目的 电动汽车在起步、急加速、能量回收（正、反转交替）过程中,其差速器承担着较大的瞬时扭矩,其零部件磨损失效概率相较于燃油汽车显著升高。在高载荷作用下零部件接触特征及其引发表面磨损的具体机制尚未完全清楚,针对该问题的表面结构设计相对少见。探索差速器磨损失效机理,进一步提高电动汽车的运行安全性和稳定性。方法 在差速差扭工况下开展某型号电动汽车差速器的耐久性台架试验,获取零部件发生磨损的主要位置,并结合差速器有限元模型,创新地以行星齿轮轴承载变形及其对零件间接触相互作用的影响为切入点,将局部性的表面接触与整体性的结构变形统筹考虑,更为准确地剖析磨损形成机理。结果 实验结果表明,在长时重载运行实验条件下,差速器的行星齿轮轴和行星齿轮内孔出现了犁沟、胶合及塑性变形等磨损失效。通过接触分析发现,行星齿轮轴在多点载荷和约束作用下呈“S”形弯曲变形,轴、孔中线不平行,形成了边缘接触,表面压力集中在狭窄区域内,并出现局部高峰值,导致磨损的发生。对行星齿轮内孔进行圆弧修形可有效缓解边缘接触造成的应力集中,在最佳修形量下行星齿轮轴表面接触压力理论最大值降低了约50%,同时未引起轴体剪应力发生显著变化（仅增大了3.6%）。结论 行星齿轮轴和行星齿轮内孔接触面上的压力集中是造成零件表面磨损的关键因素。对行星齿轮内孔进行修形设计是缓解应力集中问题的有效途径。研究结果可从抗磨损失效角度为差速器零部件表面结构设计提供一定的科学依据。
Abstract
During the process of starting, rapid acceleration, and energy recovery (forward and reverse rotation), the reducer and differential of electric vehicles are subject to large instantaneous torque. So the probability of wear and failure of their components is significantly higher than that of fuel vehicles. However, the contact characteristics of components under high load and the specific mechanism of surface wear caused by them are not yet fully understood, and there are rare surface structure design for this problem. Exploring the wear and failure phenomenon and mechanism of differential under high load conditions is an important content to further improve the safety and stability of electric vehicles. Based on the differential experimental platform, a durability test of the differential is carried out to obtain the wear morphology of the key components of the differential. Combined with finite element numerical simulation, the deformation of the planetary gear shaft and its influence on the contact interaction between parts are innovatively used as the key entry point to analyze the load distribution of the parts surface, and then reveal the formation mechanism of wear. The test results show that under the long-term heavy-load operation experimental conditions, the differential planetary gear shaft and the inner hole of the planetary gear have wear failures such as plowing, bonding, and plastic deformation. Contact analysis shows that the planetary gear shaft is in contact with multiple components at the same time, and there is an obvious local stress concentration phenomenon. For the main reasons, on the one hand, the axes of the planetary gear shaft and the inner hole of the planetary gear are not parallel after being stressed, and the inner hole edge of the planetary gear squeezes the surface of the shaft to form a local contact stress concentration; on the other hand, the locating pin constrains the axial movement of the planetary gear shaft, and the deformation of the shaft near the pin end is small, and the contact between the shaft and the hole surface cannot be effectively coordinated through elastic deformation. Therefore, the contact pressure peak of the shaft surface near the pin end is higher. The contact pressure concentration caused by the two factors is superimposed, and surface wear is formed under the joint action. Therefore, alleviating the local contact pressure concentration on the surface of electric vehicle differential parts under high load is a key entry point to solve the current wear problem. Arc modification of the inner hole of the planetary gear can effectively alleviate the stress concentration caused by edge contact. After modification, the contact area moves from the edge of the shaft hole overlap area to the middle, the contact area is significantly expanded, the theoretical maximum value of the contact pressure can be reduced by about 50%, and the shear stress of the shaft body does not change much (increased 3.6%). In conclusion, the local pressure concentration on the contact surface between the planetary gear shaft and the inner hole of the planetary gear is an important factor causing surface wear of the parts. Modification design of the inner hole of the planetary gear is an effective way to alleviate the stress concentration. The research results of this paper can provide a certain scientific basis for the surface structure design of differential components from the perspective of anti-wear failure.
关键词
电动汽车 /
差速器 /
接触 /
磨损 /
修形
Key words
electric vehicle /
differential /
contact /
wear /
modification
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基金
国家自然科学基金（51822508）; 中央高校基本科研业务费专项资金（2682024CG008）
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