Research On Contact And Wear Characteristics Of Aviation Spline

Spline couplings provide technical support for reliability,durability and accurate transmission of aero engines due to their high torque transmission capability and misalignment compensation.During takeoff,cruise and landing,the spline vice is under high cyclic load for a long time,and the damage occurs between the two surfaces clamped together by torque of the spline coupling,which is nominally at rest but has a small amplitude,which poses a serious threat to the long-term operation of the turbine drive system.To design high-performance aero-engine splines couplings,accurate prediction of micro-motion wear is a key technology.At present,the basic theory and prediction methods of aero spline in wear are not perfect enough to meet the current engineering needs,and there is an urgent need to carry out in-depth research work.In this paper,the wear finite element models of involute spline is established by combining experiment and simulation.Frist,the ball-disk friction wear experiment of aerospace material TC4 is used as an entry point to obtain the friction coefficient and wear coefficient under different working conditions.Then the ABAQUS subroutine UMESHMOTION is used to carry out the ball-disk wear simulation and experimental comparison verification.Finally,the wear model is used for the contact characteristic analysis.The purpose is to study the interaction between surface wear and contact characteristics of spline vice,and to provide a practical and effective finite element analysis method and experimental research ideas for the prediction of wear of involute splines under dynamic conditions.Specifically,it includes:(1)To investigate the wear behavior of the involute spline pair under micro-motion conditions,wear experiments were conducted on the aerospace material TC4 and the material with surface treatment,and the wear coefficient and friction coefficient of TC4 under different working conditions were measured by micro-motion wear tests using SRV-IV testing machine.(2)Combined with the test data,a three-dimensional ball-disk wear simulation of TC4 wear was performed by combining finite element and Archard theory,and the finite element results were compared with the test to optimize the predictive capability of the wear model with the goal of improving accuracy.(3)Considering the operating conditions of the actual spline vice,a three-dimensional contact calculation model of the spline vice is established,and the effects of torque and misalignment on the Mises stress distribution are obtained by using pure elasticity theory to analyze the stress state and slip distance at specific locations of the actual spline.(4)Combining the contact calculation model of the spline pair with the surface wear model of Archard’s wear equation,the interaction between tooth wear and contact characteristics of the spline pair under different conditions is studied to find the wear distribution along the tooth surface and to determine the applicability of the wear model to the spline pair.The prediction of the spline vice wear model shows that the worn surface profile has considerable influence on the magnitude and distribution of the spline contact pressure,while the contact pressure also has a great influence on the worn tooth profile.Finally,a spline friction and wear test bench is designed to provide an experimental design plan for testing the vibration and wear characteristics of the spline under different speed and torque conditions.The research results provide a theoretical model and experimental data for the finite element modeling of spline wear,and provide an effective means to reduce engine failures and the anti-wear design of aerospace splines.