高端滚动轴承智能设计与制造关键技术及服役可靠性研究

The high performance rolling bearing is the key basic component of advanced equipment. Aiming at the general problems of the intelligent design and manufacturing and service reliability of the high performance rolling bearing, the ultra-high speed precision ceramic ball bearing for high-grade numerical control machine tool is selected as case study. Novel shape controlled and performance controlled machining methods for ceramic ball and ring race, including shape controlled machining method for ceramic ball based on even surface-covering principle, performance controlled machining method for ceramic ball based on tribochemical solid state reaction, and dual-electrolysis grinding for ring race are proposed to achieve high accuracy, high consistency and high surface integrity machining of ceramic ball and ring race. Intelligent manufacturing support technologies including data acquisition and data mining methods, knowledge description method of process data and cloud platform of intelligent manufacturing will be developed to optimize the allocation of resources, and improve process stability, product consistency and manufacturing efficiency. Intelligent design key technologies including knowledge representation method, expert knowledge reproduction technology and intelligent design knowledge base will be investigated to improve the ability of design innovation and design efficiency. Service reliability issues including service reliability analysis method based on multiparameter data fusion detection and service performance management system will be studied to improve service reliability. Based on the above researches, the key technology system of intelligent design and manufacture of high performance rolling bearing and service reliability analysis method will be established. It will have important theoretical significance and engineering application value to improve the manufacturing level of the high performance rolling bearing in China.

高端滚动轴承是高端装备的核心基础件。针对高端滚动轴承智能设计与制造及服役可靠性存在的共性问题，以高档数控机床超高速精密陶瓷球轴承为研究对象，提出陶瓷球和滚道控形控性加工新方法：基于球面均匀包络的陶瓷球控形加工技术、基于摩擦化学固相反应的陶瓷球控性加工技术以及滚道双电解磨削技术，实现轴承关键元件高精度、高一致性、高表面完整性加工；研发数据采集与挖掘方法、工艺数据知识化描述及智能制造云平台等智能制造支撑技术，优化资源配置，提高制造的工艺稳定性、产品一致性及制造效能；研发设计知识表达方法、专家知识重现技术与智能设计知识库等智能设计关键技术，提升设计创新能力和效能；研究基于多参数数据融合检测的服役可靠性分析方法及与服役性能管理系统等服役可靠性问题，提高服役可靠性；建立高端滚动轴承智能设计与制造关键技术体系及服役可靠性分析方法。项目研究对提高我国高端滚动轴承制造水平具有重要的理论意义及工程应用价值。

高性能滚动轴承具有高精度、高可靠性等优越使役性能，是决定高端装备性能的核心基础件。但是，由于在设计方面缺乏专家经验与现有设计理论的高效融合，导致高端滚动轴承设计效能低；在制造方面，缺乏高一致性加工技术、制造过程实时数据的获取及工艺智能决策，导致高端滚动轴承产品一致性差，制造效能低；在轴承服役方面，缺乏服役过程性能数据及其与设计参数和加工质量参数的关联机制，导致高端滚动轴承服役可靠性差等问题。本项目建立了球体变曲率沟槽研磨三点驱动模型，通过运动学分析及磨削轨迹仿真，表明单周期研磨轨迹能够实现球体表面的全包络。研究了加工工艺参数对陶瓷球控形控性加工结果的影响规律，得到的圆度0.09μm、圆度一致性0.0114μm、直径一致性分别为0.108μm。搭建了滚道双电解磨削平台，建立了滚道几何形状创成模型，优化了滚道磨削工艺参数。基于轴承磨削过程多目标数据采集与处理、磨削工艺多目标决策等技术，实现了轴承套圈磨削工艺高效优质低耗低碳优化。建立了基础数据知识化描述方法与工艺数据库、知识库系统模型，实现了轴承加工的智能化分析、决策与优化。通过对比数值模拟的结果，优化智能决策过程，建立了加工结果预报、判断方法以及知识规则的自动扩充机制，实现了高端滚动轴承智能制造数据的存储、共享与扩展功能。实现了专家隐性经验的知识显性化、可移植化和共享，建立了高端滚动轴承设计知识表达方法及智能设计知识库系统。基于多参数数据融合技术实现了轴承早期故障诊断，实现了轴承产品服役可靠性管理，优化轴承服役条件，提高轴承服役可靠性和使用寿命。本项目对提高我国高端滚动轴承制造水平具有重要的理论意义及工程应用价值。