壳体设计规范.ppt

Introduction介绍FunctionOverview功能概述GearboxTypes壳体类型DesignGuidelines设计指南Gears&Shafts,Bearings,Fasteners,Flanges,FlangeSealing,Ribs,Joints,Radii,Wallthickness,Corrosion,Surfacetreatment,NVH齿轮、轴，轴承、紧固件、凸缘、凸缘密封、筋、过渡连接，倒圆角，壁厚，腐蚀，表面处理、噪音MaterialsOptions材料选择MaterialWeight材料重量SuitableCastingOptions铸造类型SandCasting砂型铸造GravityDie重力铸造,DieCasting压铸LowPressure低压HighPressure高压CastingToleranceComparison铸造公差比较MaterialComparison材料比较HeatTreatment-Comparison热处理-比较MaterialMachinability材料可加工性能TypicalTransmissioncasematerials传统变速箱壳体材料Pro/ECasingModellingProcessPro/E的建模过程TypicalDesignProcess典型的设计过程CasingDesign-Summary外壳设计-总结CaseStudyMgvsAluminium案例分析-镁合金与铝合金比较,Theaimofthisguideistohelpthedesignertomakeaninformedchoicewhendesigningatransmissioncaseorcasings.Thechoicestakenwilldependonmanyfactorssuchas:本指南的目的是帮助设计人员在设计变速箱外壳时，作出正确的选择。需要考虑的因素如下：,Time时间Availabletimetodesignandormanufacture设计和制造所用时间Cost成本CostTargets(Ofdesign,Materials,ManufacturingandProcesses)成本目标（设计，材料，制造）Numberofunits组件数量Small,mediumoflargevolumes小件，中件，大件Function功能Structural,Nonstructural,LoadedvsNon-Loaded结构性或者非结构性功能，承载或者非承载结构,Size尺寸Overallsizeoftransmission,Castability,Machinability,变速器外形尺寸，铸造性能，机械加工性能Complexity复杂性InfluencedbySizeandFunctioncompromisedbyCastability/machinability受尺寸、功能、铸造性能/可加工性的影响Material材料Iron,AluminumorMagnesiumAlloys铁，铝合金或镁合金,Environment环境ExternalRegime,packageaswellasrecyclabilityofmaterials外部政策，包装以及材料可回收性Duty工况Life,DutyCycle,Loadregime,TorqueandPower路谱，负载，扭矩和动力Weight重量TargetVehicleweight,Transmissiontargetweightseematerials目标车辆的重量，变速箱的目标重量-由变速箱材料决定VehicleType车辆类型Transverse,Longitudinal,FWD,RWD,2WD,4WD横置，纵置，前轮驱动，后轮驱动，两轮驱动，四轮驱动,Toprovideasuitablehousingsothatspeedandtorquecanbetransmittedfromtheinputviashafts,gearsorpulleystotheoutput.Thesespeedsandtorquescanbe一个结构合理的壳体，可以使速度和扭矩从发动机经过输入轴，齿轮或滑套传到输出轴。使速度和扭矩达到如下变化：Continuous连续Stepped阶梯Constantlychanging不断变化的Speedsandtorquesimpartloadsasaresultofthegears,shaftanddifferentials.Thehousingreacttheseloadsandforces齿轮，轴和差速器的速度和转矩最终以力的形式作用到壳体,ProvideanOilreservoirforcoolingandlubrication为变速箱冷却和润滑提供油路系统Inadditionmountorsupportothersubsystemssuchas为其他子系统提供安装支撑，如下：DriveClutches驱动离合器CSCEngineStarterMotors发动机起动马达ManualShifterSystems手动换档系统Shiftmechanisms,Rails&Forks,CableBrackets换挡机构、手柄、拨叉、拉线支架HydraulicShifterSystems液压换挡系统AutomatedManualShiftMechanisms自动换挡系统WetClutchesPowershiftetcPumps,Accumulators,Coolers,Filtersetc湿式离合器-动力换档原件，如泵，蓄能器，冷却器，过滤器等ParkBrakes驻车制动,DependingonthetypeofLoadsandinstallationcasingscanbedividedintotwotypes:根据载荷的不同，可将壳体分为两类：NonStructuraltheloadsthecasingseesarefromtheshaftsandgearsonlywiththecasinghangingofftheengineandthevehiclesidemember非结构性壳体-齿轮和轴作用到壳体上的作用力最后作用到发动机和车辆侧梁privatevehicles乘用车commercialvehicles商用车Structural结构性壳体Tractorchassis-Transaxles牵引车底盘-驱动桥Thetransmissioncaseisanintegralpartofthechassis.变速箱是底盘的一个组成部分Motor-sportapplications赛车的应用TransaxledesignsVehicleloadsgoingthroughthecasingsuchasTractorTransaxlesuspensionhardpointslocatedonthem.驱动桥设计-车辆荷载通过变速箱壳体悬置部位传递到它们,NonStructural,Motor-sportTransaxle,TractorTransaxle牵引车驱动桥,Thesearethemaincomponentsfortransferringspeedandtorqueinatransmission在变速箱结构中，这些是用于传递速度和扭矩主要组件。Asaresulttheyimpartthefollowingtypeofloadsonthecasing齿轮和轴从下面几个方面影响作用到壳体上的作用力：SeparatingLoadsareeffectivelytryingtopushtheeachshaftandgearapart.分离载荷（径向力）有效地将每个轴和齿轮推开。TangentialLoadsactnormaltothebasecirclearearesultofthegearsreactingagainsteachother.垂直于基圆的切向力是齿轮之间相互作用的结果AxialLoadsactalongtherotatingaxisofthegearandshaft.轴向载荷沿齿轮和轴的轴向传递。Helicalgearsoverspurgearswillresultinhavingtoconsideraxialloadeffects.Thelargerthehelixanglethelargertheload.Othergearformsthatimpartaxialloadsincludebevelandhypoidgearing斜齿轮与直齿轮相比，必须考虑轴向载荷的影响。螺旋角越大轴向载荷越大。锥齿轮和准双曲面齿轮也必须考虑轴线载荷的影响,Thebearingsaretheelementsthatactuallyinteractwiththecasing.Itisherethatthegearingloadspassthroughtherollingelementsintothecasing.Thesizeandtypeareverymuchdependantontheloadsanticipatedaswellasthelayoutoftherotatingpartswithinit.轴承是直接与外壳相互作用的元件。齿轮力最终通过轴承内部的旋转件传递到外壳。轴承尺寸和类型的选择依赖于受力大小以及内部旋转件的布局。DeepGrooveBall-深沟球轴承CylindricalRoller圆柱滚子轴承TaperRoller圆锥滚子轴承Theseating/mountingofthebearingsinthecasingsneedscarefulconsideration壳体轴承的安装需要进行充分的考虑Bore轴承孔Thiswillensurethatthebearingretainsitshapewhenloaded这将确保轴承在受力时形状保持不变。,Needstobemanufacturedtotighttolerancestoensuretheboreisroundandconcentrictotheshaftaxis.需要严格按照公差加工，以确保该孔的圆度并且于轴的轴线同心。Theamountofinterference/clearancedependsonthetypeofbearingandload轴承与轴承孔之间的配合间隙取决于轴承类型和轴承力Typicaltransmissionapplicationstheouterraceisheldinthecasingwithainterferencefit.传统的变速箱应用，轴承外圈与壳体采用过盈配合Forbearingsthatrequiresomeadjustmentduringbuildatransitionfitcanbeemployed.一些需要调整的轴承，一般采用过度配合。Generalrecommendations一般建议Aluminum-0.001mmofinterferencepermmofdiameter.铝合金壳-直径方向每毫米过盈量为0.001mmMagnesium-0.0015mmofinterferencepermmofdiameter.镁合金壳-直径方向每毫米过盈量为0.0015mm,Abutment止口Thisdiametershouldconformtobearingmanufacturersrecommendations.Inadditiontheradii(orundercut)betweentheabutmentandboreshouldbealsoasperbearingmanufacturersrecommendationselsethebearingwillnotseatcorrectlyandinfluenceanypreloadvalues.该直径应符合轴承制造商的建议。此外，轴承挡圈与轴承孔之间的倒圆角，应该也是按照轴承制造商建议，否则轴承将不能正确安装和影响轴承作用到壳体上力的分布。Extraction拆卸Suitableconsiderationshouldbegiventobearing(fullorpartsuchasouterrace)extraction.Thiscouldtaketheformofslotsintheabutmentfacetoallowapullingtool.适当考虑轴承（全部或部分，如外圈）的拆卸。可以采取在接触面增加槽的方式来允许拆卸工具将轴承拆除。BearingCages轴承保持架Inthecaseoftaperrollerbearingsprovisionforbearingcageclearancemayberequired在使用圆锥滚子轴承的情况下，可能需要考虑轴承保持架的间隙。,Lubrication润滑Thebearingwillrequireadequateoilflowtoensurecorrectoperationaswellascoolingtoextendthebearingslife.为提高轴承寿命，轴承将需要足够的润滑油，以确保正常的工作，以及冷却。Suitablegalleriesorslotstoallowtheoiltoenterthebearingneedtobedesigned.设计时，需要设计合理的油槽或者油道，以保证润滑油能够对轴承进行润滑。Toomanyorpositionedinthewrongplacerelativetotheseparationloadscanleadtoareductioninboththecasingandbearingstiffness.油道或油槽布置不合理会产生相应的分离力，从而降低壳体和轴承的刚度,Twosimilarapproachestodirectingoiltobearings(Alsouptheshaftcenterdrilling)两种相似的润滑轴承的方法（轴中心钻孔也可以）,Fastenersinthiscasereferstomountingofcasingshalvesorcoversusingthreadedboltsandscrews用于连接变速箱壳体的紧固件包括螺栓和螺钉。Thefastenersensurewhenproperlyloadedthatthejointfaceintegrityisnotimpededandthereforemaintainthetransmissionsoilcarryingcapacity.当变速箱传递扭矩时，连接螺栓确保壳体连接面不分离，从而保证连接面的密封性能。Todothisasuitablenumberoffastenerscorrectlyspacedandsizedhavingthecorrecttorqueappliedwillensurethis.,为了满足以上要求，必须正确的布置紧固件的数量，选择合适大小的紧固件以及预紧扭矩。Howeverafewrulesshouldbeemployedtohelp.FortappinganddrilldepthsrefertheexistingRicardoGuidelines.可以根据一些简单规则来选择紧固件。根据现有的里卡多手册来确定攻丝和钻孔的深度。Spacingbetweenboltswilldeterminethecontactpatchbetweenthetwocasinghalvesaroundtheflangeensuringagoodseal.asaruleofthumbshouldbenogreaterthan8xBolt螺栓间的间隔将决定两壳体接触面间的密封性能。作为一个经验法则，螺栓间距不大于8*螺栓直径。,SourceRicardoFastenerGuidelinesExtractOnly,螺纹孔尺寸-粗牙,Clearancesfortighteningthefastenershouldbeconsidered.Typicalmethodsinclude必须考虑紧固件工具的安装空间。典型的安装方法包括：spanners,open,andring呆扳手、梅花扳手poweroperatedtoolswithsocketdrivingtools.使用套头的电动工具Boltpatternswithahighnumberboltsaswellasbeingbuiltinhighvolumeswillusethelatterthereforefullconsiderationshouldbegiventothesetoolsandtherepreferredclearances.将来，会出现很多在体积大的结构上装配很多螺栓的情况，因此必须考虑在这种情况下，安装工具所需的安装间隙。,对于六角头紧固件安装间距要求,SourceRicardoFastenerGuidelines,1.52xD,NotRecommended不建议,Al1xDMg-1.125xD,Al-1xDMg1.125xD,D,FlangeJoints凸缘连接Flangejointstiffnesswillensurethefastenerswilldotheirjobcorrectly凸缘连接处刚度将确保紧固件正确地完成他们的工作MgSpecific镁合金的特别要求Allowforthelowermoduluscompressiveproperty.允许较低的抗压模量属性Uselargefillets可以使用大倒角Avoidtappingbreakingthroughboss通过凸台避免攻丝破坏Smoothtransitionofform过度形式平稳Makeflanges50%CastIronBoltPatternsComparedtoCastIron与铸铁相比螺栓的要求SmallerBolts小螺栓Halfthespacing间距减,DifferentArrangementsforimprovingflangestiffnesswithoutaddingmorematerial在不增加材料的前提下，提高凸缘强度的不同方法,PullDirection拔模方向,6mmMinLandwidthforsealant为了密封，宽度最小为6mm,ORingarrangementO型密封圈结构Goodsealingsolutionlowvolumeonly降低结构体积的同时提高密封性Motorsporttypicalapplication赛车的典型应用,CautionORingcanexpandandextrude注意-O型密封圈可能被挤压变形ToOvercomethisSomeapplicationsuseatrapezoidshapedgroove为了克服这种情况，使用梯形沟槽,Ricardoplc2006,Cast45x2orRadiusChamferEnsuresbeadingofSiliconsealant沿半径方向45倒角确保硅密封胶密封良好Preventscontaminationofgearbox防止污染变速箱,NotRecommended不推荐,Jointofunequalsection变截面过渡连接,连接端面与主体的筋一般在过渡处有过渡角,UnprotectedAluminium&magnesiumismoreresistanttoatmospherethanmildstee没有采取保护措施的情况下，铝和镁比低碳钢更不容易生锈Corrosionresistancedecreasesslightlyaswallthicknessincreases随着壁厚的增加，壳体耐腐蚀性略有降低Galvaniccorrosionbetweendissimilarmaterialse.gsteelandmagnesium考虑异性材料间的电偶腐蚀，例如钢铁和镁Gooddesigncanreducetheeffects好的设计能够减少以下影响Ensuringadequatedrainage确保合理的排水Washer/spacertopreventdirectcontactbetweendissimilarmaterials在异性材料之间增加垫片/间隙，防止的直接接触Boltheaddesign螺栓头设计Goodcastingdesigntopreventdustandwateraccumulation好的壳体设计能够防止灰尘和水分积聚UseofsurfacetreatmentsonTransmissionCasings表面处理工艺被用在变速箱壳体设计中NoneforautomotiveUnderbonnetapplicationsAlsothecaseformagnesiumapplications镁合金变速箱使用该工艺Paintingcivilaircraft喷漆-民用飞机Hardanodisingmilitaryaircraft硬质阳极氧化-军用飞机Keronite,GOODDESIGN好的设计,BADDESIGN不好的设计,ElectrolyteAccumulation电解质积累,EffectiveDrainage有效的排水,Example:SteelWasher&MgCasing,Example:UseaHardanodisedaluminiumwasherwithMgCasings在镁合金壳体上使用硬质阳极氧化铝垫圈,PaintingCivilAviation喷漆-民航Recommendedminimumprotection推荐最低保护措施Precededbyachromateconversioncoatingtoactasakeyforthepaint由铬酸盐转化为涂层这个过程是喷漆工艺的关键HardanodiseMilitaryAviation硬质阳极氧化-军用航空Formsthickabrasionresistantcoating表面形成厚的耐磨涂料Inherentporosityrequiringsealingtoformaduplexfilm形成双面膜提高固有孔隙的密封性KeroniteProducesahardceramiclayerpreliminaryformagnesium在镁的表面产生一层坚硬的陶瓷层Increasesabrasivewearresistance-增加耐磨性Providescorrosionprotection-提供防腐蚀保护Reducesfatiguestrengthoftreatedalloylessthanhardanodising降低合金处理时的疲劳强度-比硬阳极氧化低,Transmissionnoise变速箱噪音ResultofTransmissionErrors变速箱设计错误所致ShaftStiffness轴刚度GearMicroGeometry齿轮微观几何HousingFlex壳体柔性PoorHousingdesignCanMagnifytheseerrors壳体的错误设计可以放大这些错误Largeflatareasoncasingscanflex壳体上大面积平面区域增大壳体柔性Changethefrequencyofthesepanelsby通过一下方式改变平面固有频率Ribs筋Step阶梯特征,Steppedsurface,CastIronGray灰铸铁Advantages优点CheapestCastablematerial价格便宜GoodCastability良好的铸造性能Strength强度VeryLargeCastingspossible可铸造超大型铸件ThermalExpansionsimilartosteel热膨胀性跟钢类似Disadvantages缺点Weight重量MachinabilityofHardouterskin外表面的可加工能力AluminiumAlloy铝合金AdvantagesoverIron相比铸铁的优势ManyCastingTechniquesavailable铸造工艺多样性Sand砂型铸造,GravityDie重力铸造LowPressureDie低压铸造HighPressureDie高压铸造HeatTreatabletoimproveproperties通过热处理来提高毛坯性能Highresistancetoshockloading高耐冲击性能Machinability加工性能GoodCorrosionresistance良好的耐腐蚀性DisadvantagesOverIron-相对于铸铁的缺点Thermalexpansionneedstobeaccountedforwhensupportinggearsandshaft需要考虑热膨胀对齿轮和轴孔的影响MagnesiumAlloy镁合金AdvantagesOverAluminium相对于铝合金的优点StrengthtoWeightRatio强度重量比MachinablityVGood加工性能良好DampingAbility阻尼能力,ExcellentDieCastingProperties卓越的压铸性能ThinWallsectionsPossible壁可以更薄ExtendedDieLife模具寿命更长FasterMaterialFlow材料流动性能更好HigherPressurespossible压力可以更高DisadvantagesOverAluminium-相对于铝合金的缺点Lowelasticmodulus弹性模量低Highnotchsensitivity缺口敏感性高Lowhardness硬度低Corrosionhazardpotential潜在的腐蚀危险Recycleability回收能力,Materials-WhyWeight材料-重量因素,WhyWeightisanissueintransmissioncasings为什么在变速箱壳体设计时需考虑重量因素Cost成本Reducedweightisreducedmaterialcost降低重量就是在降低成本Toreduceoverallvehicleweight降低整车重量Improvementsinvehicleperformance提高整车如下性能Acceleration加速性能Emissions排放Fuelconsumption燃油经济性,Improvementsinsafety提高安全性能Brakingeffort制动性能Crashenergy碰撞能量,获得同样载荷时体积质量对比,SuitableCastingProcessSandCasting铸造工艺砂型铸造,SandCasting砂型铸造ThepouringofmoltenmetalintoaSandMould熔融金属的浇注到一个砂型Advantages优点LowEquipmentCost-设备成本低LargestSizeofCastingspossible-可铸造尺寸较大铸件SuitedtoComplexShapesandCores-适用于形状复杂的件VeryLowgasporositypossible-气密性好Versatile-多功能,SuitableCastingProcessSandCasting铸造工艺砂型铸造,Disadvantages缺点WallThicknesslimitations-壁厚有一定限制PoorLinearTolerance4mm/m-铸造公差难以保证，4毫米/米RoughSurfaceFinish6.5-12.5microns-表面粗糙，粗糙度为6.5-12.5微米CoarserGrainSizethanpermanentMouldcastings-表面颗粒比金属型铸造大,SuitableCastingProcessGravityDieCasting铸造工艺重力铸造,GravityDieCasting重力铸造ThepouringofmoltenmetalintoaPermanentmouldundergravityorlowpressure在重力或低压的作用下将熔融金属的压入金属性模具中Advantages优点LowCostthanDiecasting-比压铸成本低HigherCastingRatethanSand-比砂铸铸造效率高Finergrainsize更高的表面质量HighQualityCastings-铸件质量更好Lessfinishing&polishingrequired-表面抛光要求低,SuitableCastingProcessGravityDieCasting铸造工艺重力铸造,Disadvantages缺点WallThicknesslimitationsdependingonMaterial壁厚受材料限制LinearTolerance3mm/m-铸造公差为3毫米/米SurfaceFinish4-10microns-表面粗糙度为4-10微米Limitedcomplexity-壳体结构不能太复杂,SuitableCastingProcessGravityDieCasting铸造工艺重力铸造,LowPressureDieCasting低压铸造ARepetitivecastingprocessbyinjectingmoltenmetalunderlowpressureintoametaldie.Thegaspressureholdsthemetalinthedieuntilitsolidifies在低压作用下将熔融金属注入到金属模中。压力一直保持至金属凝固。Advantages优点30castingsanhourpossible一小时可铸造30件Thinwallsthicknesspossible2-3mm壁厚可做到2-3毫米,SuitableCastingProcessGravityDieCasting铸造工艺重力铸造,BestLinearTolerances2.5mm/m尺寸公差达2.5mm/mBestSurfacefinishe.g.3microns最佳表面粗糙度可达到3微米HighYields90-98%asrunnersandrisersexcluded成品率可达到90-98Reducedfettlingandtrimming减少模具修补与保养Pore-freecastingsobtainable铸件致密性更好，内部无缩松Directionalsolidificationofcastingsadvantageous有利于铸件的定向凝固,SuitableCastingProcessGravityDieCasting铸造工艺重力铸造,Risertubedrawsmetalfrombelowthedrosslayeravoidinginclusionentrapment金属液经压力管从下压入模具，避免浮杂夹杂在铸件内部Sandcoresmaybeused.Complexcastingshapesarepossible通过砂芯的使用，可以铸造形状复杂的铸件Diecostsarelow,castironorsteeldiesareused模具成本低，模具材料可采用铸铁或钢Canfullyheattreatcastings铸件可进行热处理,SuitableCastingProcessGravityDieCasting铸造工艺重力铸造,Disadvantages缺点Sizeofcastingslimitedbymachinesize铸件的尺寸受压铸机尺寸限制Soundthicksectionsaredifficulttocast尺寸厚的部位难以成型Surfacefinishbetweenthatofgravitydieandhighpressure表面粗糙度介于重力铸造和高压铸造之间Wallthicknessnotasthinashighpressurebutbetterthangravitydie壁厚不是压力越高壁厚越薄，但比重力铸造会好一些,SuitableCastingProcessGravityDieCasting铸造工艺重力铸造,HighPressureDieCasting高压铸造ARepetitivecastingprocessbyinjectingmoltenmetalunderpressureeg1000psiintoametaldie通过高压例如1000PSI将熔融金属压入到金属模具中。Advantages优点200castingsanhourpossible一个小时可铸造200件Thinwallsthicknesspossible1-2.5mm壁厚可达到1-2.5mmBestLinearTolerances2mm/m最佳表面粗糙度可达到1.5microns,SuitableCastingProcessGravityDieCasting铸造工艺重力铸造,Veryfinesurfacegrainsize非常精细的表面晶粒尺寸Highstrengthintheascastcondition铸态强度高Tolerancesandrepeatablepropertiesobtained公差精度高和模具寿命高Castingsmaybequenched铸件可淬火,SuitableCastingProcessGravityDieCasting铸造工艺重力铸造,Disadvantages缺点Sizeofcastingslimitedbymachinesize铸件的尺寸受压铸机尺寸限制Soundthicksectionsaredifficulttocast尺寸厚的部位难以成型Castingsmaysufferfromp