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外文资料翻译题目:弹性联轴器在燃气轮机中的应用

院(系)机电工程学院

专业机械设计制造及自动化

班级120204班

姓名高云云

学号120204103

导师姚慧

2016年5月3日

弹性联轴器在燃气轮机中的应用

JON R. MANCUSO

Manager of Engineering

Zurn Industries, Inc.

Mechanical Drives Division

1801 Pittsburgh Avenue

Erie, Pennsylvania 16512

摘要

齿式联轴器作为主要的挠性联轴器,在工业燃气轮机上使用了近二十五年。由于工业燃气轮机取得了进步,所以齿式联轴器也有了较大的发展。在齿式联轴器中有很多变量可以影响它们的特性,包括齿的设计,材料和润滑方式。所有的联轴器对于连接的设备都有影响。在设计系统时,系统设计人员必须考虑这些影响。当选用一个齿式联轴器时,在很多方面可以使设计人员的工作大大简化。本文就膜盘联轴器和齿式联轴器在工业燃气轮机中的应用特性进行了比较,包括了在涡轮发电机中的应用、涡轮机械驱动器(压缩机、泵和齿轮)中的应用和所有在涡轮和其配套齿轮之间起联接作用场合中的应用。齿式联轴器和膜盘联轴器都提供了用于分析该设计和力以及力矩的产生的方法。这些分析是用于表明由膜盘联轴器产生的力和力矩不仅是可预测的,而且通常比齿式联轴器产生的力和力矩要低得多。本文表明,在大多数工业燃气轮机中的应用中,膜盘联轴器比起齿式联轴器更加具有可预测性并且更加可靠。

引言

在今天的科技下,更高的马力和更高的速度不断推进着旋转设备设计的艺术。在新的燃气轮机技术下,其系统组件在可靠性方面、质量方面、维护方面及其载荷作用方面的重要性尤为明显。膜盘联轴器和齿式联轴器通常可用于这些高性能的场合中。当在这些应用中选择联轴器时,系统设计人员必须着眼于这些待选联轴器本身的固有的设计特点。在一些不能释放出力和力矩的应用要求(这将变得很难处理)中,设计人员还应该考虑挠性联轴器如何能够很好地去适应这种情况。

有这样一些例子,在发电机、机械驱动器、以及驱动附件的联接中等使用负载联轴器。

在联轴器所联接的组件安装时轴线错位以及存在扭矩的情况下,联轴器会因

此而受到影响。如果不考虑可能引起轴或轴承等设备部件的故障,这些反作用力比起其他联轴器要大得多。通常在系统中增加尺寸和重量时,会造成大的或不可预测的影响。

联轴器的类型

联轴器基本上可以分为两种类型,即刚性联轴器和挠性联轴器。刚性联轴器通常用于联接轴线错位非常小的场合,因此大多数场合中需要使用挠性联轴器。挠性联轴器主要有以下四种类型:

1.无金属弹性元件挠性联轴器

2.非金属弹性元件挠性联轴器

3.金属弹性元件挠性联轴器

4.其他

对应用状况进行比较,无金属元件挠性联轴器和金属弹性元件挠性联轴器由于能承载扭矩、消除不对中、拥有较高的速度以及还符合环保要求经常被考虑使用。齿式联轴器是属于无弹性元件挠性联轴器中的一种,膜盘式联轴器是属于金属弹性元件挠性联轴器中的一种。这两种类型的联轴器都在其所考虑的适宜的应用场合中具有独特的特点。

齿式联轴器

齿式联轴器(图1)能适应不对中和由于不对中和由不对中引起的轴端的浮动以及在套筒的毂上齿轮的齿的滑动(图2)。由于这种机械运动形式,所以联轴器必须进行润滑,齿式联轴器最常见的失效形式是磨损,而且它是当今使用过程中最常见的和最简单的一种联轴器。由于可以影响它成功运行的因素太多,所以它通常难以设计和进行评估。一些能影响它的设计和特征的因素有:

1.齿的设计

A.直齿或齿的类型和数量

B.齿的压力角

C.齿侧间隙

D.齿距的精度

2.材料

A.材料类型

B.核心热处理的类型

C.表面处理的类型图1 高性能齿式联轴器

3.润滑

A.油

B.润滑脂

C.密封润滑

D.连续润滑

E.润滑方式

一个齿式联轴器不仅在其自身上有显著的影响,而且对其滑动或者错位时产生力和力矩的系统组件上也有着显著的影响。当一个齿式联轴器由于温度升高或者基础偏移等引起了轴端浮动,轴向作用力就会反馈到推力轴承或者其他设备上。当不对中时,齿式联轴器将会产生弯曲力矩,它将加重轴、轴承或者其他系统组件负载。轴向作用力和弯曲力矩都受到润滑和与齿轮的齿配合的部件之间的摩擦系数的重要影响。

图2 鼓形齿联轴器的错位

膜盘式联轴器

膜盘式联轴器(图3)是金属膜联轴器中的一种。它由一个或多个金属薄膜组成,金属薄膜连接在传动法兰的外径上,并且通过膜盘径向传递扭矩给附件的内径上。另一种金属弹性元件挠性联轴器是膜片式联轴器。膜片式联轴器通常由数个挠性的金属薄膜组成,,相对的法兰由螺栓交替连接起来(图4)。

金属膜联轴器的发展有助于消除一些有关润滑联接的问题。金属膜联轴器依靠金属材料的弯曲以适应设备轴的轴向移动和错位。施加在轴承和设备上的轴向力是影响膜盘挠度的一个因素,也是影响膜盘柔性单元轴向刚度的一个因素。被

传输到轴、轴承等上的弯曲力矩,是关于膜盘柔性单元的弯曲刚度和被影响偏移量的函数。

图3 膜盘式联轴器图4 膜片式联轴器

用于工业燃气轮机中的联轴器

许多工业燃气轮机是飞机燃气轮机的衍生物或是使用了它们的大多数原理而工作。这些元件在高速下运转(3600-15000r/min),它们通常需要联轴器来增加轴向移动能力以超过0.5英寸。在这种应用场合下,通常需要专门设计的联轴器并且使用在航空科技上设计的设计和制造技术。这些联轴器是采用高强度合金制造,并且其制造标准采用制造飞机零件部件时用的公差等级。

图5是一个典型的重型工业燃气轮机。该燃气轮机表明它可以并且确实同时使用了齿式联轴器和膜盘联轴器。

图5 重型工业燃气轮机

许多先进的燃气轮机已经被设计为只使用膜盘式联轴器。

齿式联轴器设计特点

齿式联轴器有好多种方式来进行分类,但最常见的是根据齿形的类型来划分。所有的齿式联轴器都具有直边内齿,这些内齿是渐开线轮廓的,通常压力角为20度。大多数齿式联轴器错位产生的间隙一般是切进内齿形成。用来齿式联

轴器分类的两种轮毂齿的形式是:

图6 直边齿图7 鼓形齿

1.直边齿(如图6所示)

2.鼓形齿(如图7所示)

鼓形齿通过在凸轮上用刀具上下滚铣塑造而成。对于八分之一度或者更小的偏移角来说,直边齿的作用和鼓形齿几乎一样。对于偏移角超

过八分之一度的状况,应该使用鼓形齿,因为其齿顶能够允许更大面积

的齿面接触,从而在偏移中减小应力。

在设计齿式联轴器时需要考虑的一个最重要因素是齿在负载和错位下所产生的热量。人们已经多次尝试去建立限制和标准,最常使用的是

压应力或者滑动速度,但是也被证实这是考虑不充分的。测试和经验表

明,对于齿式联轴器齿的设计标准应该考虑以下几点:

A.载荷

B.偏移量

C.齿的几何结构(节径,径节,齿数)

D.接触齿的百分比

E.速度

F.材料,齿的硬度和光滑度

G.润滑油的质量和类型

齿式联轴器如何影响系统

一个齿式联轴器对系统最显著的影响是当它滑动或错位时所产生的力和力矩。

1.轴向作用力

作用在推力轴承和其它系统组件上的轴向力计算公式如下:

式中:T=扭矩(IN-LB),μ=摩擦系数,R=齿轮节圆直径(IN)

2.弯曲力矩

齿式联轴器上产生的力矩将会加重设备轴和轴承的负载,并且也改变了设备的运转特性。在一个齿式联轴器中三个基本力矩如图8所示。

A.传递扭矩和角度时产生的力矩(绕Z轴旋转)

B.由摩擦产生的力矩(绕Z轴旋转)

C.由其中心载荷的偏移产生的力矩(绕Y轴旋转)

图8 齿式联轴器坐标系

齿式联轴器的失效形式

齿式联轴器最常见的失效形式是齿的磨损。齿的磨损主要来源于以下几个原因:

1.不够充分的润滑

2.不正确的齿面接触

3.冷流或焊接更频繁地发生在持续润滑的联轴器上

4.油渣污泥等的积聚可引起几乎任何系统部件的故障,如轴和轴承等

膜盘联轴器设计时的注意事项

如前所述,有两种基本类型的挠性金属膜联轴器,即膜盘联轴器和膜片联轴器。每一种类型都可以单独使用,或者通过间隔或卷筒件分离作为一对使用。金属膜联轴器的使用由于1940年代那些低扭矩低速下的场合(对偏移量的需求有

限)而受到了限制。在20世纪40年代,在看到航天领域中的使用情况后,小型燃气轮机的外观产生了对薄轮廓膜盘的需求。由于没办法适应高错位和较大的轴向运动,在工业和船舶领域中,这种联轴器的发展进程和被人们接受的程度收到了极大的阻碍。

齿式联轴器使用于蒸汽轮机、燃气轮机、压缩机和泵中已经许多年了。当马力、速度以及运转环境温度不断增加,关于齿式联轴器的许多问题也随之发展。对较低力矩、较低的力、较小的噪声特性的需求推动了在上千种应用场合中膜盘联轴器的先进发展和其用法。正因为如此发达的技术,自20世纪70年代中期以来膜盘联轴器被成功应用于燃气轮机之中。

许多制造商和旋转设备的用户增加了他们对于连接要求的清单,如下所示: A.不进行润滑

B.在不断增加的联接尺寸下更高的承载扭矩能力

C.可以适应更大的偏移

D.可以适应更大的运动

E.适用于高温下运转

F.适用于所有类型的联接:花键、锥轴、法兰等

G.产生较低的力矩和力

H.产生的力和力矩是可预测到的

I.容易保持平衡

J.多年不需要维修或者其他问题

K.没有大的振动输入设备

应用于这些场合的膜盘联轴器有两种基本形式:

A.锥形轮廓

B.多个错综复杂的膜盘

两个形状有一些外形轮廓上的改变以助于减小尺寸、提高挠性以及控制应力集中。例如,为了增加挠性,膜盘被设计为锥形轮廓以应对从内径到外径的一个恒定剪切力。

使用多个膜盘与多个平行的薄板而不是一个单一的厚的板来设计的联轴器已经提高了挠性并且通常具有较低的应力。膜盘应力、力矩、力与材料厚度的三次方成正比。因此,数个薄的膜盘会比单一的厚的产生较低的应力值。

由于膜盘联轴器通常应用于高性能且要求高可靠性的设备上,所以联接组件

通常由具有良好的抗疲劳性能的高强度合金制成。典型材料是AISI 4100或4300防腐蚀钢,PH不锈钢或是高强度镍合金。膜盘联轴器,类似于所有的金属膜联轴器,通常被设计成无限寿命。在膜联轴器应用于燃气轮机中时最重要的设计注意事项是考虑柔性膜中的运转应力。在膜盘或膜片上设计的应力应小于所使用材料的疲劳极限和符合其他一些安全因素。

齿式联轴器与膜盘联轴器的比较

图9 联轴器比较

图9列出了在典型工业燃气轮机应用中膜盘联轴器和齿式联轴器的比较,包括联轴器直径、重量、扭矩条件、弯矩和轴向力等。通过在两个不同的摩擦系数下计算出的力和力矩来证明该变量对齿式联轴器所产生的影响。摩擦系数将受到齿的设计、润滑油的质量、材料的类型和齿的表面光洁度等等的影响。膜盘联轴器上的力和力矩是可以预测的,并且只与金属膜的刚度有关。尽管齿式联轴器在高轴向行程的应用场合中通常具有较小的直径和较轻的重量,但是在系统中齿式联轴器所施加的弯曲力矩仍比等效膜盘联轴器高了几乎10倍。齿式联轴器施加的轴向力等同于膜盘联轴器受其摩擦系数的影响。在峰值扭矩条件下(5至10倍的正常操作扭矩),齿式联轴器比起膜盘联轴器,轴向力是其9倍之多,弯曲力矩更是高达50倍左右。

图9还比较了基于API标准(摩擦系数为0.25)下的要求所计算出的数据。在系统设计中力和力矩的影响是很显著的,所以要求较大的轴及轴承、加厚凸缘等与齿进行连接。

在燃气轮机使用的联轴器中,膜盘联轴器也展示出其在可靠性和维护方面的优点。尽管齿式联轴器被我们所知25年或者更长时间,它也需要定期排污以方便联轴器的连续润滑,需要对密封式联轴器进行定期更换润滑油,这是标准的维护要求。

总结

膜盘联轴器和齿式联轴器都可以在工业燃气轮机领域中使用。系统设计者必须分析诸如由不同类型的联轴器产生的力和力矩所带来的影响的这种特性。膜盘联轴器所产生的力和力矩不仅比齿式联轴器的低,而且更加可预测。

参考文献

Mancuso, Jon R., "Couplings and Joints: Design, Selection, and Application" Published by Marcel Dekker, Inc., 1986.

Zurn Catalog "High Performance Class 1 Couplings," Form No. 462-ADV. Zurn Catalog "High Performance Multiple Convoluted Diaphragm Couplings” Form No. 271 ADV.

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