精密轴承滚道谐波形态的跨工艺调控机制及协同整平策略

Bearing is one of the most important parts of the machine and bearing’s performance and quality directly determine the performance and quality of the whole machine. This project proposes the cross-process regulation mechanism and collaborative finishing strategy for the harmonic morphology of bearing races. During the process of centerless grinding of bearing race, a high frequent harmonic morphology, which is acceptable for electrochemical super-finishing, is regulated and formed to simultaneously realize the substantial finishing of roundness, waviness and roughness of the race in electrochemical super-finishing step. According to the key scientific problems of evolution behaviors and regulation mechanisms of contour harmonic morphology in the finishing processes, the law of regulation and finishing of harmonic morphology in the processes of centerless grinding and electrochemical super-finishing is studied. The technical condition of high frequent harmonic morphology in terms of acquisition by centerless grinding and finishing by electrochemical super-finishing is obtained. How to determine sensitive processing parameters of harmonic morphology and acceptance region of harmonic morphology for electrochemical super-finishing, and significant theoretical and technical problems in terms of development of key technical device in bearing races of deep groove ball bearing are solved. The collaborative optimization of centerless grinding and electrochemical super-finishing based on regulation of harmonic morphology is realized. The precise machining theoretical framework and technical system aiming at centerless grinding and electrochemical super-finishing of bearing race are formed. All these have important scientific significance and application value to enrich and improve the theory of bearing finishing, and to improve the fundamental technology level of precise transmission parts.

轴承是机器的重要基础部件，轴承性能和质量直接决定整机性能和质量。课题提出轴承滚道谐波形态的跨工艺调控机制及协同整平策略，在滚道无心磨削过程中，调控并形成电化学超精加工可接受的较高频次谐波形态，在电化学超精阶段实现滚道圆度、波纹度、粗糙度的同时高效整平。围绕轮廓谐波形态在加工过程中的演变行为和调控机理方面的关键科学问题，研究无心磨削和电化学超精过程中谐波形态的调控和整平规律，掌握高频次谐波形态的无心磨削获取和电化学超精整平的技术条件，解决谐波形态敏感工艺参量的确定、电化学超精的谐波形态接受域的确定，以及针对深沟球轴承的关键技术装置研制等方面的重要理论与技术问题，实现基于谐波形态调控的无心磨削和电化学超精加工协同优化，形成面向轴承滚道的无心磨削+电化学超精的精密加工理论架构与技术体系，对丰富和完善轴承精加工理论，提高我国精密传动件基础工艺水平具有重要的科学意义和应用价值。

轴承是机器的重要基础部件，轴承性能和质量直接决定整机性能和质量。课题提出轴承滚道谐波形态的无心磨削和电化学超精加工跨工艺调控机制及协同整平策略，围绕轮廓谐波形态在加工过程中的演变行为和调控机理方面的关键科学问题开展研究，主要研究内容和结论如下：.1.表面轮廓误差谐波形态的数学描述。通过理论分析和实验证明超精加工轴承滚道的粗糙度服从对数正态分布，基于这一统计特征设计了对数指数加权移动平均（EWMA）方法应用于实际，验证了该表面质量控制方法在超精加工中的有效性。.2.无心磨削加工条件与滚道轮廓误差谐波形态。以轴承外圈为实验对象，设计不同加工参数对加工结果影响的对比实验，探讨工艺参数对轮廓形态演化的影响规律，获得轮廓形态演化机理。.3.滚道轮廓不同形态谐波的电化学超精整平特性。通过实验掌握轮廓谐波形态在加工过程中的演变行为及其内在机理，以及对不同波长轮廓的整平机制，确定了电化学超精的谐波形态接受域，并通过调整阴极覆盖范围研究电化学作用范围对精度的影响规律及机理。.4.无心磨削和电化学超精的跨工艺优化与协调机制。从滚道轮廓谐波形态在加工过程中的演化规律入手，研究了基于轮廓谐波形态调控的无心磨削和电化学超精加工协同优化策略。通过不同轮廓形态和精度组合实验研究发现，在无心磨削阶段形成多瓣轮廓形态，在电化学超精复合加工阶段适当扩大阴极覆盖范围可实现轮廓误差的有效改善。.通过上述研究形成了面向轴承滚道的无心磨削+电化学超精的精密加工理论架构与技术体系。依托项目成果研发的工艺及装备已成功应用于实际，并可进一步推广应用于机械、能化、核电、国防军工、航空航天领域等对零部件精密度和表面质量具有高要求的多个行业，具有广阔的发展和应用前景。本项目研究对丰富和完善轴承精加工理论，提高我国精密传动件基础工艺水平具有重要的科学意义和应用价值。