机械设计——减速器齿轮箱-设计手册

1机械设计课程设计二级直齿圆柱齿轮减速器学院：专业：班级：学号：姓名：2目录一、传动方案的确定···················3二、电动机的选择····················52.1电动机类型和结构形式选择············52.2确定电动机功率···················52.3确定电动机型号滚筒工作转速·············5三、计算总传动比及分配各级的传动比············53.1计算总传动比····················53.2分配各级传动比···················6四、运动参数及动力参数及传动零件的设计计算········64.1、计算各轴转速····················64.2、计算各轴的功率···················64.3、计算各轴的扭矩···················6五、带的设计计算····················75.1、确定计算功率Pca··················75.2、选择V带的带型···················75.3、确定带轮的基准直径dd=及验算带速v·······75.4、根据V带的中心距和基准长度Ld············75.5、验算小带轮上的包角·················75.6、计算带的根数··················75.7、计算单根V带的初拉力的最小值··········835.8、计算压轴力··················85.9、带轮结构设计··················8六、齿轮的设计计算··················9第一对齿轮：6.1、选定齿轮类型、精度等级、材料及齿数········96.2、按齿面接触强度设计················106.3、计算相关数值···················106.4、按齿根弯曲强度设计················116.5、设计计算·····················126.6、齿轮结构设计···················13第二对齿轮6.7、选定齿轮类型、精度等级、材料及齿数········146.8、按齿面接触疲劳强度设计··············146.9、确定公式数值···················146.10计算相关数值···················156.11按齿根弯曲强度设计················166.12设计计算·····················166.13齿轮结构设计···················18七、轴的设计及强度校核··············`··187.1、轴的选材·····················187.2、各轴最小直径估算·················187.3、装配工作底图的设计················1947.4、高速轴的结构设计及强度校核·············197.5、中速轴的结构设计及强度校核·············237.6、低速轴的结构设计及强度校核·············267.7、轴承润滑方式确定················30八、键联接的选择及校核计算·················308.1、高速轴（A型键）···················308.2、中速轴（A型键）···················308.3、低速轴（A型键）···················31九、设计小结·················``·····32十、参考资料························325计算及说明主要结果一．传动方案的确定传动装置选用V带传动和闭式二级圆柱齿轮传动系统，具有结构简单、制造成本低的特点。V带传动布置于高速级，能发挥它的传动平稳、缓冲吸振和过载保护的优点。但本方案结构尺寸较大，带的寿命短，而且不宜在恶劣环境中工作。因而，在对尺寸要求不高、环境条件允许的情况下，可以采用本方案。二．电动机的选择2.1电动机类型和结构形式选择按照已知的动力源和工作条件选用Y系列三相异步电动机。2.2确定电动机功率1）传动装置的总效率查表得：η滚筒=0.97（传动滚筒），η带=0.97（V带），η轴承=0.99，=0.98，η联轴器=0.99。η=η×η×η×η×η=总带轴承齿轮联轴器滚筒0.97×0.97×0.994×0.982×0.99=0.8592）工作机所需电动机功率由公式得：Pd=Fv1000ή总=2000×1.61000×0.859=3.725kw2.3确定电动机型号滚筒工作转速nw=60∗1000vπD=60∗1000∗1.6π∗350=87.36r/min按推荐传动比常用范围，取V带传动比i带=2~4，二级圆柱齿轮传动比i齿=3~5，则总传动比的范围为i总=i带×i齿=6~20。因此，电动机转速的可选范围为d 6~2087.36524.16~1747.2/wimnnrin符合这一范围的电动机同步转速有1000r/min和1500r/min。因为电动机转速越高，价格越低，而传动装置的轮廓尺寸越大，综合考虑电动机价格和和传动装置尺寸及环境条件，先选择1500r/min。即电动机型号为Y112M-4。其满载转速nm=1440r/min,额定功率Ped=3kw。附表1电动机数据及总传动比电动机型号额定功率满载转速额定转速额定最大转速Y112M-44kw1440r/min2.22.3三．传动装置总传动比的计算及各级传动比的分配η=0.859总Pd=3.725kwnw=87.36r/min63.1计算总传动比i总=𝑛𝑚𝑛𝑤=144087.36=16.483.2分配各级传动比查表得，带的传动比取为i带=2，则圆柱齿轮的传动比i齿=𝑖总𝑖带=16.482=8.24if=(1.2~1.3)i,∴i1=3.21,i2=2.567四．传动装置运动及动力参数的计算4.1计算各轴转速n0=nm=1440r/minn1=𝑛0𝑖带=14402=720r/minn2=𝑛𝐼𝑖1=7203.21=224.30r/minn3=𝑛2𝑖2=224.302.567=87.378r/minn4=𝑛|||𝑖3=n3=87.378r/min4.2计算各轴功率P0=Pd=3.725kwP1=P0×ή带=3.725×0.97=3.576kwP2=P1×ή轴承×ή齿轮=3.576×0.99×0.98=3.470kwP3=P2×ή轴承×ή齿轮=3.470×0.98×0.99=3.367kwP4=P3×ή轴承×ή联轴器=3.30kw4.3计算各轴转矩T0=9550∗𝑃0𝑛0=9550∗3.7251440=24.70N·mT1=9550∗𝑃1𝑛1=9550∗3.576720=47.432N·mT2=9550∗𝑃2𝑛2=9550∗3.470224.3=147.742N·mT3=9550∗𝑃3𝑛3=9550∗3.36787.367=368.04N·m传动比效率20.96（带）3.210.98×0.992.5670.98×0.99i总=16.48i1=3.21,i2=2.567n0=1440r/minn1=720r/minn2=224.30r/minn3=87.378r/minn4=87.378r/minP0=3.725kwP1=3.576kwP2=3.470kwP3=3.367kwP4=3.30kwT0=24.70N·mT1=47.432N·mT2=147.742N·mT3=368.04N·mT4=360.72N·m7T4=9550∗𝑃4𝑛4=9550∗3.3087.367=360.72N·m附表2各轴的运动及动力参数轴功率转速转矩03.7251440r/miin24.70N·m13.576720r/min47.432N·m23.470224.30r/min147.742N·m33.36787.378r/min368.00N·m43.3087.378r/min360.67N·m五．减速器外的传动零件的设计——带传动的设计计算5.1确定计算功率Pca由载荷变动较小、每天单班制工作，查表取带传动工作情况系数KA=1.0，则Pca=KA×Pd=1.0×3.725=3.725kw。5.2选择V带的带型根据求得的Pca=3.725kw以及n0=1440r/min，查图得选用A型V带。5.3确定带轮的基准直径dd=及验算带速v1）初选小带轮的基准直径dd1取小带轮的基准直径dd1=90mm。2）验算带速vV=𝜋𝑑𝑑1𝑛060∗1000=𝜋∗90∗144060∗1000=6.7824m/s∵5m/svd30m/s，故带速合适。3）计算大带轮的基准直径dd2dd2=i带×dd1=2×90=180mm5.4根据V带的中心距和基准长度Ld1）根据0.7（dd1+dd2）a02（dd1+dd2），得189a0540。初定中心距a0=300mm。2）计算所需的基准长度LdLd0≈2a0+𝜋2(dd1+dd2)+(𝑑𝑑1−𝑑𝑑2)24𝑎0=2×300+𝜋2(90+180)+(180−90)24×300=1030.65mm。查表可选带的基准长度Ld=1000mm。修正系数KL=0.893）按计算式计算实际中心距a0010001030.65(300)284.67522ddLLaammmm中心距的变化范围为269.675314.675mmmm10.99×0.99KA=1.0Pca=3.725kwA型V带V=6.7824m/sa0=300mmLd0=1030.65mmKL=0.89284.675amm小带轮包角合适85.5验算小带轮上的包角112157.357.318018018090161.885120284.675dddda小带轮包角合适。5.6计算带的根数1）计算单根V带的额定功率rP由1901440minddmmnr和查表可得01.064Pkw根据1440min2nri，和A型带，查表可得00.168Pkw、0.954k、0.89Lk。故r00P1.06440.16920.9540.891.0474LPPkkkw2）计算V带的根数Zr3.7253.556P1.0474caP故取V带根数为4根。5.7计算单根V带的初拉力的最小值0minF查表可得A型带的单位长度质量0.10qkgm20min2.5500cakPFqvkZv22.50.9433.725(5000.16.739)115.850.94336.739NN应使带的实际初拉力00minFF。5.8计算压轴力pF压轴力的最小值为01.064Pkw00.168Pkw0.954k0.89LkrP1.0474kwV带根数为40min115.85FNmin915.24PFN910minmin2sin2PFZF161.88524115.85sin2。915.24N附表3V带传动主要参数名称结果名称结果名称结果带型A型传动比i带=2根数Z=4基准直径dd1=90mm基准长度Ld=1000mm预紧力F0（min）=115.85Ndd2=180mm中心距a=284.675压轴力Fp（min）=915.24N5.9带轮结构设计带轮材料采用HT150。查得：bd=11.0mm，hamin=2.75mm，hfmin=8.7mm，e=15mm±0.3mm，fmin=9mm，现取ha=3mm，f=10mm，hf=9mm。1）小带轮结构设计小带轮采用实心式。由电动机输出端直径d=28mm，查得：d11=(1.8~2)d=(1.8~2)×28