Grinding Process Optimization Of Wind Turbine Gearbox’s Input Shaft Based On CAE And DOE

The input shaft is an important part of the wind turbine gearbox,which is the link between the motor and the sun gear.Its manufacturing accuracy directly affects the reliability of the operation.The input shaft and the sun gear adopt interference fit.After assembly,the external diameter of the input shaft will be slightly deformed,resulting in the external diameter out of tolerance.However,the current grinding process cannot solve this problem.Therefore,this thesis takes input shaft as the research object,and use finite element analysis and DOE test design to provide technical and method support for grinding process optimization.The main research work of this thesis is as follows:Based on CAE to analyze the input shafts’ s external diameter deformation.Based on the finite element software ANSYS,and carry out the finite element analysis to the input shafts’ s external diameter deformation after assembling the sun gear,and modify the ANSYS modeling and parameters through process test verification to ensure that the finite element analysis results are basically consistent with the actual measured values.Based on DOE to analyze the mathematical model of input shafts’ s external diameter deformation.The factors that affect the external diameter deformation are firstly identified by experimental design.Secondly,through experimental planning,CAE is used to simulate the external diameter deformation under different parameter settings of each factor.Finally,based on the simulation results,the regression analysis was carried out to obtain the mathematical model between the input shafts’ s external diameter deformation and each factor.Thus,only need to get the input shafts’ s variable parameters into the mathematical model to obtain the deformation of the external diameter,avoiding repeated ANSYS modeling analysis.Optimize three types of input shaft’s gringding reserved size.Firstly,based on the mathematical model obtained by DOE,the external diameter deformation of each type of input shaft was calculated after assembling the sun gear,and then the input shafts were divided into three types according to the deformation characteristics.Secondly,for each type of input shaft,the gringding reserved size scheme has planned.Finally,the reserved size optimization scheme was tested and verified to ensure that the external diameter of the input shaft was qualified after assembling the sun gear.Optimize input shaft’s grinding process: using turning instead of grinding,combined with cutting parameter optimization,automatic clamping,automatic measurement,abnormal warning,program standardization,etc.,which greatly improves the processing efficiency of input shaft.