Research On The Large Gear Structure Filled With Aluminum Foam

With the development of modern industry, heavy mechanical transmission requirements in high-speed, high-power, light weight, small, high efficiency, high reliability and environ-mental protection continue to improve, in the heavy machinery transmission, heavy-duty gear as the transmission components are usually dynamic load under high, this requires the structure must have good static, dynamic performance and high specific stiffness, and aluminum foam lightweight, damping and high specific stiffness, strength and other excellent performance has been investigated for test had proved. So there is a feasible scheme that added the aluminum foam metal and its composite materials to gear in order to improving the mechanical properties of structures which is a key technical problem in the manufacturing process.Taken the MG400/920-WD typeShearer reducer gear as the prototype, a heavy gear with aluminum foam-filled structure was designed. It took cast iron material as a shell and aluminum foam as filled material. The simplified gear is analyzed according to the theories of mechanics of materials. The results indicate that its flexibility, strength and stiffness were meeting the design requirements, and were much quality than prototype structure of cast iron.The static and dynamic performances of gears were analyzed in numerical simulation by ANSYS finite element software. The inherent frequency of gear with aluminum foam-filled structure was improved, while its maximum response amplitude was reduced, so its structure playing a positive role in reducing the vibration of system.The shape of gear with aluminum foam-filled structure was optimized by MATLAB. Obtaining the optimal design scheme with its structure has the best performances according to the design requirements. This scheme could be achieve only under the current design requirements and processing conditions.