oil supply methods can effectively enhance oil film stability. Surface strengthening treatment and coating technology can improve residual stress distribution and reduce friction coefficient. By optimizing the gear manufacturing process, improving the working and lubrication conditions of gears, and rationally designing the geometric parameters of gears, the anti-scuffing performance of gears can be effectively improved. Finally, the development trend of gear scuffing is prospected. Future research should combine multidisciplinary cross-technology, integrate advanced calculation methods and experimental means, and improve the accuracy and applicability of gear scuffing prediction. At the theoretical level, it is necessary to further explore the material failure mechanism at the microscopic scale. In terms of calculation methods, efficient numerical models coupled with multiple physical fields should be developed. Multi-faceted analyses should be conducted by integrating factors such as heat, force and flow, and machine learning techniques should be introduced to enhance the prediction efficiency under complex working conditions. In addition, efforts should focus on developing new anti-scuffing composite materials and surface engineering technologies, optimizing lubrication methods, and establishing a complete performance database for the entire life cycle of gears. These innovations will drive gear transmission systems towards greater efficiency and reliability, thereby meeting the demanding requirements of high-end application scenarios such as new energy vehicles.

导出引用

郭栋, 邓文丰, 李明, 辛玉, 方川. 齿轮胶合研究综述：机理、计算方法及优化策略[J]. 表面技术. 2025, 54(19): 14-15 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.19.002

GUO Dong, DENG Wenfeng, LI Ming, XIN Yu, FANG Chuan. Research Review of Gear Scuffing: Mechanism, Calculation Methods and Optimization Strategies[J]. Surface Technology. 2025, 54(19): 14-15 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.19.002

中图分类号： TH117

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