基于磨具可控变形的圆锥滚子凸度成形柔性超精研加工方法研究

Such development tendencies as individual customization and flexible production have already taken place in manufacture industry. In order to meet processing requirement of high precision and high flexibility in customized intelligent manufacture, a novel superfinishing method of tapered rollers is proposed in order to achieve the flexible generation of different crown profiles defined by function curves based on the principle of controllable deformation of abrasive tool, utilizing the characteristic of plastic deformation of the rubber bonded abrasives, combining automation and information technology. In this method, the geometric profile of abrasive tool could be regulated by controlling the loaded pressure distribution, and further the crown profile of roller could be generated due to the basic forming principle of geometric surface and profile replication. Through the theoretical analysis, computer simulation and experiments, the project will analyze the characteristic of plastic deformation of the rubber bonded abrasives, the influence of loaded pressure distribution on deformation of abrasive tool, as well as the influence of geometrical profile of abrasive tool on the contact pressure distribution for workpiece surface, so as to establish the material removal model and the geometric profile forming model for the workpiece, and reveal the mechanism of crown generation of tapered roller due to the controllable deformation of abrasive tool, finally achieve the flexible processing of high precision tapered rollers of different crown profiles. This study is in favor of enriching the theory and technology system of ultra-precision processing for bearing roller, actively promoting the upgrading of bear industry of China toward the industry 4.0 and intelligent manufacture.

制造领域呈现出个性化定制、柔性化生产的发展趋势。为满足定制化智能制造的高精度、高柔性加工需求，提出一种基于磨具可控变形、适用于圆锥滚子母线凸度柔性成形的超精研加工方法：利用橡胶磨具的弹性变形特性，综合应用自动化和信息化技术，通过控制加载压力分布来改变磨具几何形状，以面形复制为基本成形原理，从而实现圆锥滚子不同函数曲线凸度的柔性超精加工。通过理论分析、计算机仿真与实验研究，分析橡胶磨具的弹性变形特性，加载压力分布对磨具变形的影响规律，以及磨具形状对工件表面接触力分布的影响规律，进而建立工件表面材料去除模型和几何轮廓成形模型，揭示基于磨具可控变形的圆锥滚子凸度轮廓成形机理，最终实现不同凸度形状高精度圆锥滚子的柔性加工。本研究有助于丰富轴承滚动体超精加工理论与技术体系，对中国轴承产业升级，向工业4.0、智能制造转型产生积极推动作用。

本项目提出了应用游离磨料和弹性抛光垫的轴承圆锥滚子无心超精研磨抛光加工方法，自主研制了相应加工设备，对相应加工技术开展了理论和实验研究。在理论方面，综合应用几何运动学、弹性接触理论、单颗磨粒微切削理论以及三体磨损理论，构建了工件外圆轮廓材料去除和成圆理论模型，实现了加工过程数值仿真以及精度预测，经实验验证，仿真分析结果准确有效。在实验方面，应用微细氧化铝游离磨料和聚氨酯弹性抛光垫对GCr15轴承钢圆锥滚子进行无心超精研磨抛光加工，开展正交试验、方差分析和水平响应分析，分析了加载压力、磨料浓度和磨料粒径对圆度、表面粗糙度和材料去除率的影响规律，在优化后的加工工艺条件下，使工件外圆轮廓的圆度误差达到了0.34μm左右，表面粗糙度达到了20nm左右，实现了高精度轴承圆锥滚子的加工。. 项目负责人作为第一或通讯作者发表国内期刊论文2篇，SCI期刊论文1篇，另投稿SCI期刊论文1篇，作为其他作者发表国内外期刊论文8篇；获得授权发明专利2件，另申请发明专利1件；参加了5次学术会议；作为第二成员获得2019年度浙江省科学技术进步三等奖，另获得2017年中国机械工程学会第七届上银优秀机械博士论文优秀奖。项目组成员中，已毕业博士2人，在读博士1人，本项目另培养本科生5名。. 本项目研究成果有助于进一步深入理解金属材料非平面工件研磨抛光加工的材料去除和几何轮廓成形的物理本质，对于材料去除和几何轮廓成形的模型构建和仿真方法具有参考价值。. 本项目研究成果可推广于陶瓷轴承滚子、高精度液压伺服阀芯等中小型轴类零件的研磨抛光。