轴承滚子电化学机械加工技术研究
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摘要
圆柱滚子轴承在承载状态下,滚子的两侧端部在和内、外滚道接触处会产生高度应力集中,由此所导致的疲劳破坏、剥落会向中间发展,导致整个轴承失效,大大减少了轴承的寿命。
对滚子进行凸度设计后,即将滚子的直母线改为凸度母线,能有效地改善滚子和内外圈接触区的应力分布,对提高轴承的使用寿命有很大帮助。目前,发达国家对圆柱、圆锥滚子轴承滚子都要求带凸度,因此对滚子凸度设计的研究就很重要,即能提高轴承本身的寿命,还能增加国家在轴承设计上的技术优势。本文利用有限元分析软件ANSYS进行对数母线滚子凸度的设计,对不同载荷,不同凸度量下的接触区的应力分布做了详细的比较分析,最后得到了一个较为合理的凸型和凸度量区间。
另外,轴承滚子的表面粗糙度对轴承的寿命也有很大的影响,较低的粗糙度值对降低摩察系数,减小噪声,提高滚子旋转精度等起到明显的作用。考虑到电化学机械光整加工在改善表面粗糙度方面所起到的效果,本文提出了轴承滚子的电化学机械复合光整加工,设计和制造了电化学机械光整轴承滚子的实验装置,包括电源、电解液循环系统、滚子的运动系统、机械磨削装置和阴极的进给装置等,并通过正交实验初步研究了工件转速、电流密度、砂带压力、砂带粒度和加工时间等工艺参数对轴承滚子表面质量的影响。研究结果表明,电化学机械复合光整技术在降低滚子的表面粗糙度方面作用明显。该方法工艺简单,易操作,具有很好的实用性。
利用直母线加工轴承滚子的优化参数,设计和制造了圆弧型阴极,尝试加工凸度滚子,把电流和加工时间作为影响凸度加工的重要参数,设计了新的实验表,实验结果表明,电化学机械复合光整加工技术能够在降低滚子表面粗糙度的同时,实现凸度的加工。
High stress concentration happens on both sides of the rollers, also the inner and outer raceway generating lines, when cylindrical roller bearing is in a state of being loaded. The stress concentration mentioned above often leads to further development of fatigue collapse and breakingoff toward to the core, which could make the entire bearing fail. This plays an important role in the decaying of the bearing life.
The design of crowning roller, which changes the direct bus of roller to crowning bus, can effectively improve the stress distribution of rolling contact zone. At present, the developed countries require the cylindrical, tapered roller to be with crowning profile. So it becomes very important to do research into the design of crowning roller. By means of finite element method software ANSYS, the design of roller with logarithmic profile has been done. Through the comparison of stress distribution of contact zone under different loads, finally get a more reasonable crowning profile and crowning metric.
At the same time, the surface roughness of bearing roller has a great influence on the bearing life. The lower roughness can reduce the friction coefficient, noise and improve the precision of rotation. Research has proved that electrochemical mechanical finishing can improve the surface roughness greatly. This paper presents ECM-mech finishing of bearing roller, designs and manufactures a set of ECM-mech finishing equipment including power supply, recycle system of electrolyte, roller motion system, grinding device, cathode feeding device and so on. The influence of technologic parameters, such as speed of workpiece, electric current density, pressure of belt, granularity of belt and processing time have been researched primarily by orthogonal experiment, which provide the foundation for optimization of technological parameters. Finally experiments analysis shows that ECM-mech finishing can improve the surface quality and reduce the surface roughness greatly. The method is simple, practical and easy to operate.
Then design and manufacture a crowning cathode, consider electric current density and processing time as the main parameters to do the experiment of crowning rollers. The results shows that ECM-mech finishing can not only reduce the surface roughness greatly, but also get the crowning profile.
对滚子进行凸度设计后,即将滚子的直母线改为凸度母线,能有效地改善滚子和内外圈接触区的应力分布,对提高轴承的使用寿命有很大帮助。目前,发达国家对圆柱、圆锥滚子轴承滚子都要求带凸度,因此对滚子凸度设计的研究就很重要,即能提高轴承本身的寿命,还能增加国家在轴承设计上的技术优势。本文利用有限元分析软件ANSYS进行对数母线滚子凸度的设计,对不同载荷,不同凸度量下的接触区的应力分布做了详细的比较分析,最后得到了一个较为合理的凸型和凸度量区间。
另外,轴承滚子的表面粗糙度对轴承的寿命也有很大的影响,较低的粗糙度值对降低摩察系数,减小噪声,提高滚子旋转精度等起到明显的作用。考虑到电化学机械光整加工在改善表面粗糙度方面所起到的效果,本文提出了轴承滚子的电化学机械复合光整加工,设计和制造了电化学机械光整轴承滚子的实验装置,包括电源、电解液循环系统、滚子的运动系统、机械磨削装置和阴极的进给装置等,并通过正交实验初步研究了工件转速、电流密度、砂带压力、砂带粒度和加工时间等工艺参数对轴承滚子表面质量的影响。研究结果表明,电化学机械复合光整技术在降低滚子的表面粗糙度方面作用明显。该方法工艺简单,易操作,具有很好的实用性。
利用直母线加工轴承滚子的优化参数,设计和制造了圆弧型阴极,尝试加工凸度滚子,把电流和加工时间作为影响凸度加工的重要参数,设计了新的实验表,实验结果表明,电化学机械复合光整加工技术能够在降低滚子表面粗糙度的同时,实现凸度的加工。
High stress concentration happens on both sides of the rollers, also the inner and outer raceway generating lines, when cylindrical roller bearing is in a state of being loaded. The stress concentration mentioned above often leads to further development of fatigue collapse and breakingoff toward to the core, which could make the entire bearing fail. This plays an important role in the decaying of the bearing life.
The design of crowning roller, which changes the direct bus of roller to crowning bus, can effectively improve the stress distribution of rolling contact zone. At present, the developed countries require the cylindrical, tapered roller to be with crowning profile. So it becomes very important to do research into the design of crowning roller. By means of finite element method software ANSYS, the design of roller with logarithmic profile has been done. Through the comparison of stress distribution of contact zone under different loads, finally get a more reasonable crowning profile and crowning metric.
At the same time, the surface roughness of bearing roller has a great influence on the bearing life. The lower roughness can reduce the friction coefficient, noise and improve the precision of rotation. Research has proved that electrochemical mechanical finishing can improve the surface roughness greatly. This paper presents ECM-mech finishing of bearing roller, designs and manufactures a set of ECM-mech finishing equipment including power supply, recycle system of electrolyte, roller motion system, grinding device, cathode feeding device and so on. The influence of technologic parameters, such as speed of workpiece, electric current density, pressure of belt, granularity of belt and processing time have been researched primarily by orthogonal experiment, which provide the foundation for optimization of technological parameters. Finally experiments analysis shows that ECM-mech finishing can improve the surface quality and reduce the surface roughness greatly. The method is simple, practical and easy to operate.
Then design and manufacture a crowning cathode, consider electric current density and processing time as the main parameters to do the experiment of crowning rollers. The results shows that ECM-mech finishing can not only reduce the surface roughness greatly, but also get the crowning profile.
引文
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[24]Poritstsky H. Stress and deflections of cylindrical bodies in contact[J]. Applied Mech. 1950,17(1):193-201.
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[31]张朝辉.ANSYS11.0有限元分析理论与工程应用[M].北京市：电子工业出版社,2008.
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[37]Ludwik kanin.Modelling of Rollers in Calculation of Slewing Bearing with the Use of Finite Elements[J]. Mechanism and Machine Theory.2006,41:1359-1376.
[38]S. Satyanarayana, S. N. Melkote. Finite Element Modeling of Fixture-workpiece Contacts: Single Contact Modeling and Experimental Verification [J]. International Journal of Machine Tools& Manufacture.2004,44:903-913.
[39]Ju, S. H.,Horng, T. L., Cha, K. C. Comparisons of Contact Pressures of Crowned Rollers. Proceedings of the Institution of Mechanical Engineers, Part J:Journal of Engineering Tribology.2000,214,147-155.
[40]马星国,孙雪,尤小梅.基于ANSYS的滚针轴承的有限元分析[J].中国工程机械学报.2008,6(3)：328-332.
[41]刘宁,张刚,高刚等.基于ANSYS圆柱滚子轴承有限元应力分析[J].轴承.2006,(12)：8-10.
[42]高红斌.基于有限元法的滚动轴承结构和模态分析与研究[J].机械工程与自动化.2007,8(4)：90-95.
[43]王大力,孙立明,单服兵等.ANSYS在求解轴承接触问题中的应用[J].轴承.2002,(9)：1-5.
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[2]Lundberg G,Palmgren A.Dynamic Capacity of Rolling Bearings. Acta Polytechnica Mechanical Engineering Series[J].1947,1(3)
[3]魏延刚.圆柱滚子轴承滚子凸度量的有限元分析[J].轴承.2004,(4)：1-4.
[4]陈家庆,张沛,徐林林.滚动轴承滚子凸度设计的理论研究进展[J].北京石油化工学院学报.2001,9(1)：32-38.
[5]马玲.滚子轴承滚道凸度电化学砂带磨削加工技术研究[D]：(硕十学位论文).辽宁：大连理工大学,2005.
[6]周敏,燕阳,凌颖等.滚动轴承电化学机械光整加工[J].冶金设备.2003,(6)：51-53.
[7]高作斌,丁海善.滚子凸度加工技术现状及发展趋势[J].轴承.2003,(8)：36-41.
[8]王世峰,段富宣,姚志国.圆柱滚子凸度设计应用.制造技术及机床[J].2004,7：91-92.
[9]夏新涛,马伟,颉谭成等.滚动轴承制造工艺学[J].北京：机械工业出版社,2007.
[10]刘仲辉.滚子轴承外圈滚道凸度的磨削[J].轴承.1998,(10)：9-12.
[11]陶彬.轴承滚道电化学机械凸度成型与光整加工技术基础研究[D]：(博士学位论文).辽宁：大连理工大学,2009.
[12]王有为,魏丽芳.凸度圆柱滚子的磨削与分析[J].轴承.2000,(4)：22-23.
[13]吴飞科.圆锥滚子轴承接触应力分析及凸度设计[D]：(硕士学位论文).河南：河南科技大学,2007.
[14]Hertz H. On the contact of elastic solids. J. Reine und Angew[J].1881,92(5):156-171.
[15]Hertz H. On the contact of elastic solids and on hardness[J]. J. Reine und Angew. 1896,45(2):189-192.
[16]Beeching R. Theoretical discussion of pitting failures in gears[J]. Proceeding of the Institution of Mechanical Engineers.1984,158:317-326.
[17]Timoshenko S, J.N. Goodier. Theory of Elasticity [M].3rd. New York:McGraw Hill,1970, 45-87.
[18]Ewen E M. Stresses in elastic cylinders in contact along a generatrix[J]. Phiosophical Magazine.1949,40(303):454-459.
[19]Kalker J J.A survey of wheel-rail rolling contact theory[J]. Vehicle System Dynamics.1979,5(317):35-41.
[20]Thommas H R. V. A. Hoersch. Stress due to the pressure of one elastic solid upon another[J]. Univ.Illinois, Engins.1930,212(2):66-99.
[21]Smith J 0. G. K Liu. Stresses due to tangential and normal loads on an elastic solid with applications to some contact stress problems[J]. Applied Mechanics.1953,20(2):157-166.
[22]Lundberg G,Sjovall H.Stress and deformation in elastic solids[M]. Sweden:Chalmers Univ.1958.
[23]H.Fessler. Contact Stresses in toroids under radial loads[J]. Applied Physics. 1957,8:387-393.
[24]Poritstsky H. Stress and deflections of cylindrical bodies in contact[J]. Applied Mech. 1950,17(1):193-201.
[25]王建伟.圆锥滚子轴承凸度的有限元分析[D]：(硕士学位论文).河南：河南科技大学,2003.
[26]Nayak L, Johnson K. L. Pressure between Elastic Bodies Having a Slender Area of Contact and Arbitrary Profiles[J].International Journal of Mechanical Sciences.1979,21: 237-247.
[27]Reusner H. The Logarithmic Roller Profile —the Key to Superior Performance of Cylindrical and Taper Roller Bearing[J]. The Ball Bearing Journal.1987, (203):2-10.
[28]张兰,孙立明,夏新涛,陈原.工程机械车桥专用圆柱滚子轴承的设计[J].轴承.2009,(10)：5-8.
[29]马家驹,徐文,刘双表等.对数滚子的工程设计[J].轴承,1997,(6)：2-5.
[30]陈家庆,张沛,刘林林.滚动轴承滚子凸度设计的理论研究进展[J].北京石油化工学院学报.2001,9(1)：32-38.
[31]张朝辉.ANSYS11.0有限元分析理论与工程应用[M].北京市：电子工业出版社,2008.
[32]尚晓江,邱峰,赵海峰等.ANSYS结构有限元高级分析方法与范例应用[M].北京市：中国水利水电出版社,2008.
[33]博弈创作室.ANSYS9.0经典产品基础教程与实例详解[M].北京：中国水利水电出版社,2006.
[34]余伟炜,高炳军等.ANSYS在机械与化工装备中的应用[M].北京：中国水利水电出版社,2006.
.[35]龚曙光等.ANSYS工程应用实例解析[M].北京：机械工业出版社,2003.
[36]博弈创作室.ANSYS9.0经典产品高级分析技术与实例详解[M].北京：中国水利水电出版社,2005.
[37]Ludwik kanin.Modelling of Rollers in Calculation of Slewing Bearing with the Use of Finite Elements[J]. Mechanism and Machine Theory.2006,41:1359-1376.
[38]S. Satyanarayana, S. N. Melkote. Finite Element Modeling of Fixture-workpiece Contacts: Single Contact Modeling and Experimental Verification [J]. International Journal of Machine Tools& Manufacture.2004,44:903-913.
[39]Ju, S. H.,Horng, T. L., Cha, K. C. Comparisons of Contact Pressures of Crowned Rollers. Proceedings of the Institution of Mechanical Engineers, Part J:Journal of Engineering Tribology.2000,214,147-155.
[40]马星国,孙雪,尤小梅.基于ANSYS的滚针轴承的有限元分析[J].中国工程机械学报.2008,6(3)：328-332.
[41]刘宁,张刚,高刚等.基于ANSYS圆柱滚子轴承有限元应力分析[J].轴承.2006,(12)：8-10.
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