一级圆锥齿轮减速器的设计

1目录第一章一级圆锥齿轮减速器的设计任务·····································31-1设计题目··················································31-2设计任务··················································31-3具体作业··················································3第二章电动机的选择··············································42-1选择电动机类型和结构形式·····································42-2选择电动机的容量·············································42-3确定电动机的转速，总传动比与各级传动比······················52-4计算传动装置的运动和运动参数·······························5第三章圆锥齿轮传动的设计计算···································73-1圆锥齿轮传动的设计计算······································7第四章轴的设计计算··············································104-1轴一的设计················································104-2轴二的设计·················································14第五章滚动轴承的校核·············································195-1滚动轴承的校核·············································19第六章键的校核··················································206-1轴一键的校核··············································206-2轴二键的校核··············································20第七章润滑方式及密封方式的选择··································217-1润滑方式·················································217-2密封方式及密封形式的选择···································21第八章减速器箱体设计·············································238-1箱体设计···················································23心得体会··························································24参考文献··························································252第一章一级圆锥齿轮减速器的设计1-1.设计题目用于带式运输机的一级圆锥齿轮减速器。传动装置简图如右图所示。（1）带式运输机数据见数据表格。（2）工作条件两班制工作，空载启动，单向连续运转，载荷平稳。运输带速度允许速度误差为±5%。（3）使用期限工作期限为十年，每年工作300天；检修期间隔为三年。（4）生产批量小批量生产。2.设计任务1)选择电动机型号；2)确定链传动的主要参数及尺寸；3)设计减速器；4)选择联轴器。3.具体作业1)减速器装配图一张；2)零件工作图二张（大齿轮，输出轴）；3)设计说明书一份。运输带工作拉力F/N1500180020002200240026002800280027002500运输带工作速度v/(m/s)1.51.51.61.61.71.71.81.81.51.4运输带滚筒直径D/mm250260270280300320320300300300第二章电动机的选择32-1选择电动机类型和结构型式由电动机工作电源，工作条件荷载和特点选择三相异步电动机。2-2选择电动机容量标准电动机的容量由额定功率表示。所选电动机额定功率应等于或稍大于工作要求的功率。容量小于工作要求，则不能保证工作机正常工作，或使电动机长期过载，发热大而过早损坏；容量过大，则增大成本，并且由于效率和功率因数低而造成浪费。由于工作所给的运输带工作压力F=2600N，运输带工作速度V=1.7m/s得工作及所需功率WPP为WP=FV/1000=4.42kw电动机至工作机之间传动装置的总效率为：=12345=0.9216所需电动机的功率为：dp=WP/=3.52/0.859=4.796kw式中：1——联轴器的效率；2——圆锥齿轮效率；3——滚动轴承的效率；4——卷筒的效率；5——V带的效率。因为电动机的额定功率额p略大于dp，选同步转速750r/min，由表12-1差得可选Y132S-4型三相异步电动机，其额p=5.5KW，mn=720r/min2-3确定电动机的转速，总传动比与各级传动比wn=DV60000=600001.73.14320=101.51r/min传动装置的总传动比为：i=wmnn=720101.51=7.4式中：wn——电动机的满载转速，r/min；4mn——工作机的转速，r/min。二级传动中，总传动比为7.4减速器传动比01i=3，则链式传动传动比02i=01ii=2.42-4计算传动装置的运动和运动参数1）各轴转速：传动装置从电动机到工作机有三轴，依次为1，2，3轴，则：电动机轴0n=mn=720r/min；高速轴1n=mn=720r/min；低速轴2n=011in=720/3=260r/min;滚筒轴3n=2n/02i=260/3=86.6r/min。2）各轴转矩：电动机轴0T=95504.42750=46.3N.m;高速轴1T=95504.2432250=163N.m;低速轴2T=95503.87136.6=270.53N.m;滚筒轴3T=95503.04136.6=255.66N.m。3）各轴输入输出功率：电动机轴0p=dp=4.42KW;高速轴1P=0p1=4.420.96=4.2432KW;低速轴2P=1P12=4.24320.960.96=3.87027KW;滚筒轴3P=2P34=3.870.960.98=3.64KW。运动和动力参数的计算如下表2-1所示：表2-1各轴运动及运动参数轴名功率P/KW转矩T/N.m转速传动比效率输入输出输入输出电动机轴4.4256.3072010.965高速轴4.244.15163161.3772030.96低速轴3.873.83270267.302402.40.98滚筒轴3.643.60255252.45136第三章3-1圆锥齿轮传动的设计计算1选定齿轮的类型，精度等级，材料及齿数：（1）选择材料及热处理小圆锥选用40Cr，调质处理，调质硬度为280HBS；大圆锥选用45#钢，调质处理，调质硬度为240HBS。（2）选齿轮小齿轮选1z=24，大齿轮选2z=72；大小圆锥均选用7级精度。（3）轴交角为90度的直齿圆锥齿轮传动u=12zz=4=tan2=cot1，得2=74，1=16。2按齿面解除疲劳强度计算：3192.2d21)5.11()(RRHEKTz1）定公式内的各计算数值（1）计算小圆锥齿轮的转矩1T=5.628410N.mm；（2）查表可知锥齿轮传动的齿宽系数d=1；（3）从表10-6查得材料的弹性影响系数Ez=189.8MPa；（4）有图10-21d按齿面硬度查得大小齿轮的解除疲劳强度极限1limH=600MPa，2limH=550MPa；（5）计算应力的循环次数：1N=60jLnh1=2.073910，2N=4.147910/4=6.91810;6（6）计算接触疲劳许用应力取失效概率为1%，安全系数S=1，由式（10-12）得[H1]=1lim1HNK/S=0.9600=540MPa；[2]H=2lim2HNK/S=0.95550=522.5MPa；（7）计算载荷系数由表10-2得AK=1，VK=1.1，HK=1.2，HK=1.436则K=AKVKHKHK=1.8962）计算试算小齿轮分度圆直径3192.2d21)5.11()(RRHEKTz=80mm计算锥齿轮平均分度圆处的圆周速度为V=10006011nd=3.1477720601000=2.86m/s根据v=2.86m/s，7级精度由图10-8查得动载荷系数VK=1.2，则K=AKVKHKHK=1.273）计算模数m=1d/1z=80/24=3.333按齿面弯曲疲劳强度计算：m][1)5.01(4221213FRSaFauZYYKT（1）计算载荷系数K=AKVKFKFK=11.1411.22=1.3908（2）由图10-18查得弯曲疲劳寿命系数1FNK=0.85，2FNK=0.88；（3）由图10-20C查得小齿轮的弯曲疲劳强度极限1FE=500MPa，大齿轮的弯曲疲劳强度极限2FE=380MPa；（4）计算弯曲疲劳许用应力取弯曲疲劳安全系数S=1.3，得111[]303.57FNFEFKMPaS7222[]238.86FNFEFKMPaS（5）查取齿形系数由表10-5查得65.21FaY，58.11SaY，22.226FaY，21.764FaY，（6）计算大小齿轮的][FSaFaYY并加以比较1112.651.580.01379[]303.57FaSaFYY2222.181.7040.01644[]238.86FaSaFYY大齿轮数值大。（7）设计计算m][1)5.01(4221213FRSaFauZYYKT=1.57对此结果，齿面接触疲劳强度计算的模数m大于由齿根弯曲强度计算的模数，由于齿轮模数m的大小主要取决于弯曲强度所决定的承载能力，而齿面接触疲劳强度所决定的承载能力仅与齿轮的直径有关。取由弯曲强度算得的模数，就近圆整为m=3。按接触算的得分度圆直径1d=47.45mm，算得小齿轮齿数1z=24，大齿轮齿数2z=96。这样设计的齿轮传动既满足了齿面接触强度又满足了齿根弯曲疲劳强度，并做到了结构紧凑，避免浪费。4几何尺寸计算：1）计算分度圆直径1d=1zm=98mm2d=2zm=293mm2）锥度R=1d221319822u219mm3）锥齿宽度b=RR=1219=219mm。8第四章轴的计算和设计4-1轴一的设计一）输出轴上的功率，转速和转矩:1)输入轴上的功率1P4.26KW,转速1n=720r/min，转矩1T=326.9310/Nma=22.3;2）求作用在齿轮上的力因已知高速级小锥齿轮的分度圆直径为1d=42mm，而112tTFd226.9342=1282N;tanrtFF1cos108N;1tansinatFF101.2N。3)初步确定轴的最小直径先按式（15-2）初步估算轴的最小直径。选取轴的材料为45#钢，调制处理。根据表15-3，取0A120，于是得3310444.1120(1)1440(10.5)PdAn=17.4mm输入轴的最小直径显然是安联轴器的直径12d，为使所选的轴的直径12d与联轴器的孔径相适应，故需同时选联轴器的型号