目的 改善齿轮啮合过程中的润滑状态,减少齿面磨损与胶合失效,提升传动系统稳定性和使用寿命。方法 提出在齿面制备椭圆微织构的方法,通过计算流体力学（CFD）仿真与圆柱滚子正交试验,系统分析织构参数对润滑行为的影响规律,确定各参数的显著性并优选出椭圆织构的尺寸参数;随后,制备具有优化织构的齿轮试样,开展摩擦磨损试验。结果 椭圆织构的设计参数对其润滑性能具有显著影响。润滑性能随面积率的增加而提升,且在椭圆率不变时,长轴较长的椭圆织构更有利于降低摩擦。通过CFD仿真与摩擦磨损正交试验,优选出椭圆织构的最佳参数组合为深度h=20 μm、长轴半径ra=150 μm、椭圆率γ=0.7、偏转角度θ=0°。齿轮试验表明,引入该优化织构后,齿面磨损机制由严重黏着磨损转变为轻微划痕,最大与最小损伤面积率分别降低81.11%和76.97%。结论 合理设计参数的椭圆微织构可显著改善齿轮齿面润滑状态,抑制磨损与胶合失效,有效提升摩擦学性能。本研究为齿轮表面改性提供了理论依据与工艺参考,对高性能齿轮传动系统的可靠性设计具有重要工程意义。
Abstract
Gear transmissions are critical components in the modern industry, whose reliability and durability directly affect the performance and lifespan of mechanical systems. Under extreme operating conditions such as high speed and heavy load, it is often difficult to maintain a complete lubricating oil film between meshing teeth. This leads to increased friction, temperature rise, and severe surface failures such as scuffing and wear. To address this issue, surface texturing technology has emerged as a promising approach for enhancing lubrication and anti-wear performance. Given the complex kinematics in gear engagement, including combined rolling and sliding, time-varying contact stress, and entrainment speed variation, the design of surface textures requires careful optimization. Although previous studies have compared various texture shapes, the systematic influence of geometric parameters on lubrication performance remains insufficiently explored. Elliptical textures offer high design flexibility due to adjustable parameters such as major and minor axis radii, inclination angle, depth, and area ratio. Therefore, this study focuses on elliptical micro-textures to improve gear tribological performance.
The research employs an integrated approach combining numerical simulation and experimental validation. Based on Hertz contact theory, the gear tooth contact is simplified to a cylinder-on-plane configuration to facilitate the analysis of texture behaviors under rolling-sliding conditions. A CFD model is developed using the Navier-Stokes equations, treating the lubricant as an incompressible Newtonian fluid. Simulations are conducted to evaluate the effects of area ratio (δ), ellipticity (γ=rb/ra), inclination angle (θ), major axis radius (ra), and depth (h) on dimensionless load capacity (W*), wall friction force (F*), and dynamic pressure coefficient (K=W*/F*). The results show that elliptical textures significantly enhance hydrodynamic pressure distribution. The area ratio and inclination angle are identified as the most influential parameters, with optimal values around 25%-30% and 45°, respectively. Ellipticity and major axis radius also play important roles, while depth exhibits more complex effects, with shallower textures generally performing better.
An L9(34) orthogonal array is designed for experimental verification. The 40Cr steel rollers are textured using a picosecond laser with nine parameter combinations. Tests are conducted on an MMS-2A tribometer under a load of 1 800 N, speed of 400 r/min, and duration of 30 minutes, lubricated with L-CKC68 gear oil. Most textured specimens exhibit lower friction coefficients and reduced wear mass loss compared with the non-textured baseline. Range analysis indicates that h has the greatest influence on the friction coefficient, followed by γ, ra, and θ. For wear loss, the order of influence is h>ra>γ>θ. The optimal combination is determined as h=20 μm, ra=150 μm, γ=0.7, and θ=0°. SEM observations reveal that surfaces with optimized textures display mild abrasive wear, in contrast to severe pitting and adhesion on untextured specimens.
Finally, gear scuffing tests are performed on an MFZG-1W rig according to GB/T 13672—2022, using gears textured with the optimal parameters. The results demonstrate a transition from severe adhesive wear to mild scratching on textured tooth surfaces. Quantitative analysis via ultra-depth microscopy shows reductions of 81.11% in the maximum damage area ratio and 76.97% in the minimum damage area ratio. Moreover, damage distribution becomes more uniform and stable. In conclusion, this study demonstrates that optimally designed elliptical micro-textures can significantly improve lubrication, reduce wear, and enhance the scuffing resistance of gears. The findings provide valuable insights and practical guidelines for surface modification in high-performance gear transmission systems.
关键词
椭圆微织构 /
摩擦学特性 /
正交试验 /
滚滑线接触 /
磨损
Key words
elliptical micro-texture /
tribological performance /
orthogonal test /
rolling-sliding line contact /
wear
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基金
国家自然科学基金面上项目（52205055）; 福建省海洋装备抗疲劳制造工程研究中心开放基金（AFMMEKF202401）
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