多头大导程滚珠螺母滚道电解加工关键技术研究

To be included in the basic parts to the ball screw as a typical representative and universal parts (2006-2020) priority theme of national manufacturing industry in key areas. The large lead ball screw nut due to difficult processing currently rely on imports, the existing process and dynamic performance of machine tool requirements, tool wear, lift angle limited, innovation research group the ball head of oblique nozzle cathode in electrochemical machining large lead ball nuts raceway process, and further puts forward the multi nuts raceway synchronous processing of new ideas, and the use of raceway "ditch bottom cutting" double arc raceway "new ideas. The new technology has the advantages of no high-speed moving parts, no tool loss, roll road or angle restrictions and other advantages. The electrochemical properties of paper specific workpiece materials; to establish a special experimental platform; analysis of spherical cathode flow field characteristics; to explore the" spike (convex residual) "on the formation mechanism. The flow field influence; "undocked" phenomenon caused by the lack of liquid, the confinement ring and sacrificial layer magnet solution; the flow field modeling, simulation analysis, experimental correction method to grasp the forming rules, methods to calculate the cathode size; research on multi raceway synchronous processing electric field, flow field coupling problem, through the solution of the key problem of science and technology, for the practical application of the new technology to lay a solid foundation. modeling, simulation analysis, experimental correction master forming rule for cathode size calculation. In this paper, the problem of the electric field and the flow field coupling of the multi roller synchronous processing is studied. The solution of the above problems is the foundation for the practical application of the new technology

以滚珠丝杠副为典型代表的基础件和通用部件被列入（2006-2020）国家制造业重点领域的优先主题。大导程滚珠丝杠副由于螺母难加工目前基本依赖进口，现有工艺存在机床动态性能要求高、刀具损耗大、升角受限等缺陷，课题组创新提出球头斜喷嘴阴极电解加工大导程滚珠螺母滚道新工艺，并进一步提出多头螺母滚道同步加工新构思，及利用滚道“沟底过切”加工“类双圆弧”滚道新思路。新工艺具有无高速运动部件、无工具损耗、滚道升角不受限制等优势。课题将研究特定工件材料的电化学性能；建立专用实验平台；分析球头阴极流场特点；探讨“spike（凸起残留）”形成机制，对流场影响；对“切入/切出”引起的缺液现象，提出约束环和牺牲层+磁铁的解决方案；采用流场建模、仿真分析、实验修正手段掌握成形规律，给出阴极尺寸计算方法；研究多滚道同步加工电场、流场耦合问题，通过对关键科学和技术问题的解决，为新工艺的实际应用打下扎实基础。

大导程滚珠螺母传动副属基础传动件，是国家重点发展的领域。目前国内基本空白， 产品被德、日、台垄断。项目首次提出采用电解工艺进行大导程螺母加工，充分发挥电解加工优势，高效、高表面质量、无加工作用力、无工具损耗等优势，可以实现任意升角的螺旋线加工，与此相比，现有技术螺旋升角一般不大于17°。1.加工平台建立。专用电解加工平台设计，含专用四轴数控机床、电源、电解液系统；2.单滚道展成电解加工基础研究。深入研究单滚道电解加工工艺特性及基本规律，包括：滚道电解加工全过程各阶段（“切入/切中/切出”阶段）流场分析与设计、工件“Spike凸起残留”对加工的影响规律、超高频脉冲电解加工机理、工艺参数优化、单/双圆弧滚道加工的阴极形状尺寸“反求”计算公式等；3.多滚道同步电解加工工艺规律。主要针对同步加工时各滚道区域及各区域间的特殊电场、流场特征及其耦合作用机制、多滚道的同步成型规律、多头阴极结构设计及阴极尺寸计算、对准对中技术等开展研究，建立相关数学模型，并进行理论分析和实验验证；4.大导程螺母滚道的加工、传动副性能评价。利用上述研究成果和结论进行大导程滚珠螺母内滚道的设计加工和装配测试取得了显著效果：1.研制出专用四轴数控电解加工装备，含机床、电源、电解液系统；2.制作了成套专用工装夹具、阴极；3.进行了流场仿真，并得出有意义结论，用于指导实际加工；4.加工出了大导程螺母内滚道，升角40°，轮廓截型误差±0.025mm；5.装配了一套含新工艺加工的螺母的滚珠丝杠副；实现了加工速度高达3mm/min，表面粗糙度达0.6μm的多头大导程滚珠螺母内滚道高效、高质电解加工；通过提出的一种全新的大导程滚珠螺母内滚道的加工方法，为我国大导程滚珠螺母内滚道加工另辟蹊径，实现技术突破；2.相比于现有工艺加工滚道螺旋升角一般小于17°，个别订制可以达到35°，新方法可以实现任意升角的滚道加工，具有明显技术优势；3.拓展了电解加工应用领域，充分发挥了其技术优势。