Abstract
Gear transmission is the most basic transmission component in mechanical transmission system. Many scholars have done a lot of research on gear reliability. When the variation coefficient is used to calculate and optimize the reliability of bevel gear, in order to calculate the reliability of bevel gear, it is often assumed that the gear works under constant torque, that is, the coefficient of variation (COV) is zero, but this is not the case in practice. In this paper, a gear reliability method based on discrete element simulation is proposed. The purpose of this method is to simulate the actual working conditions of gears, calculate more accurate coefficient of variation in the real world, and improve the accuracy of gear reliability design. Firstly, the real working conditions of the bevel gear transmission are simulated by discrete element method (DEM), and in the transmission system, the tangential force COV of the bevel gear is proved to be equal to the torque COV of the crusher central shaft. Secondly, the multi-objective function model of the gear transmission system is established based on the double tooth roll crusher (DTRC). The optimal volume and reliability of the bevel gear transmission are taken as the objective function, and the teeth number, module and face width factor of basic parameters of gear are optimized by genetic algorithm (GA). Finally, the accuracy of the optimization results is verified by Monte Carlo method. The main purpose of the manuscript is to analyse the effect of actual conditions (DEM simulation) on the optimization results. The results show that the COV of nominal tangential load of bevel gear is about 0.65 under actual working conditions, so in order to guarantee the same reliability, total volume need to be increased by 34.4%. This method is similar to the selection of gear safety factor. In practical production, the selection of safety factor is often based on experience. This paper provides a new method to optimize the reliability of bevel gear, combining with DEM simulation, which provides theoretical guidance for optimal design of bevel gear
Highlights
Gear transmission is one of the most common transmission in mechanical systems, and is widely used in various precision mechanical transmission components, such as machine tools, vehicles, etc
When the Monte Carlo method is used to calculate the reliability of gear transmission, the parameters related to the geometric dimensions of the gears are regarded as constants, while the other parameters are considered to obey normal distribution
The multi-objective function model of bevel gear is established, and the parameters of bevel gear are optimized by GA and discrete element method (DEM)
Summary
Gear transmission is one of the most common transmission in mechanical systems, and is widely used in various precision mechanical transmission components, such as machine tools, vehicles, etc. Zhang [47] established the optimization design of reliability of large ball mill gear transmission based on the Bayesian analysis algorithm of Kriging model and verified the reliability calculation results by Monte Carlo method. The double tooth roll crusher ( 2PGC1040 × 3610 ) is taken as an example to simulate and calculate the torque change of the central shaft of the DTRC under a certain working condition with of equivalent model. According to the load of transmission system, as shown, a series transmission in this paper is adopted, so the load of the crusher central shaft is a) Real particle b) Equivalent model in DEM transferred to the bevel gear in a certain proportion.
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