Design And Experimental Study Of Gear Wear Testing Machine For Polymer Material Based On Virtual Prototype

The rapid development of polymer composite materials and the continuous improvement of performance.It promotes the application of polymer composite gears in automobiles and other projects,and leads the mechanical industry towards the direction of lightweight.In order to study the friction and wear mechanism and design method of polymer material gears,it is of great engineering significance to develop and design a polymer gear testing machine.Virtual prototyping technology is an integrated multidisciplinary technology that provides a completely new approach to product development.Compared with the traditional design and manufacturing,virtual prototype design can effectively shorten the product development cycle and improve product performance.Based on virtual prototyping technology,the system design and performance simulation of the polymer composite gear testing machine were carried out by combining theoretical analysis and experimental research.The finite element software ANSYS Workbench is used to analyze the static behavior of polymer composite gears.The data of the contact stress of the simulated gear are fitted by the Matlab software,and the mathematical model between the equivalent stress and the load torque is established to calculate the maximum torque that the selected gear can withstand.Based on Hertz contact theory,the contact stress of gears is analyzed theoretically,and the loading range of loading system of testing machine is determined by combining theoretical analysis and simulation analysis results.Based on the mechanical analysis of viscoelastic body,the loading scheme of ball screw weight supported by single hinge is determined.In the process of testing,the range of deflection angle of adjustable test gearbox is very small,so the test system uses discontinuous phase method to measure the deflection angle of adjustable test gearbox.The mechanical structure design of transmission system,loading system and clamping system is carried out by using SolidWorks software,and the working principle of loading system and testing system is analyzed.Through ANSYS Workbench software,the strength of the screw support frame of the loading device is checked.The results show that the structure design of the support frame meets the strength requirements.The virtual assembly of the testing machine is carried out based on SolidWorks software,and the kinematics simulation analysis is carried out.The simulationresults show that the motion is non-interference,and the structure device of the testing machine meets the design requirements.Using ANSYS Workbench software,the modal analysis of the whole testing machine is carried out,which avoids the resonance phenomenon in the working process of the testing machine.Through ADAMS software,the dynamic simulation analysis of gear meshing force under different load torques is carried out on the virtual prototype model.The dynamic curves of gear meshing force with time are obtained.The simulation mean of meshing force is basically consistent with the theoretical calculation value.The rotational speed curve of driven shaft is analyzed,and the reliability and stability of the testing machine model are verified.The friction and wear test of polymer composite gear was completed by physical prototype,and the curve of gear meshing force varying with time was obtained.Compared with ADAMS simulation gear meshing force curve,the change trend of simulation curve and test curve was the same,which verified the rationality of virtual prototype design.The system error of the virtual prototype is studied.The loading process of the loading system and the causes of the errors are analyzed.The results show that the loading system and the testing system meet the accuracy requirements.