目的 在无油润滑条件下,柔轮磨损是造成谐波减速器性能退化的主要原因之一,严重影响其传动性能与服役寿命。本文对比研究谐波减速器柔轮与刚轮材料配副、柔轮与柔性轴承材料配副在干摩擦条件下的摩擦学性能以及磨损机理。方法 采用有限元方法分析柔轮与刚轮、柔轮与柔性轴承之间的接触压力,并通过重载往复摩擦磨损试验仪设计和开展销盘摩擦磨损实验,探讨两种配副材料在不同工况下的摩擦系数与磨损率变化规律;结合电镜图（SEM）以及能谱图（EDS）,深入研究材料在干摩擦状态下的磨损机理。结果 对于GCr15/40CrNiMoA和45钢/40CrNiMoA两种配副,在载荷较大或频率较大时,摩擦系数趋于稳定所需的时间较短;稳定后的平均摩擦系数随着载荷的增大而增大,随着频率的增大而减小;磨损率随着载荷的增大而逐渐减小,随着频率的增加而增大。在相同工况下,GCr15/40CrNiMoA配副的磨损率略高于45钢/40CrNiMoA配副。结论 GCr15/40CrNiMoA摩擦副的磨损表面呈现显著的分层特征,形貌粗糙,磨损程度严重;而45钢/40CrNiMoA摩擦副因两种材料硬度相近,接触界面的应力分布更为均匀,有效避免了单方面的剧烈切削,磨损表面较为光滑,仅可见浅层磨痕,未发生明显的分层或剥落,因此表现出更优的耐磨性能。45钢/40CrNiMoA配副表现出更优的磨损性能。
Abstract
Under oil-free lubrication conditions, flexspline wear is a main cause of performance degradation in harmonic reducers, severely affecting their transmission performance and service life. A comparative study of the wear performance and wear mechanisms of the flexspline material, the steel wheel material, and the flexible bearing material under dry friction conditions is conducted to provide experimental evidence and theoretical support for material selection and matching design of high-wear-resistance, long-life harmonic reducers, thereby enhancing their transmission reliability and extending their service life.
The finite element method is employed in conjunction with the actual working conditions of the harmonic reducer to analyze the contact pressure between the flexspline and the circular spline, as well as between the flexspline and the flexible bearing. The obtained contact pressure is then converted into the required loading conditions for experimental validation. A pin-on-disk friction and wear test is designed with a heavy-duty reciprocating friction and wear tester. Based on the results of friction coefficient and wear rate, the dynamic behaviors of the friction interface under different working conditions are investigated. Furthermore, scanning electron microscopy (SEM) images and energy-dispersive X-ray spectroscopy (EDS) data are utilized to conduct an in-depth analysis on the wear mechanisms of the two contact pairs under dry friction conditions.
Research indicates that for both GCr15/40CrNiMoA and 45 steel/40CrNiMoA contact pairs, the time required for the friction coefficient to stabilize is shorter under higher loads or frequencies. After stabilization, the average friction coefficient increases with the increasing load but decreases with the increasing frequency. In contrast, the wear rate gradually decreases with the increasing load, while it increases with the increasing frequency. Under the same operating conditions, the wear rate of the GCr15/40CrNiMoA pair is slightly higher than that of the 45 steel/40CrNiMoA pair. For the 45 steel/40CrNiMoA contact pair, under low load and low frequency conditions (300 N, 3 Hz), severe abrasive wear and adhesive wear dominate. At higher loads (400 N, 3 Hz), the wear mechanism transitions to mild abrasive wear and oxidative wear. Under higher frequency conditions (300 N, 5 Hz), thermal softening effects intensify material extrusion delamination and block-like spalling, leading to an increased wear volume. In contrast, for the GCr15/40CrNiMoA friction pair, under low load and low frequency conditions (400 N, 3 Hz), mild adhesive wear and abrasive wear are observed. At higher loads (500 N, 3 Hz), spall pits formed by the fracture of oxide films appear, with wear debris contributing to load-bearing. Under higher frequency conditions (500 N, 5 Hz), intensified cyclic stress promotes fatigue crack propagation and three-body wear, resulting in a significant increase in wear severity.
The worn surface of the GCr15/40CrNiMoA tribological pair displays significant delamination and a rough topography, indicative of severe wear. Conversely, for the 45 steel/40CrNiMoA tribological pair, the similar hardness levels of the two materials lead to a more uniform stress distribution across the contact interface, effectively mitigating severe unilateral cutting. The worn surface is smooth, exhibiting only shallow wear tracks with no evident delamination or spalling, thus demonstrating enhanced wear resistance. Accordingly, the 45 steel/40CrNiMoA tribological pair shows superior wear performance.
关键词
柔轮磨损 /
有限元仿真 /
销盘实验 /
摩擦系数 /
磨损率 /
磨损机理
Key words
flexspline wear /
finite element simulation /
pin-on-disk test /
friction coefficient /
wear rate /
wear mechanism
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基金
河南省科技攻关项目（242102220088）
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