二级圆锥齿轮减速器设计说明书.docx
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二级圆锥齿轮减速器设计说明书
一¸设计任务书····················································································2
二¸电机的选择计算
1.择电机的转速·················································································2
2.工作机的有效功率···········································································2
3.选择电动机的型号···········································································3
三¸运动和动力参数的计算
1.分配传动比·············································································3
2.各轴的转速·············································································3
3.各轴的功率·············································································4
4.各轴的转矩····················································································4
四¸传动零件的设计计算
1.闭式直齿轮圆锥齿轮传动的设计计算·················································4
2.闭式直齿轮圆柱齿轮传动的设计计算·················································6
五¸轴的设计计算
4.减速器高速轴I的设计·······························································9
5.减速器低速轴II的设计····························································11
3.减速器低速轴III的设计··································································14
六¸滚动轴承的选择与寿命计算
1.减速器高速I轴滚动轴承的选择与寿命计算·········································16
2.减速器低速II轴滚动轴承的选择与寿命计算········································17
3.减速器低速III轴滚动轴承的选择与寿命计算·····································18
七¸键联接的选择和验算
1.联轴器与高速轴轴伸的键联接·························································19
2.大圆锥齿轮与低速轴II的的键联接···················································19
3.大圆柱齿轮与低速轴III的的键联接···········································20
八¸润滑油的选择与热平衡计算
1.减速器的热平衡计算·······································································21
2.润滑油的选择···············································································22
九¸参考文献···················································································23
计算内容
计算结果
一对圆锥滚子轴承的效率η3=0.98
一对球轴承的效率η4=0.99
闭式直齿圆锥齿传动效率η5=0.95
闭式直齿圆柱齿传动效率η6=0.97
b.总效率η=η1η22η33η4η5η6=0.96×0.992×0.983×0.99×0.95×0.97=0.808
c.所需电动机的输出功率Pr=Pw/η=2.4/0.808=3kw
3.选择电动机的型号
查参考文献[1]表4-12.2得表1.1
方案号
电机
类型
额定
功率
同步
转速
满载
转速
总传
动比
1
Y100L2-4
3
1500
1420
22.294
2
Y132S-6
3
1000
960
15.072
根据以上两种可行同步转速电机对比可见，方案2传动比小且质量价格也比较合理，所以选择Y132S-6型电动机。
三，动和动力参数的计算
6.分配传动比
（1）总传动比i=15.072
（2）各级传动比：
直齿轮圆锥齿轮传动比i12=3.762，
直齿轮圆柱齿轮传动比i23=4
（3）实际总传动比i实=i12i34=3.762×4=15.048,
∵Δi=0.021﹤0.05，故传动比满足要求满足要求。
7.各轴的转速（各轴的标号均已在图1.1中标出）
n0=960r/min，n1=n0=960r/min，n2=n1/i12=303.673r/min，n3=n2/i34=63.829r/min，n4=n3=63.829r/min
8.各轴的功率
η=0.808
Pr=3kw
选用三相异步电动机Y132S-6
p=3kw
n=960r/min
i=15.072
i12=3.762
i23=4
n0=960r/min
n1=960r/min
n2=303.67r/min
n3=63.829r/min
n4=63.829r/min
3.
计算内容
计算结果
p0=pr=3kw，p1=p0η2=2.970kw,p2=p1η4η3=2.965kw,p3=p2η5η3=2.628kw,p4=p3η2η3=2.550kw
4.各轴的转矩，由式：
T=9.55Pi/ni可得：
T0=29.844N·m,T1=29.545N·m,T2=86.955N·m,
T3=393.197N·m,T4=381.527N·m
四，传动零件的设计计算
1.闭式直齿轮圆锥齿轮传动的设计计算
a．选材：
小齿轮材料选用45号钢，调质处理，HB=217~255，
σHP1=580Mpa，σFmin1=220Mpa
大齿轮材料选用45号钢，正火处理，HB=162~217，
σHP2=560Mpa，σFmin2=210Mpa
b.由参考文献[2]（以下简称[2]）式（5—33），计算应力循环次数N：
N1=60njL=60×960×1×8×11×250=1.267×10
N2=N1/i2=1.267×10/3=2.522×10
查图5—17得ZN1=1.0，ZN2=1.12，由式（5—29）得
ZX1=ZX2=1.0，取SHmin=1.0，ZW=1.0，ZLVR=0.92，
∴[σH]1=σHP1ZLVRZWZX1ZN1/SHmin=580×0.92=533.6Mpa，
[σH]2=σHP2ZN2ZX2ZWZLVR/SHmin=560×1.12×0.92=577Mpa
∵[σH]1>[σH]2，∴计算取[σH]=[σH]2=533.6Mpa
c．按齿面接触强度设计小齿轮大端模数（由于小齿轮更容易失效故按小齿轮设计）：
取齿数Z1=21，则Z2=Z1i12=3.762×32=79，取Z2=79
∵实际传动比u=Z2/Z1=79/21=3.762，且u=tanδ2=cotδ1，
∴δ2=72.2965
=72
1635，δ1=17.7035
=17
4212，则小圆锥齿轮的当量齿数zm1=z1/cosδ1=21/cos17.7035
=23，zm2=z2/cosδ2=79/cos72.2965
=259.79
p0=3kw
p1=2.970kw
p2=2.965kw
p3=2.628kw
p4=2.550kw
T0=29.844N·m
T1=29.545N·m
T2=86.955N·m
T3=393.197N·m
T=381.527N·m
σHP1=580Mpa，
σFmin1=220Mpa
σHP2=560Mpa，
σFmin2=210Mpa
[σH]=533.6Mpa
圆锥齿轮参数
Z1=21
Z2=79
δ1=17
4212
δ2=72
1635
4.
计算内容
计算结果
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进入店铺搜索二级圆锥齿轮减速器可获得此设计的整套资料，下面为此套资料的文件列表截图
由[2]图5-14，5-15得
YFa=2.8，Ysa=1.55，YFa2=2.23，Ysa2=1.81
ZH=√2/cosα×sinα=√2/cos20
×sin20
=2.5
由[2]表11-5有ZE=189.8，取Kt·Z
=1.1，由[2]取K=1.4
又∵T1=28.381N·m，u=3.762，фR=0.3
由[2]式5-56计算小齿轮大端模数：
m≥√4KT1YFaYsa/{фRZ
[σF]（1-0.5фR）2√u2+1}
将各值代得m≥1.498
由[2]表5-9取m=3㎜
d．齿轮参数计算：
大端分度圆直径d1=mz1=3×21=63㎜，d2=mz2=3×79=237㎜
齿顶圆直径da1=d1+2mcosδ1=63+6cos17.7035=68.715㎜，
da2=d2+2mcosδ2=237+6cos72.2965
=238.827㎜
齿根圆直径df1=d1-2.4mcosδ1=63-7.2cos17.7035
=56.142㎜
df2=d2-2.4mcosδ2=237-7.2×cos72.2965
=231.808㎜
齿轮锥距R=√d1+d2/2=122.615㎜，
大端圆周速度v=∏d1n1/60000=3.14×63×960/60000=3.165m/s，
齿宽b=RфR=0.3×122.615=36.78㎜
由[2]表5-6，选齿轮精度为8级
由[1]表4.10-2得Δ1=（0.1～0.2）R
=（0.1～0.2）305.500=30.05～60.1㎜
取Δ1=10㎜，Δ2=14㎜,c=10㎜
轮宽L1=（0.1～0.2）d1=（0.1～0.2）93=12.4㎜
L2=（0.1～0.2）d2=（0.1～0.2）×291=39㎜
e．验算齿面接触疲劳强度：
按[2]式5-53
σH=ZHZE√2KT1√u+1/[bd
u（1-0.5фR）2]，代入各值得
圆锥齿轮参数
m=3㎜
d1=63㎜
d2=237㎜
da1=68.715㎜
da2=238.827㎜
df1=56.142㎜
df2=231.808㎜
R=122.615㎜
v=3.165m/s
b=36.78㎜
Δ1=10㎜
Δ2=14㎜
c=10㎜
L1=12.4㎜
L2=39㎜
5.
计算内容
计算结果
σH=470.899﹤[σH]=533.6Mpa
∴小齿轮满足接触疲劳强度，且大齿轮比小齿轮接触强度高，故齿轮满足接触强度条件
f．齿轮弯曲疲劳强度校核：
按[2]式5-55
由[2]图5-19得YN1=YN2=1.0，
由[2]式5-32及m=2﹤5㎜，得YX1=YX2=1.0
取YST=2.0，SFmin=1.4，由[2]式5-31计算许用弯曲应力：
[σF1]=σFmin1YFa1Ysa1YST/SFmin=220×2.0/1.4=314.29Mpa
[σF2]=σFmin2YFa2Ysa2YST/SFmin=210×2.0/1.4=300Mpa
∵[σF1]﹥[σF2]，∴[σF]=[σF2]=300Mpa
由[2]式5-24计算齿跟弯曲应力：
σF1=2KT1YFa1Ysa1/[b1md1（1-0.5фR）]=2×1.4×80070×2.8×1.55/0.85×2×28.935×62=181.59﹤300Mpa
σF2=σF1YFa2Ysa2/（YFa1Ysa1）=181.59×1.81×2.23/（2.8×1.55）=178.28﹤300Mpa
∴两齿轮满足齿跟弯曲疲劳强度
2.闭式直齿轮圆柱齿轮传动的设计计算
a．选材：
小齿轮材料选用45号钢，调质处理，HB=217~255，
σHP1=580Mpa，σFmin1=220Mpa
大齿轮材料选用45号钢，正火处理，HB=162~217，
σHP2=560Mpa，σFmin2=210Mpa
b.由参考文献[2]（以下简称[2]）式（5—33），计算应力循环次数N：
N1=60njL=60×960×1×8×11×250=1.267×10
，N2=N1/i23=1.267×10/3=2.522×10
查图5—17得ZN1=1.05，ZN2=1.16，由式（5—29）得
ZX1=ZX2=1.0，取SHmin=1.0，ZW=1.0，ZLVR=0.92，
[σH]1=σHP1ZLVRZWZX1ZN1/SHmin=580×1.05×0.92=560.28MPa
[σH]=533.6Mpa
[σF]=300Mpa
σHP1=580Mpa
σFmin1=220Mpa
σHP2=560Mpa
σFmin2=210Mpa
6.
计算内容
计算结果
[σH]2=σHP2ZN2ZX2ZWZLVR/SHmin=560×1.16×0.92=597.63MPa
∵[σH]1>[σH]2，∴计算取[σH]=[σH]2=560.28Mpa
c.按齿面接触强度计算中心距（由于小齿轮更容易失效故按小齿轮设计）：
∵u=i34=4，фa=0.4，
ZH=√2/cosα·sinα=√2/cos200·sin200=2.5
且由[2]表11-5有ZE=189.8，取Kt·Z
=1.1
∴[2]式5-18计算中心距：
a≥（1+u）√KT1（ZEZHZε/[σH]）2/（2uφa）=5×√1.1×86955×2.5×189.8/（2×4×0.4×560.28）=147.61㎜
由[1]表4.2-10圆整取a=160㎜
d．齿轮参数设计：
m=（0.007～0.02）a=180（0.007～0.02）=1.26～3.6㎜
查[2]表5-7取m=2㎜
齿数Z1=2a/m（1+u）=2×160/2（1+4）=32
Z2=uZ1=4×32=128取Z2=128
则实际传动比i=149/31=4
分度圆直径d1=mz1=2×32=64㎜，d2=mz2=2×128=256㎜
齿顶圆直径da1=d1+2m=68㎜，da2=d2+2m=260㎜
齿基圆直径db1=d1cosα=64×cos20o=60.14㎜
db2=d2cosα=256×cos20o=240.56㎜
齿根圆直径df1=d1-2.5m=64-2.5×2=59㎜
df2=d2-2.5m=256-2.5×2=251㎜
圆周速度v=∏d1n2/60×103
=3.14×256×63.829/60×103=1.113m/s，
中心距a=（d1+d2）/2=160㎜
齿宽b=aΦa=0.4×160=64㎜
由[2]表5-6，选齿轮精度为8级
[σH]=560.28Mpa
圆柱齿轮参数
m=2㎜
Z1=32
Z2=128
d1=64㎜
d2=256㎜
da1=8㎜
da2=260㎜
db1=60.14㎜
db2=240.56㎜
df1=59㎜
df2=251㎜
v=1.113m/s
a=160㎜
b=64㎜
7.
计算内容
计算结果
e.验算齿面接触疲劳强度
按电机驱动，载荷平稳，由[2]表5-3，取KA=1.0；由[2]图5-4（d），按8级精度和VZ/100=∏dn/60000/100=0.30144，得Kv=1.03；由[2]表5-3得Ka=1.2；由[2]图5-7和b/d1=72/60=1.2，得KB=1.13；
∴K=KvKaKAKB=1.03×1.2×1.0×1.13=1.397
又∵ɑa1=arccosdb1/da1=arccos（60.14/68）=28.0268
=28
136；
ɑa2=arccosdb2/da2=arccos（2240.56/260）=22.0061
=22
017
∴重合度εa=[z（tanɑa1-tanɑ）+z（tanɑa1-tanɑ）]/2∏=[32（tan28.0268
-tan20）+128（tan22.0061
-tan20）]=1.773
即Zε=√（4-εa）/3=0.862，且ZE=189.8，ZH=2.5
∴σH=ZHZEZε√2KT1（u+1）/bd21u=2.5×189.8×0.862√2×1.397×83510×5.8065/（72×622×5.024）=240.63﹤[σH]=560.28Mpa
∴小齿轮满足接触疲劳强度，且大齿轮比小齿轮接触强度高，故齿轮满足接触强度条件
f．齿轮弯曲疲劳强度校核：
按Z1=32，Z2=128，由[2]图5-14得YFa1=2.56，YFa2=2.18；由[2]图5-15得Ysa1=1.65，Ysa2=1.84
由[2]式5-23计算
Y=0.25+0.75/εa=02.5+0.75/1.773=0.673
由[2]图5-19得YN1=YN2=1.0，
由[2]式5-32切m=2﹤5㎜，得YX1=YX2=1.0
取YST=2.0，Sfmin=1.4，由[2]式5-31计算许用弯曲应力：
[σF1]=σFmin1YFa1Ysa1YST/Sfmin=220×2.0/1.4=314.29Mpa
[σF2]=σFmin2YFa2Ysa2YST/Sfmin=210×2.0/1.4=300Mpa
[σF1]=314.29Mpa
[σF2]=300Mpa
8.
计算内容
计算结果
∵[σF1]﹥[σF2]，∴[σF]=[σF2]=300Mpa
由[2]式5-24计算齿跟弯曲应力：
σF1=2KT1YFa1Ysa1Y/bd1m=2×1.397×83510×2.56×1.65×0.673/（2×64×64）=71.233﹤300Mpa
σF2=σF1YFa2Ysa2/YFa1Ysa1=71.233×1.84×2.18/（2.56×1.65）=67.644﹤300Mpa
∴两齿轮满足齿跟弯曲疲劳强度
五，轴的设计计算
9.减速器高速轴I的设计
a.选择材料：
由于传递中小功率，转速不太高，故选用45优质碳素结构钢，调质处理，
按[2]表8-3查得σB=637Mpa，[σb]-1=59Mpa
b.由扭矩初算轴伸直径：
按参考文献[2]有d≥A√p/n
∵n0=960r/min，p1=2.97kw，且A=0.11~0.16
∴d1≥16~23㎜取d1=20㎜
c.考虑I轴与电机伸轴用联轴器联接。
并考虑用柱销联轴器，因为电机的轴伸直径为dD=38㎜，查[1]表4.7-1选取联轴器规格HL3（Y38×82，Y30×60），根据轴上零件布置，装拆和定位需要该轴各段尺寸如图1.2a所示
d.该轴受力计算简图如图1.2b，齿轮1受力：
（1）圆周力Ft1=2T1/dm1=2×29.545/（64×10-3）=915.52N，
（2）径向力Fr1=Ft1·tanα·cosδ1
=915.52×tan200·cos17.70350=317.44N，
（3）轴向力Fa1=Ft1·tanα·sinδ1
=915.52×tan200·sin17.70350=101.33N，
e.求垂直面内的支撑反力：
∵ΣMB=0，∴Rcy=Ft1（L2+L3）/L2=915.52（74+55）/74=1595.97.97N
∵ΣY=0，∴RBY=Ft1-Rcy=915.52-1595.97=-680.45N，
[σF]=300Mpa
σB=637Mpa，
[σb]-1=59Mpa
d1=20㎜
选用柱销联轴器
HL3（Y38×82，Y30×60）
Ft1=915.52N
Fr1=317.44N
Fa1=101.33N
Rcy=1595.97N
RBY=-680.45N
9.
计算内容
计算结果
∴垂直面内D点弯矩Mdy=0，M
=RcyL3+RBY（L2+L3）=1595.97×55-680.45×129=3662.14N·㎜=3.662N·m
f.水平面内的支撑反力：
∵ΣMB=0，∴RCz=[Fr1（L3+L2）-Fa1dm1/2]/L2=[317.44（74+55）-680.45×64]/74=419.07N，
∵ΣZ=0，∴RBz=Fr1-RCz=317.44-419.07=-101.63N，
∵水平面内D点弯矩MDz=0，M
=RCzL3+RBz（L3+L2）=419.07×55-101.63×129=-7.095N·m
g.合成弯矩：
MD=√M
+M
=0N·m，
M
=√M
+M
=7.98N·m
h.作轴的扭矩图如图1.2c所示，
计算扭矩：
T=T1=29.545N·m
I.校核高速轴I：
根据参考文献[3]第三强度理论进行校核：
由图1.2可知，D点弯矩最大，故先验算D处的强度，
∵MD＜M
，∴取M=M
=7.98N·m，
又∵抗弯截面系数：
w=∏d3min/32=3.14×203/32=1.045×10
m
∴σ=√M
+T
/w=√7.98
+29.545
/1.045×10
=39.132≤[σb]-1=59Mpa
故该轴满足强度要求。
2.减速器低速轴II的设计
a.选择材料：
因为直齿圆柱齿轮的小轮直径较小（齿跟圆直径db1=62㎜）需制成齿轮轴结构，故与齿轮的材料和热处理应该一致，
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