盆状砂轮磨削钟形壳椭圆沟道的研究
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摘要
等速万向节钟形壳是汽车的重要部件之一，其内球表面具有弧形轨道和直形轨道两种形式，其轨道的截面为椭圆弧形，材料为55钢。目前，生产厂家大多采用指状砂轮近似磨削椭圆沟道，理论误差较大。为了减小钟形壳椭圆沟道磨削的理论误差，本文提出用CBN盆状砂轮磨削椭圆沟道的一种新方法，并建立了盆状砂轮的数学模型。分别采用模拟椭圆圆弧的方法、单纯形法、随机方向搜索法对盆状砂轮形状进行了优化。对某钟形壳椭圆沟道的仿真结果表明，最大理论误差可减小到0．631μm，小于数控钟形壳沟道磨床运动控制的最小单位。
针对弧形沟道和直形沟道的不同磨削特点，分别讨论了盆状砂轮对刀点位置的确定以及沟道磨床的运动过程。利用Pro／Engineer建立了等速万向节钟形壳沟道专用CNC磨床的运动仿真系统，分析了CBN盆状砂轮的修磨量对沟道磨床对刀点的影响。进行了弧形沟道和直形沟道的磨削实验，并利用柔性关节臂座标测量机对磨削的沟道廓形进行了测量，进一步证实了这种磨削工艺的可行性。
为了计算盆状砂轮磨削钟形壳椭圆沟道的磨削力，将该磨削过程简化为：均匀分布的磨粒沿着假想椭圆上绕砂轮轴高速移动，同时假想椭圆又在与砂轮轴成一定夹角的直线上作进给运动。
将磨粒简化为圆锥形，且假设只有第一圈磨粒参与磨削工作，详细研究了轴向进给周边轮廓磨削稳定阶段和切入阶段的磨削力模型；根据磨粒间距测量实验、CBN砂轮平面磨削55钢的实验，采用随机方向搜索法对所建立的基于未变形磨屑厚度的平面磨削力通用模型进行了优化拟合，得到了磨削55钢的CBN砂轮的参数；根据CBN砂轮的参数和平面磨削实验数据，得到了CBN砂轮磨削55钢的单位磨削力的拟合公式；通过CBN砂轮轴向进给周边轮廓磨削55钢的实验，对建立的轴向进给周边轮廓磨削力模型进行了验证和分析。
对CBN盆状砂轮磨削等速万向节钟形壳椭圆沟道的磨削力进行了分析。结果表明：在盆状砂轮磨削万向节钟形壳椭圆沟道的过程中，可以通过提高砂轮转速或减小进给速度的办法来减小磨削力和提高表面加工质量；盆状砂轮的总磨削力随磨粒间距的减小而增加，但单颗磨粒的磨削力和残留高度均随磨粒间距的减小而减小，因此在保证表面质量的前提下，可以使用磨粒间距较大的砂轮来减小磨削功率。
利用Deforn-3D软件，针对单个磨粒分别进行了平面磨削和轴向进给周边轮廓磨削的有限元仿真分析，进一步验证了本文所建立的平面磨削力模型和轴向进给周边轮廓磨削力模型。
The outer race of constant universal velocity joint (CVJ) is one of the most important components of vehicles, and its inner spherical surface has axially arc grooves or axially straight grooves with elliptical section, whose material is steel 55. At present, the finger-like grinding wheel is widely used to approximately grind elliptical groove in many manufacturers of CVJ, but the theoretical error of this method is large. In order to decrease the error, a novel grinding method with basin-like grinding wheel is proposed in this dissertation. Then the dissertation establishes the mathematical model, optimizes the parameters by means of simulating elliptical arc, restrictive random direction method and simplex method respectively. The results of simulation for a kind of elliptical groove ground by basin-like grinding wheel indicate that the maximum theoretical error will be reduced to 0.631μm, which is less than the resolution of grinding wheel axial motion of outer race ball track grinding machine.
Refer to the different grinding characteristics between straight grooves and arc grooves, the dissertation focus on the grinding process of elliptical groove grinding machine, fixes the cutter setting position, establishes the simulation system of CNC outer race ball track grinding machine by Pro/ Engineer, and analyses the influence of dressing quantity on the cutter setting position of CBN basin-like grinding wheel in different elliptical groove grinding machine.The grinding experiments of arc grooves and straight grooves with the basin-like grinding wheel were completed ,and the measurements of the grooves by portable arm coordinate measuring machine were carried out, which validates the feasiblity of this grinding technology.
In order to calculate the grinding force of the basin-like grinding wheel in grinding outer race elliptical grooves, the dissertation simplifies the grinding process as follow: the evenly distributed abrasive grains move around grinding wheel axis along an imaginary ellipse at high speed, while the imaginary ellipse moves along the trace deflected from the grinding wheel axis simultaneously.
Simplifying the geometric shape of abrasive grains as cone-shape, the dissertation studies the grinding force models both of the cut-in phase and stable phase in profile grinding with axial feed in detail on the assumption that the first circuit abrasive grit of grinding wheel took part in the grinding process; According to the experiments of inter-grain spacing measures and surface grinding of steel 55 with CBN grinding wheel,optimizes the parameters of universal calculation model of grinding force based on undeformed chip thickness by restrictive random direction method, obtains the parameters of the CBN grinding wheel, then presents the optimum fitting equations of unit grinding force in grinding steel 55 with CBN grinding wheel; According to the experimental results for axial feed grinding of steel 55 with CBN grinding wheel, validates and analyses the grinding force model of profile grinding with axial feed.
The analysis of grinding force in CVJ outer race elliptical groove grinding with basin-like grinding wheel reveals that, the grinding force will be decreased and the surface quality will be improved, if wheel velocity increased and feed velocity decreased. On the other hand, the grinding force of basin-like grinding wheel will be increased but the grinding remain height and the grinding force of abrasive grit will be decreased with the decrease of inter-grain spacing. Therefore, on the premise of guaranting surface quality, the grinding method of using bigger inter-grain spacing can reduce grinding power.
At last, the dissertation further validates the grinding force models of surface grinding and profile grinding with axial feed by finite element simulation analysis of unit abrasive grit using Deform-3D.
针对弧形沟道和直形沟道的不同磨削特点，分别讨论了盆状砂轮对刀点位置的确定以及沟道磨床的运动过程。利用Pro／Engineer建立了等速万向节钟形壳沟道专用CNC磨床的运动仿真系统，分析了CBN盆状砂轮的修磨量对沟道磨床对刀点的影响。进行了弧形沟道和直形沟道的磨削实验，并利用柔性关节臂座标测量机对磨削的沟道廓形进行了测量，进一步证实了这种磨削工艺的可行性。
为了计算盆状砂轮磨削钟形壳椭圆沟道的磨削力，将该磨削过程简化为：均匀分布的磨粒沿着假想椭圆上绕砂轮轴高速移动，同时假想椭圆又在与砂轮轴成一定夹角的直线上作进给运动。
将磨粒简化为圆锥形，且假设只有第一圈磨粒参与磨削工作，详细研究了轴向进给周边轮廓磨削稳定阶段和切入阶段的磨削力模型；根据磨粒间距测量实验、CBN砂轮平面磨削55钢的实验，采用随机方向搜索法对所建立的基于未变形磨屑厚度的平面磨削力通用模型进行了优化拟合，得到了磨削55钢的CBN砂轮的参数；根据CBN砂轮的参数和平面磨削实验数据，得到了CBN砂轮磨削55钢的单位磨削力的拟合公式；通过CBN砂轮轴向进给周边轮廓磨削55钢的实验，对建立的轴向进给周边轮廓磨削力模型进行了验证和分析。
对CBN盆状砂轮磨削等速万向节钟形壳椭圆沟道的磨削力进行了分析。结果表明：在盆状砂轮磨削万向节钟形壳椭圆沟道的过程中，可以通过提高砂轮转速或减小进给速度的办法来减小磨削力和提高表面加工质量；盆状砂轮的总磨削力随磨粒间距的减小而增加，但单颗磨粒的磨削力和残留高度均随磨粒间距的减小而减小，因此在保证表面质量的前提下，可以使用磨粒间距较大的砂轮来减小磨削功率。
利用Deforn-3D软件，针对单个磨粒分别进行了平面磨削和轴向进给周边轮廓磨削的有限元仿真分析，进一步验证了本文所建立的平面磨削力模型和轴向进给周边轮廓磨削力模型。
The outer race of constant universal velocity joint (CVJ) is one of the most important components of vehicles, and its inner spherical surface has axially arc grooves or axially straight grooves with elliptical section, whose material is steel 55. At present, the finger-like grinding wheel is widely used to approximately grind elliptical groove in many manufacturers of CVJ, but the theoretical error of this method is large. In order to decrease the error, a novel grinding method with basin-like grinding wheel is proposed in this dissertation. Then the dissertation establishes the mathematical model, optimizes the parameters by means of simulating elliptical arc, restrictive random direction method and simplex method respectively. The results of simulation for a kind of elliptical groove ground by basin-like grinding wheel indicate that the maximum theoretical error will be reduced to 0.631μm, which is less than the resolution of grinding wheel axial motion of outer race ball track grinding machine.
Refer to the different grinding characteristics between straight grooves and arc grooves, the dissertation focus on the grinding process of elliptical groove grinding machine, fixes the cutter setting position, establishes the simulation system of CNC outer race ball track grinding machine by Pro/ Engineer, and analyses the influence of dressing quantity on the cutter setting position of CBN basin-like grinding wheel in different elliptical groove grinding machine.The grinding experiments of arc grooves and straight grooves with the basin-like grinding wheel were completed ,and the measurements of the grooves by portable arm coordinate measuring machine were carried out, which validates the feasiblity of this grinding technology.
In order to calculate the grinding force of the basin-like grinding wheel in grinding outer race elliptical grooves, the dissertation simplifies the grinding process as follow: the evenly distributed abrasive grains move around grinding wheel axis along an imaginary ellipse at high speed, while the imaginary ellipse moves along the trace deflected from the grinding wheel axis simultaneously.
Simplifying the geometric shape of abrasive grains as cone-shape, the dissertation studies the grinding force models both of the cut-in phase and stable phase in profile grinding with axial feed in detail on the assumption that the first circuit abrasive grit of grinding wheel took part in the grinding process; According to the experiments of inter-grain spacing measures and surface grinding of steel 55 with CBN grinding wheel,optimizes the parameters of universal calculation model of grinding force based on undeformed chip thickness by restrictive random direction method, obtains the parameters of the CBN grinding wheel, then presents the optimum fitting equations of unit grinding force in grinding steel 55 with CBN grinding wheel; According to the experimental results for axial feed grinding of steel 55 with CBN grinding wheel, validates and analyses the grinding force model of profile grinding with axial feed.
The analysis of grinding force in CVJ outer race elliptical groove grinding with basin-like grinding wheel reveals that, the grinding force will be decreased and the surface quality will be improved, if wheel velocity increased and feed velocity decreased. On the other hand, the grinding force of basin-like grinding wheel will be increased but the grinding remain height and the grinding force of abrasive grit will be decreased with the decrease of inter-grain spacing. Therefore, on the premise of guaranting surface quality, the grinding method of using bigger inter-grain spacing can reduce grinding power.
At last, the dissertation further validates the grinding force models of surface grinding and profile grinding with axial feed by finite element simulation analysis of unit abrasive grit using Deform-3D.
引文
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