秘密TECHNICAL SPECIFICATIONOF CYLINDRICAL GEAR CONTACT FATIGUE TEST RIG (160mm CENTER DISTANCE) 圆柱齿轮接触疲劳试验器（160mm中心距）技术规格书中机生产力促进中心制造工程研究所2012-11FOREWORD 前言Since the complexity of the gear shape, the raw material property tested by bars can’t represent the material property of gears. The way of manufacturing of gear such as cutting, heat treatment and final process which affect gear surface, the lubrication oil used for the gears etc. make a great difference to the gear material properties. As result, it has become common practice that the gear fatigue life are tested through specifically designed and manufactured gears together with the actual oil on specific test rigs following specific procedures. It is used to evaluate gear manufacturing process by testing gears manufactured by different way.由于齿轮形状的复杂性，原材料试棒的试验性能并不能代表齿轮的材料特性。
齿轮加工工艺不同和使用条件的不同，对齿轮的强度和寿命的影响很大。
不同的机加工工艺、不同的热处理条件、使用不同的润滑油，都会使得齿轮的材料特性产生很大的差异。
因此，对专门设计和制造的齿轮，使用实际的润滑油，在专用的试验台架上按规定的流程进行齿轮强度和寿命测试，得到普遍的应用。
通过对不同加工工艺制造完成的齿轮进行疲劳强度测试，可以评价齿轮加工工艺的优劣和工艺参数的合理性。
1 TECHNICAL DESCRIPTION技术描述1.1 Background 背景Test rigs designed by Design Unit of The University of Newcastle upon Tyne have been developed in the past twenty years in order to carry out research into contact fatigue and bending fatigue strength of gears. The rigs were designed to remedy the shortcomings of the test rigs which were at that time commercially available. Over the years the test rigs have been improved based on practical experience of their use.英国纽卡斯尔大学齿轮技术中心设计的试验器是在过去的20年间开发出来的，用以研究齿轮接触疲劳和弯曲疲劳强度。
此试验器可以弥补商业化试验器的不足。
经过这么多年，在长期使用经验基础上，试验器不断完善。
1.2 General Description of Gear Contact Fatigue S-N Curve Test Rig (160mm center distance) The cylindrical gear contact fatigue test rigs (160mm center distance) operated with back to back (power re-circulating) are high performance gear test rigs capable of operating at high speed and torque with high test power (‘re-circulating’power). They are used for contact fatigue testing (pitting and micropitting), for bending fatigue and scuffing tests. They have been designed for good reliability and long life and continuous, 24 hour per day unattended operation.圆柱齿轮接触疲劳试验器（160mm中心距）是拥有高转速，高扭矩以及高功率（再循环功率）的高性能齿轮试验器，用于齿轮的接触疲劳（包括点蚀和微观点蚀）和齿根弯曲疲劳以及胶合的试验，设计目的就是为了实现高可靠性，长寿命以及每天24小时无人看守持续工作的能力。
A general view of the test rigs is shown in Photo 1 below. These are of a back to back configuration, with two identical test gearboxes joined by torsion bars to provide torsional compliance and to decouple the gear vibrations in each gearbox. A servo hydraulic torque actuator is fitted in one shaft line which controls the torque applied to the gears. The servo hydraulic torque actuator allows the test rig and gears to be run at zero or low torque until a stable operating temperature has been reached, and enables the torque to be changed while the gearbox is running. The test rig is arranged as a compact unit with a substantial frame on top of which are mounted two test gearboxes and the servo hydraulic torque actuator. Below the gearboxes are positioned individual lubricant tanks, coolers and lubrication systems for each test gearbox, as well as the servo hydraulic system for generating the test torque.试验器的外观如照片1，是背靠背布置的。
试验器包括两个被扭力杆连接的同样的齿轮箱，扭力杆可以提供扭转柔度以及降低每个齿轮箱中齿轮的振动。
液压扭矩加载器安装在齿轮箱轴上，用来控制齿轮的实际承载扭矩。
扭矩加载器在齿轮箱油温恒定之前保持齿轮和试验器的零或低扭矩，当齿轮箱正常运转后可以改变承载扭矩。
试验器布局紧凑，机架牢固稳定，机架上安装有两个测试齿轮箱以及液压伺服扭矩加载器。
齿轮箱下部是独立的润滑油箱，冷却器以及每个齿轮箱的润滑系统及产生试验扭矩的液压系统。
Figure 1: General view of the 160mm test rigs. 160mm中心距试验台总体图Test Rig – General Machine Specification试验器-设备规格Center Distance (mm)中心距160Optional Ratio 可选速比1～1.5 （recommend 1～1.1）Face Width (mm) 齿宽10～60Module (mm) 模数2～10 (spur) 4～8 (helix)Working Speed (rpm) 工作转速0～4500 Max. Test Torque (Nm) 最大测试扭矩6000 Maximum Continuous Motor Power (kW)最大持续电机功率55 Maximum (for up to 30 min) Motor Power (kW)最大（最多30分钟）电机功率75 Accuracy of Torque Control 扭矩控制精度±1.5% FS Helix Angle 螺旋角0～30°Area of Equipment Main Machine 主机占地面积(mm) Control Cabinet 控制柜占地面积(mm) 2800×1230 2000×600Performance: 性能6000 Nm, continuous6000 Nm时持续运转（1000～3000 ）rpm 4500 rpm, continuous4500 rpm 时持续运转（500～3750）Nm 4500 rpm, for up to 30 minutes,4500rpm时持续运转30分钟4200NmMax. Test Power (kW) 最大试验功率(kW) 20001.3 The Test Gear Boxes试验齿轮箱The test gear boxes are very rigid with a substantial main casing which is bolted to the machine frame by a system of flexures to give compliance and avoid axial over-constraint between the two gearboxes. A special feature of the test box is the design of the moving half of the casing which is mounted on a pivoting arm and gives very good access to the gears for mounting and visual inspection. This is shown in Photo 2.试验齿轮箱刚性非常好，其固定式的箱体通过缓冲系统连接在机架上，避免两个齿轮箱过约束。