A Gear Digital Design Method and Platform

Abstract

A digital gear design method and platform integrates gear design services and gear parameter optimization services to improve gear design efficiency. At the same time, by using a large amount of data in databases such as material libraries, heat treatment libraries, and SN curve libraries, a multi-objective genetic algorithm performs multi-objective optimization of the material parameters, heat treatment process parameters, and strengthening process parameters of gears for life and cost, achieving efficient gear design and parameter optimization, ensuring the efficiency and accuracy of gear design; while reducing design costs and improving product reliability.

Description

Technical Field

[0001] The present invention belongs to the technical field of gear design, and particularly relates to a gear digital design method and platform. Background Art

[0002] With the development of industrial automation and intelligent manufacturing, gears, as key components in mechanical transmission systems, play a crucial role in the performance of the entire transmission system. Gear design is one of the important steps in the design of transmission systems. Traditional gear design methods often rely on the experience of engineers, with low efficiency and high costs. In addition, a large amount of information such as materials, heat treatment, and processing technologies needs to be searched during the design process. These data are not integrated, and searching for them takes a lot of time. Most existing gear parameter optimization methods rely on manual experience, lacking systematicness and efficiency, and unable to fully utilize the advantages of a large amount of gear-related design, processing, and test data accumulated in the past. Summary of the Invention

[0003] Aiming at the above problems, the purpose of the present invention is to provide a gear digital design method and platform to solve the problems of traditional gear design relying on experience and low efficiency.

[0004] To achieve the above purpose, the technical solutions adopted by the present invention include:

[0005] A gear digital design method includes the following steps:

[0006] S1. Design the macroscopic parameters of the gear according to the gear design conditions to obtain a gear macroscopic parameter design report; the gear design conditions include at least the load spectrum, center distance, speed ratio, and accuracy of a pair of gears;

[0007] S2. Perform modification judgment on the macroscopic parameters of the gear to obtain a modification result and generate a gear modification report; if it is judged that no modification is required, the modification result is no modification; if it is judged that modification is required, select a modification method and calculate the modification result;

[0008] S3. Obtain the SN curve, and perform strength judgment on the macroscopic parameters of the gear and their corresponding modification results through the SN curve and the load spectrum; if the strength judgment fails, it is necessary to re-execute S1 to design the macroscopic parameters of the gear; if the strength judgment passes, generate a gear strength judgment report;

[0009] S4. Conduct a machining feasibility analysis on the macro parameters of the gears that pass the strength judgment and their corresponding modification results. If the machining conditions cannot be met, it is necessary to re-execute S1 to design the macro parameters of the gears. If the machining conditions are met, determine whether the existing cutting tools can machine this pair of gears. If they can be machined, directly select the existing cutting tools in the cutting tool data and machine the gears. If there are no existing cutting tools available, perform customized cutting tool design and machine the gears, generating a cutting tool call / design report.

[0010] S5. Obtain material data, heat treatment data, strengthening process data, and SN curves. Through multi-objective genetic algorithms, perform multi-objective optimization of the life and cost of the material parameters, heat treatment process parameters, and strengthening process parameters of the gears using the material data, heat treatment process data, strengthening process data, SN curves, and the macro parameters of the gears that pass the combination strength judgment and their corresponding modification results, obtaining the gear material, heat treatment process, and strengthening process, and generating a material, heat treatment process, and strengthening process report.

[0011] S6. Select a 3D model, and input the macro parameters of the gears that pass the strength judgment and their corresponding modification results into the 3D model to generate a gear 3D model and a gear 2D drawing.

[0012] S7. Select a simulation model, and input the macro parameters of the gears that pass the strength judgment and their corresponding modification results, the gear material, heat treatment process, and strengthening process obtained in S5, and the gear 3D model obtained in S6 into the simulation model for simulation analysis, and generate a model simulation analysis report.

[0013] Further, it also includes the following steps: S8. Integrate the gear macro parameter design report in S1, the gear modification report in S2, the gear strength judgment report in S3, the cutting tool call / design report in S4, the material, heat treatment process, and strengthening process report in S5, the gear 3D model and gear 2D drawing in S6, and the model simulation analysis report in S7 to generate a gear design report.

[0014] Preferably, the macro parameters of the gears at least include the number of teeth, module, pressure angle, helix angle, helix direction, tooth width, modification coefficient, addendum coefficient, and dedendum coefficient.

[0015] Preferably, the modification includes tooth profile modification and tooth direction modification. The tooth profile modification at least includes K modification and parabolic modification, and the tooth direction modification at least includes barrel modification and helix modification.

[0016] Preferably, the strength judgment at least includes contact strength, bending strength, and scuffing strength.

[0017] A gear digital design system includes a user UI interface, an application layer, a gear database layer, and a cloud platform infrastructure.

[0018] The user UI interface is used to implement the interaction between the application layer and the user;

[0019] The application layer includes a gear design module, a gear parameter optimization module, and a user management module. The gear design module is used to execute steps S1 - S4 of the gear digital design method disclosed in this application; the gear parameter optimization module is used to execute steps S5 - S7 of the gear digital design method disclosed in this application; the user management module is used to manage user information;

[0020] The gear database layer includes the following databases: material library, heat treatment library, strengthening library, SN curve library, tool library, 3D model library, and simulation model library; the material library is used to provide material data, the heat treatment library is used to provide heat treatment data, the strengthening library is used to provide strengthening process data, the SN curve library is used to provide SN curves, the tool library is used to provide tool data, the 3D model library is used to provide 3D models, and the simulation model library is used to provide simulation models;

[0021] The cloud platform infrastructure is used to call each database in the gear database layer and send it to the application layer, as well as store the gear design report.

[0022] Compared with the prior art, the advantages of the present invention are:

[0023] (1) The gear digital design method and platform of the present invention realize efficient gear design and parameter optimization, improve the efficiency and accuracy of gear design, reduce design costs, and enhance the reliability of products.

[0024] (2) The gear digital design method and platform of the present invention integrate gear design services and gear parameter optimization services, improve gear design efficiency. At the same time, using a large amount of data in databases such as the material library, heat treatment library, and SN curve library, the multi - objective genetic algorithm performs multi - objective optimization of the life and cost of the material parameters, heat treatment process parameters, and strengthening process parameters of the gear, ensuring the high efficiency and accuracy of gear design. Brief Description of the Drawings

[0025] The drawings are used to provide a further understanding of the present invention, and constitute a part of the specification. Together with the following specific embodiments, they are used to explain the present invention, but do not constitute a limitation to the present invention. In the drawings:

[0026] Figure 1 is the architecture of the gear digital design platform of the present invention. Detailed Description of the Invention

[0027] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below. The described embodiments should not be regarded as limitations on the present invention. All other embodiments obtained by those of ordinary skill in the art without creative efforts fall within the scope of protection of the present invention.

[0028] In the following description, reference is made to "this embodiment", which describes a subset of all possible embodiments. However, it can be understood that "this embodiment" can be the same subset or different subsets of all possible embodiments and can be combined with each other without conflict. Unless otherwise defined, all technical and scientific terms used in the embodiments of the present invention have the same meaning as commonly understood by those skilled in the technical field to which the embodiments of the present invention belong. The terms used in the embodiments of the present invention are only for the purpose of describing the embodiments of the present invention and are not intended to limit the present invention.

[0029] Embodiment 1

[0030] This embodiment discloses a gear digital design method, including the following steps:

[0031] S1. Design the macroscopic parameters of the gear according to the gear design conditions, as shown in Table 1, to obtain a gear macroscopic parameter design report. The gear design conditions in this embodiment include the load spectrum of a pair of gears (torque 2800 Nm, rotational speed 1800 Rpm, time 50 h), center distance (139.5 mm), speed ratio (1.4 ± 0.1), and accuracy (Grade 8). The macroscopic parameters of the gear in this embodiment at least include the number of teeth, module, pressure angle, helix angle, helix direction, tooth width, modification coefficient, addendum coefficient, and dedendum coefficient. The gears designed in this embodiment are all cylindrical gears.

[0032] Table 1 Macroscopic Parameters of the Gear

[0033]

[0034] S2. Perform modification judgment on the macroscopic parameters of the gear to obtain the modification result and generate a gear modification report. If it is judged that no modification is required, the modification result is no modification required. If it is judged that modification is required, select the modification method and calculate the modification result.

[0035] The modification includes tooth profile modification and tooth direction modification. The tooth profile modification at least includes K modification and parabolic modification. The tooth direction modification at least includes barrel modification and helix modification. The modification result in this embodiment is that modification is required, and the modification method is selected as barrel modification, and the barrel amount is 0.015 - 0.035, and a gear modification report is generated.

[0036] S3. Obtain the SN curve. Based on the SN curve and the load spectrum, perform strength judgments on the macroscopic parameters of the gear and their corresponding modification results, including contact strength, bending strength, and scuffing strength, with the safety factors all greater than 1;

[0037] If the strength judgment fails, it is necessary to re - execute S1 to design the macroscopic parameters of the gear; in this embodiment, the strength judgment passes, and a gear strength judgment report is generated.

[0038] S4. After passing the strength judgment, determine that the machining method of the designed gear is shaving. Conduct a machining feasibility analysis on the macroscopic parameters of the gear that has passed the strength judgment and their corresponding modification results through a tool verification program. If the machining conditions cannot be met, it is necessary to re - execute S1 to design the macroscopic parameters of the gear; in this embodiment, the shaving machining meets the machining conditions, then determine whether the existing tools can machine this pair of gears;

[0039] If it can be machined, directly select the existing tools in the tool data and machine the gear. If there are no existing tools available, conduct a customized tool design and machine the gear, generating a tool call / design report;

[0040] Conduct a machining feasibility analysis on the gear that has passed the strength judgment through a tool verification program. This pair of gears can be shaved. Call the data in the tool library and search whether the existing tools in the tool library data can machine this pair of gears. There is no substitute tool in the tool library, so conduct a customized tool design and machine the gear, generating a tool call / design report.

[0041] The tool verification program disclosed in this embodiment is designed based on the gear tool design book using existing commercial software, such as romax or kisssoft, to check whether the gear parameters can be machined.

[0042] S5. Obtain material data, heat treatment data, strengthening process data, and the SN curve. Use the multi - objective genetic algorithm on the material data, heat treatment process data, strengthening process data, SN curve, and the macroscopic parameters of the gear that has passed the combination strength judgment and their corresponding modification results to perform multi - objective optimization of the gear's material parameters, heat treatment process parameters, and strengthening process parameters for life and cost, obtaining the gear material, heat treatment process, and strengthening process, and generating a material, heat treatment process, and strengthening process report.

[0043] The multi - objective optimization of life and cost disclosed in this embodiment is as follows:

[0044] ① Design a cost objective function as minimizing the cost, as shown in Equation (1)

[0045] (1)

[0046] The material data of this embodiment at least includes material density, the price of the material per unit mass, and the lifespan of the material; in formula (1) is the material cost, specifically see formula (2), and it is calculated based on the material cost per unit volume or mass in the material library, combined with the volume or mass of the gear:

[0047] (2)

[0048] where is the material density, is the volume of the gear, is the price of the material per unit mass.

[0049] The heat treatment process data of this embodiment at least includes the cost coefficients corresponding to different heat treatment methods; in formula (1) is the heat treatment process cost, see formula (3), and according to the selection of the heat treatment process, the heat treatment cost per unit volume or mass can be obtained from the heat treatment library:

[0050] (3)

[0051] where is the cost coefficient corresponding to different heat treatment methods.

[0052] The strengthening process parameters of this embodiment at least include the cost coefficients corresponding to different strengthening process methods; in formula (1) is the strengthening process cost, see formula (4), and it is calculated according to the cost of each process in the shot peening process library:

[0053] (4)

[0054] where is the cost coefficient corresponding to different strengthening process methods.

[0055] The cost calculation of this embodiment can also introduce various costs such as manufacturing, transportation, and energy in the gear manufacturing process. In formula (1) is the cost of manufacturing, transportation, energy, etc. in the gear manufacturing process.

[0056] ② The design life objective function is to maximize the lifespan, see formula (5)

[0057] (5)

[0058] In formula (5) is the lifespan of the material, see formula (6)

[0059] (6)

[0060] where is the gear contact fatigue limit, is the gear contact stress, and both belong to the content in the gear macroscopic parameter design report; is the fatigue life index, directly obtained from the SN curve;

[0061] In Equation (5), and are the correction factors of the strengthening process and heat treatment process on the life respectively, determined according to the life curves of different strengthening processes and heat treatment processes in the SN curve.

[0062] ③Perform multi-objective optimization on the cost objective function and life objective function obtained in ① and ②, with the lowest cost and the longest life as the objectives. After multiple generations of iteration, the optimization function outputs 3 sets of Pareto optimal solutions, specifically as follows:

[0063] Solution 1, 20MnCr5 + hardened layer depth 0.82 - 1.31 + surface hardness 55 - 60 + shot peening, this solution has a lower cost and the lowest safety factor of 1.05;

[0064] Solution 2, 20Cr2Ni4 + hardened layer depth 1.12 - 1.61 + surface hardness 55 - 60 + shot blasting, this solution has a higher cost and the lowest safety factor of 1.15;

[0065] Solution 3, 8620RH + hardened layer depth 0.82 - 1.31 + surface hardness 55 - 60 + shot blasting, this solution has a medium cost and the lowest safety factor of 1.1.

[0066] In this embodiment, Solution 3 is finally selected according to the requirements, and a report on materials, heat treatment processes and strengthening processes is generated.

[0067] S6, Select and obtain the 3D model, and input the macroscopic parameters of the gear whose strength judgment is passed and their corresponding modification results into the 3D model to generate the gear 3D model and gear 2D drawings.

[0068] S7, Select the simulation model, and input the macroscopic parameters of the gear whose strength judgment is passed and their corresponding modification results, the gear materials, heat treatment processes and strengthening processes obtained in S5, and the gear 3D model obtained in S6 into the simulation model and perform simulation analysis, and generate a model simulation analysis report.

[0069] S8, Integrate the gear macroscopic parameter design report in S1, the gear modification report in S2, the gear strength judgment report in S3, the tool call / design report in S4, the report on materials, heat treatment processes and strengthening processes in S5, the gear 3D model and gear 2D drawings in S6, and the model simulation analysis report in S7, and generate a gear design report.

[0070] Embodiment 2

[0071] This embodiment discloses a gear digital design system, which is based on the gear digital design method of Embodiment 1 and includes a user UI interface, an application layer, a gear database layer, and a cloud platform infrastructure;

[0072] The user UI interface is used to realize the interaction between the application layer and the user, and realize the functions of receiving and displaying user information, including obtaining the gear design conditions input by the user and sending them to the application layer, and providing each report obtained by the application layer to the user according to the user's needs;

[0073] The application layer includes a gear design module, a gear parameter optimization module, and a user management module. The gear design module is used to execute steps S1 - S4 of the gear digital design method disclosed in Embodiment 1; the gear parameter optimization module is used to execute steps S5 - S7 of the gear digital design method disclosed in Embodiment 1; the user management module is used to manage user information, including user registration, login and other information;

[0074] The gear database layer includes a material library, a heat treatment library, a strengthening library, an SN curve library, a tool library, a 3D model library, and a simulation model library. The material library is used to provide material data, the heat treatment library is used to provide heat treatment data, the strengthening library is used to provide strengthening process data, the SN curve library is used to provide SN curves, the tool library is used to provide tool data, the 3D model library is used to provide 3D models, and the simulation model library is used to provide simulation models;

[0075] The cloud platform infrastructure includes a network and a storage module. The network is used to enable the application layer to call each database in the gear database layer and send it to the application layer, and the memory is used to store gear design reports.

[0076] The preferred embodiments of the present disclosure have been described in detail above in conjunction with the accompanying drawings. However, the present disclosure is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present disclosure, various simple modifications can be made to the technical solutions of the present disclosure, and these simple modifications all fall within the protection scope of the present disclosure.

[0077] In addition, it should be noted that, in the above specific embodiments, the various specific technical features described can be combined in any suitable manner without conflict. To avoid unnecessary repetition, the present disclosure will not separately describe various possible combination methods.

Claims

1. A gear digital design method, characterized in that: The steps include: S1, design the macro parameters of the gear according to the gear design conditions and obtain the gear macro parameter design report; The gear design conditions include at least the load spectrum, center distance, speed ratio and accuracy of a pair of gears; S2, making modification judgment on the macro parameters of the gear, obtaining modification results, and generating a gear modification report; If it is determined that no shaping is required, the shaping result is that no shaping is required; if it is determined that shaping is required, a shaping method is selected and the shaping result is calculated; S3, obtaining an SN curve, and performing strength judgment on the macro parameters of the gear and its corresponding modification results through the SN curve and the load spectrum; If the strength judgment fails, S1 needs to be re-executed to design the macro parameters of the gear; if the strength judgment passes, a gear strength judgment report is generated; S4, conduct a processing feasibility analysis on the macro parameters of the gears that have passed the strength judgment and their corresponding modification results. If the processing conditions cannot be met, it is necessary to re-execute S1 to design the macro parameters of the gears; if the processing conditions are met, determine whether the existing tools can process the pair of gears; If the gear can be processed, the existing tool in the tool data is directly selected to process the gear. If there is no existing tool to choose from, a customized tool is designed to process the gear and generate a tool call / design report. S5, obtaining material data, heat treatment data, strengthening process data and SN curve, combining the material data, heat treatment process data, strengthening process data, SN curve and macro parameters of the gear that has passed the strength judgment and its corresponding modification results, and performing multi-objective optimization of the gear material parameters, heat treatment process parameters and strengthening process parameters in terms of life and cost through a multi-objective genetic algorithm, obtaining the gear material, heat treatment process and strengthening process, and generating a material, heat treatment process and strengthening process report; S6, selecting a three-dimensional model, and inputting the macro parameters of the gear that has passed the strength judgment and its corresponding modification results into the three-dimensional model, to generate a three-dimensional model of the gear and a two-dimensional drawing of the gear; S7, select the simulation model, and input the macro parameters of the gear that passes the strength judgment and its corresponding modification results, the gear material, heat treatment process and strengthening process obtained in S5, and the gear three-dimensional model obtained in S6 into the simulation model and perform simulation analysis, and generate a model simulation analysis report.

2. The gear digital design method according to claim 1, characterized in that: The following steps are also included: S8 integrates the gear macro parameter design report of S1, the gear modification report of S2, the gear strength judgment report of S3, the tool calling / design report of S4, the material and heat treatment process and strengthening process report of S5, the gear three-dimensional model and gear two-dimensional drawing of S6, and the model simulation analysis report of S7 to generate a gear design report.

3. The gear digital design method according to any one of claims 1 or 2, characterized in that: The macro parameters of the gear include at least the number of teeth, module, pressure angle, helix angle, hand direction, tooth width, modification coefficient, tooth top height coefficient and tooth root height coefficient.

4. The gear digital design method according to any one of claims 1 or 2, characterized in that: The shaping includes tooth profile shaping and tooth direction shaping. The tooth profile shaping includes at least K shaping and parabola shaping, and the tooth direction shaping includes at least drum shaping and helix shaping.

5. The gear digital design method according to any one of claims 1 or 2, characterized in that: The strength judgment includes at least contact strength, bending strength and bonding strength.

6. A gear digital design system, characterized in that: Including user UI interface, application layer, gear database layer and cloud platform infrastructure; The user UI interface is used to realize the interaction between the application layer and the user; The application layer includes a gear design module, a gear parameter optimization module and a user management module, wherein the gear design module is used to execute steps S1-S4 of the gear digital design method according to any one of claims 1-5; the gear parameter optimization module is used to execute steps S5-S7 of the gear digital design method according to any one of claims 1-5; and the user management module is used to manage user information; The gear database layer includes the following databases: material library, heat treatment library, strengthening library, SN curve library, tool library, three-dimensional model library and simulation model library; the material library is used to provide material data, the heat treatment library is used to provide heat treatment data, the strengthening library is used to provide strengthening process data, the SN curve library is used to provide SN curves, the tool library is used to provide tool data, the three-dimensional model library is used to provide three-dimensional models, and the simulation model library is used to provide simulation models; The cloud platform infrastructure is used to call various databases of the gear database layer and send them to the application layer, as well as store gear design reports.

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