精密冷滚轧机床本体关键技术研究
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摘要
精密冷滚轧是金属塑性成形与轧制成形相结合的一种新的无切削加工方法，主要应用于渐开线花键的批量生产。
冷滚轧机床齿形模具运动的同步精度和机床刚度与花键成型精度密切相关。论文通过对齿轮齿条同步机构同步误差的理论分析与定量计算，确定了各误差因素在总误差中所占比重并给出了减小同步误差的具体措施。
论文针对机架结构及承载特性，研制结构优化设计程序OPT XP4，以结构重量最小为目标函数，以满足机架变形要求为前提，以板厚、梁高及拉杆尺寸为设计变量，对机架进行优化计算，并得出各设计变量对机架刚度影响的一般规律。
论文以大型非线性有限元软件MARC作为分析工具，对优化后的机架、滑台及垫板进行三维接触计算，对机床的三维变形分布进行了定量分析，并根据分析结果提出了相应的改进设计方案及合理化建议。
Precision CRF(Cold Roll Forming) is a kind of new technology in non-chiped process, which integrates the metal plastic forming and rolling forming is mainly used in massproduced involute spline production because of good efficiency and processing quality.
The precision of involute spline forming is closely-related with the synchro accuracy and the rigidity of CRF machine. Through the theoretical analysis and stint computation of the synchro-mechanism, the proportion that each error factor takes in total error are determined and corresponding measures for improving synchronized accuracy of CRF machine are suggested.
Aimed at the frame structure and bearing property, optimization calculation program OPT_XP4 is composed independently, with machine weight minimum as goal function, under the condition that the frame deformation requirement was fulfilled, the optimization calculation is carried out for some design variables including plate thickness, beam high and pulling bolt size etc, the general regulation of various design variables' effect on the frame rigidity was obtained.
Take the large non-linear FEM software MARC as the analysis tool to calculate the 3D deformation distribution of CRF machine frame,slide seat and boslter plate. Combine with the calculation result, corresponding improving design scheme is presented.
冷滚轧机床齿形模具运动的同步精度和机床刚度与花键成型精度密切相关。论文通过对齿轮齿条同步机构同步误差的理论分析与定量计算，确定了各误差因素在总误差中所占比重并给出了减小同步误差的具体措施。
论文针对机架结构及承载特性，研制结构优化设计程序OPT XP4，以结构重量最小为目标函数，以满足机架变形要求为前提，以板厚、梁高及拉杆尺寸为设计变量，对机架进行优化计算，并得出各设计变量对机架刚度影响的一般规律。
论文以大型非线性有限元软件MARC作为分析工具，对优化后的机架、滑台及垫板进行三维接触计算，对机床的三维变形分布进行了定量分析，并根据分析结果提出了相应的改进设计方案及合理化建议。
Precision CRF(Cold Roll Forming) is a kind of new technology in non-chiped process, which integrates the metal plastic forming and rolling forming is mainly used in massproduced involute spline production because of good efficiency and processing quality.
The precision of involute spline forming is closely-related with the synchro accuracy and the rigidity of CRF machine. Through the theoretical analysis and stint computation of the synchro-mechanism, the proportion that each error factor takes in total error are determined and corresponding measures for improving synchronized accuracy of CRF machine are suggested.
Aimed at the frame structure and bearing property, optimization calculation program OPT_XP4 is composed independently, with machine weight minimum as goal function, under the condition that the frame deformation requirement was fulfilled, the optimization calculation is carried out for some design variables including plate thickness, beam high and pulling bolt size etc, the general regulation of various design variables' effect on the frame rigidity was obtained.
Take the large non-linear FEM software MARC as the analysis tool to calculate the 3D deformation distribution of CRF machine frame,slide seat and boslter plate. Combine with the calculation result, corresponding improving design scheme is presented.
引文
1 邱宣怀等．机械设计．第四版．北京：高等教育出版社，1999：126-127
2 NACHI(日本)株式会社产品样本
3 EX-CELL-O(德国)公司产品样本
4 Dale J. Garden et al. Method Of Conditioning The Surface Of A Spline Forming Rack. United States Patent, 1996:5509287
5 James T. Killop et al. Rack Assembly For Forming Splines In Thin-Wall Member. United States Patent, 1989:4852375
6 Donald E. Blue et al. Tooth Forming Rack With Replaceable Inserts. United States Patent, 1977:4028921
7 Robert I. Miller et al. Toothed Forming Tool. United States Patent, 1973:3857273
8 孙士宝，崔世强，高才良等．渐开线花键冷搓成型工艺中咬入条件的建立．锻压技术，1999，(3)：35-37
9 孙士宝，崔世强，高才良等．渐开线花键冷搓成型工艺模具设计及制造．锻压技术，1999，(4)：43-45
10 顾永生．现代轿车先进制造工艺．上海：上海交通大学出版社，1998：243-249
11 James C. Everlove et al. Vertical Rack Spline Forming Machine. United States Patent, 1999:5950471
12 Marvin R. Anderson et al. Gear Forming Machine. United States Patent, 1974:3793866
13 Harald N. Jungesjo et al. Forming Machine Including Rotary Drive Mechanism. United States Patent, 1981:4270375
14 Robert G. Roth et al. Forming Machine Including Drive Mechanism Having Rack And Gear Synchronization. United States Patent, 1985:4519231
15 Harald N. Jungesjo et al. Tooth Forming Machine. United States Patent, 1979:4155236
16 Donald E. Blue et al. Tooth Forming Machine. United States Patent, 1974:3818736
17 Leland F. Blatt et al. Equal Area Displacement Hydraulic Cylinder. United States Patent, 1976:3949650
18 朱伟成．汽车零件精密锻造技术．北京：北京理工大学出版社，1999：139-140
19 孙士宝．渐开线花键轴冷搓工艺的研究．[燕山大学工学硕士论文]．1993：85-93
20 孙恒，陈作模．机械原理．第五版．北京：高等教育出版社，1996：245-294
21 楠波，成电．精密齿轮传动装置—理论与实践．北京：国防工业出版社，1978：92-150
22 狄岚，狄锦如．提高数控机床主轴组轴承性能特性的方法．制造技术与机床，1999，(5)：7-10
23 何贡．互换性与测量技术．第二版．天津：天津科学技术出版社，1993：91-137
24 马世麟，傅仁本．材料力学(上册)．北京：机械工业出版社，1996：229-250
25 S．P．铁木辛哥，J．M．格尔．材料力学(上册)．李春亮．第二版．台湾：晓园出版社，1992：275-326
26 S．P．铁木辛哥，J．M．格尔．材料力学(下册)．李春亮．第二版．台湾：晓园出版社，1992：459-516
27 万长森．滚动轴承的分析方法．北京：机械工业出版社，1987：44-271
28 Brian Siler, Jeff Spotts. Visual Basic 6.0开发使用手册．康博创作室．北京：机械工业出版社，1999：107-150
29 胡鹏浩，费业泰，黄强先．考虑受力变形和受热变形的滚动轴承初始游隙的确定．机械设计，1999，(9)：41-43
30 O.C.Zienkiewicz. The Finite Elenment Method In Engineering Science. London: Mcgraw-Hill, 1971:35-47
31 O.C.Zienkiewicz. The Finite Elenment Method. London: McGraw-Hill, 1977:13-24
32 Robert D.Cook. Concept and Application of Finite Element Analysis. A Second Edition. London: John Wiley & Sons, 1981:55-63
33 俞新陆．液压机现代设计理论．北京：机械工业出版社，1987：52-105
34 天津市锻压机床厂．中小型液压机设计计算．天津：天津人民出版社，1977：115-130
35 何德誉．曲柄压力机．第二版．北京：机械工业出版社，1981：166-173
36 范钦珊．材料力学计算机分析．北京：高等教育出版社，1987：339-354
37 朱伯芳．有限单元法原理与应用．第二版．北京：中国水利水电出版社，1998：1-31
38 王勖成，邵敏．有限单元法基本原理和数值方法．第二版．北京：清华大学出社，1997：275-300
39 李庆扬，王能超，易大义．数值分析．第三版．武汉：华中理工大学出版社，1986：239-247
40 吕丽萍．有限元法及其在锻压工程中的应用．西安：西北工业大学出版社，1987：52-105
41 刘维信．机械最优化设计．第二版．北京：清华大学出版社，1994：143-154
42 宋天霞．大型复杂结构优化设计计算．武汉：华中理工大学出版社，1992：23-28
43 马世麟，傅仁本．材料力学(下册)．北京：机械工业出版社，1996：229-250
44 徐士良．FORTRAN常用算法程序集．北京：清华大学出版社，1992：351-360
45 Walter S. Brainerd, Charles H. Goldberg, Jeanne C. Adams. Fortran90编程指南．袁驷，叶康生．第三版．北京：高等教育出版社，2000：90-118
46 范贻明，沈雪梅．FORTRAN77／90程序设计及软件基础．北京：人民邮电出版社，1995：226-267
47 唐章宏，薛赛男，冯峰等．Visual Fortran程序设计．北京：人民邮电出版社，2000：74-88
48 New Features Guide. U.S.A. MSC. Software Corporation, 2000:199-215
49 Training Guide. U.S.A. MSC. Software Corporation, 2000:89-117
50 User's Guide. U.S.A. MSC. Software Corporation, 2000:85-129
51 Theory And User Information Index. U.S.A. MSC. Software Corporation, 2000:411-595
52 Element Library. U.S.A. MSC. Software Corporation, 2000:130-136
53 Demonstration Problems. U.S.A. MSC. Software Corporation, 2000:1409-1673
54 Chen Wen-Hwa, Yen Jyi-Tyan. Finite Element Analysis of Finite Deformation Contact Problems with Friction. Computer & Structures, 1988,29(3):423-436
55 周杰，伍驭美，Siegert K.拉紧镙栓预紧力对闭式组合机身压力机精度的影响．锻压机械．2001，36(1)：35-38
2 NACHI(日本)株式会社产品样本
3 EX-CELL-O(德国)公司产品样本
4 Dale J. Garden et al. Method Of Conditioning The Surface Of A Spline Forming Rack. United States Patent, 1996:5509287
5 James T. Killop et al. Rack Assembly For Forming Splines In Thin-Wall Member. United States Patent, 1989:4852375
6 Donald E. Blue et al. Tooth Forming Rack With Replaceable Inserts. United States Patent, 1977:4028921
7 Robert I. Miller et al. Toothed Forming Tool. United States Patent, 1973:3857273
8 孙士宝，崔世强，高才良等．渐开线花键冷搓成型工艺中咬入条件的建立．锻压技术，1999，(3)：35-37
9 孙士宝，崔世强，高才良等．渐开线花键冷搓成型工艺模具设计及制造．锻压技术，1999，(4)：43-45
10 顾永生．现代轿车先进制造工艺．上海：上海交通大学出版社，1998：243-249
11 James C. Everlove et al. Vertical Rack Spline Forming Machine. United States Patent, 1999:5950471
12 Marvin R. Anderson et al. Gear Forming Machine. United States Patent, 1974:3793866
13 Harald N. Jungesjo et al. Forming Machine Including Rotary Drive Mechanism. United States Patent, 1981:4270375
14 Robert G. Roth et al. Forming Machine Including Drive Mechanism Having Rack And Gear Synchronization. United States Patent, 1985:4519231
15 Harald N. Jungesjo et al. Tooth Forming Machine. United States Patent, 1979:4155236
16 Donald E. Blue et al. Tooth Forming Machine. United States Patent, 1974:3818736
17 Leland F. Blatt et al. Equal Area Displacement Hydraulic Cylinder. United States Patent, 1976:3949650
18 朱伟成．汽车零件精密锻造技术．北京：北京理工大学出版社，1999：139-140
19 孙士宝．渐开线花键轴冷搓工艺的研究．[燕山大学工学硕士论文]．1993：85-93
20 孙恒，陈作模．机械原理．第五版．北京：高等教育出版社，1996：245-294
21 楠波，成电．精密齿轮传动装置—理论与实践．北京：国防工业出版社，1978：92-150
22 狄岚，狄锦如．提高数控机床主轴组轴承性能特性的方法．制造技术与机床，1999，(5)：7-10
23 何贡．互换性与测量技术．第二版．天津：天津科学技术出版社，1993：91-137
24 马世麟，傅仁本．材料力学(上册)．北京：机械工业出版社，1996：229-250
25 S．P．铁木辛哥，J．M．格尔．材料力学(上册)．李春亮．第二版．台湾：晓园出版社，1992：275-326
26 S．P．铁木辛哥，J．M．格尔．材料力学(下册)．李春亮．第二版．台湾：晓园出版社，1992：459-516
27 万长森．滚动轴承的分析方法．北京：机械工业出版社，1987：44-271
28 Brian Siler, Jeff Spotts. Visual Basic 6.0开发使用手册．康博创作室．北京：机械工业出版社，1999：107-150
29 胡鹏浩，费业泰，黄强先．考虑受力变形和受热变形的滚动轴承初始游隙的确定．机械设计，1999，(9)：41-43
30 O.C.Zienkiewicz. The Finite Elenment Method In Engineering Science. London: Mcgraw-Hill, 1971:35-47
31 O.C.Zienkiewicz. The Finite Elenment Method. London: McGraw-Hill, 1977:13-24
32 Robert D.Cook. Concept and Application of Finite Element Analysis. A Second Edition. London: John Wiley & Sons, 1981:55-63
33 俞新陆．液压机现代设计理论．北京：机械工业出版社，1987：52-105
34 天津市锻压机床厂．中小型液压机设计计算．天津：天津人民出版社，1977：115-130
35 何德誉．曲柄压力机．第二版．北京：机械工业出版社，1981：166-173
36 范钦珊．材料力学计算机分析．北京：高等教育出版社，1987：339-354
37 朱伯芳．有限单元法原理与应用．第二版．北京：中国水利水电出版社，1998：1-31
38 王勖成，邵敏．有限单元法基本原理和数值方法．第二版．北京：清华大学出社，1997：275-300
39 李庆扬，王能超，易大义．数值分析．第三版．武汉：华中理工大学出版社，1986：239-247
40 吕丽萍．有限元法及其在锻压工程中的应用．西安：西北工业大学出版社，1987：52-105
41 刘维信．机械最优化设计．第二版．北京：清华大学出版社，1994：143-154
42 宋天霞．大型复杂结构优化设计计算．武汉：华中理工大学出版社，1992：23-28
43 马世麟，傅仁本．材料力学(下册)．北京：机械工业出版社，1996：229-250
44 徐士良．FORTRAN常用算法程序集．北京：清华大学出版社，1992：351-360
45 Walter S. Brainerd, Charles H. Goldberg, Jeanne C. Adams. Fortran90编程指南．袁驷，叶康生．第三版．北京：高等教育出版社，2000：90-118
46 范贻明，沈雪梅．FORTRAN77／90程序设计及软件基础．北京：人民邮电出版社，1995：226-267
47 唐章宏，薛赛男，冯峰等．Visual Fortran程序设计．北京：人民邮电出版社，2000：74-88
48 New Features Guide. U.S.A. MSC. Software Corporation, 2000:199-215
49 Training Guide. U.S.A. MSC. Software Corporation, 2000:89-117
50 User's Guide. U.S.A. MSC. Software Corporation, 2000:85-129
51 Theory And User Information Index. U.S.A. MSC. Software Corporation, 2000:411-595
52 Element Library. U.S.A. MSC. Software Corporation, 2000:130-136
53 Demonstration Problems. U.S.A. MSC. Software Corporation, 2000:1409-1673
54 Chen Wen-Hwa, Yen Jyi-Tyan. Finite Element Analysis of Finite Deformation Contact Problems with Friction. Computer & Structures, 1988,29(3):423-436
55 周杰，伍驭美，Siegert K.拉紧镙栓预紧力对闭式组合机身压力机精度的影响．锻压机械．2001，36(1)：35-38