花键轴冷滚压精密成形理论与实验研究
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摘要
课题来源：国家自然科学基金项目（NO.50675145）“螺纹、花键类零件冷滚压精密成形工艺理论与实验研究”和山西省科技攻关项目(NO.2006031147)“轴类零件冷滚压精密成形新工艺研究与装备开发”。
花键轴冷滚压精密成形是一种无切屑的先进制造技术，具有成形效率高、零件综合性能好等优点。冷滚压成形是一种冷体积塑性变形过程，变形机理复杂，迄今还缺乏一套系统的理论和计算依据，因而影响了该工艺在生产实践过程中的推广和应用。本论文针对成形工艺与装备理论、成形零件精度控制中存在的问题，采用理论分析与试验研究相结合的方法，对花键轴冷滚压精密成形机理、力能参数计算、齿面强化机理、成形精度与质量控制等进行了系统的研究。主要研究内容和结论如下：
通过花键轴冷滚压精密成形过程的理论分析，得到分齿阶段的旋转条件和成形几何条件，提出了限定滚压轮最小齿数和齿顶涂层增加摩擦改善旋转条件的滚压轮设计方案；基于双面无侧隙啮合运动，获得了冷滚压齿部成形时滚压轮和工件接触区特征和接触点的滑动方式；应用滑移线场理论，精确分析了花键轴冷滚压成形过程的单位平均应力，给出了滚压轮和工件齿部接触面积的计算方法和影响因素，并对冷滚压成形过程滚压力和滚压力矩进行了计算。为成形工艺参数的确定、机床及滚压轮的设计提供了理论依据。
在理论分析的基础上，提出冷滚压机床主轴阻尼减振方案，与企业合作研制了专用数控冷滚压机床，解决了冷滚压成形变形力剧烈波动导致零件成形精度低等关键问题；自主设计研制了花键轴冷滚压精密成形过程的力能参数测试系统，实现了对实际零件成形过程中动态滚压力和滚压力矩变化的在线测试，研究了滚压轮转速、进给速度对最大滚压力和最大滚压力矩的影响，并对力能参数的理论计算结果进行了验证；首次对冷滚压精密成形精度、表面质量和力学性能进行了综合试验，分析了花键零的齿面金属的流动特征，得到了变形区的作用范围。揭示了冷滚压成形及工艺参数对零件精度、质量和性能的影响，获得了齿面强化和硬化机理。结果表明，花键轴冷滚压精密成形不仅能赋予零件复杂形状与精确尺寸，而且使成形零件原有微观组织得到改善，提高了花键的综合性能，达到了零件的“成形/成性”的一体化调控，尤其适合国防等工业对于高质量、高精度轴类件生产的需求。
通过对自由分度式花键轴冷滚压精密成形齿距累积误差的分析，建立了齿距累积误差与各工艺参数之间的关系，提出了一种速度强制同步控制滚压方案，实现了冷滚压过程的动态分度，提高了零件的成形精度。分析了常见成形缺陷产生的原因，提出了花键轴冷滚压成形质量的控制措施，解决了花键轴冷滚压精密成形工艺走向工业应用的关键技术问题，丰富了花键轴冷滚压精密成形工艺理论，对花键轴冷滚压精密成形技术的推广和应用具有一定的理论价值和实际指导意义。
This work is supported by the National Natural Science Foundation ofChina(NO.50675145, Theoretical and Experimental Study on the Cold RollingPrecision Forming Process of Thread or Spline) and the Key Scientific Project ofShanxi Province(NO.50675145, Study on New Technology and EquipmentDevelopment for the Cold Rolling Precision Forming Process of Shaft).
Cold rolling precision forming process of spline shafs is one of the non-chipforming advanced manufacturing technologies. It has the characteristics such as havinghigh forming efficiency, forming components with better property and so on. But it hasnot been widely used in the practical production because of the lack of knowledge aboutthe complex cold rolling forming mechanism as a kind of cold volume plasticdeformation. Aiming at those problems exited in the theoretical and equipment researchon forming process and in the precision control on component forming, this work givesa systematic study on the precision forming mechanism of cold rolling process of splineshafts, the calculation of force and energy parameters, the strengthening mechanism ofgear tooth surface, the forming precision and quality control based on the combinationof theoretical analysis and experimental study. The following main research contentsand conclusions have been made.
According to the theoretical analysis on the cold rolling precision forming processof spline shafts, the revolving condition and the geometric condition to form on theindexing stage were worked out, moreover, the rolling wheel design was schemed outwhich limits the minimum number of teeth and requests addendum electroplating toimprove the revolving condition. Based on the analysis of the double-sidednon-backlash meshing, the characteristics of contact area between rolling wheel andworkpiece and the sliding mode of the contact point were brought out. On the basis ofslip line field theory, the unit average stress at the cold rolling forming process of splineshaft was worked out precisely, the method and influencing factors to calculate thecontact area between rolling wheels and tooth was presented, meanwhile, the rollingpressure and rolling moment in the cold rolling process were calculated. The theoreticalanalysis is the support for both the determination of process parameters and the designof machine or rolling wheels.
According to the theoretical analysis, a vibration damping design applied to the spindle of the cold rolling machine has been brought out and has been used in thedevelopment of special NC cold rolling machine which is co-developed with enterprise.As the result, the key problem has been solved which is the deformation force variationleading to the low forming precision during the cold rolling forming. A system wasinnovatively constructed for testing the force and energy parameters during the coldrolling precision forming of spline shafts, and the variation of rolling pressur and rollingmoment were in-circiut tested. The effect of the rotational speed and feed rate of therolling wheel on the maximal rolling pressur and the maximal rolling moment wasanalyzed and the theoretical calculation of the force and energy parameters was verified.A comprehensive test system was firstly designed to obtain cold rolling deformationaccurary, surface quality and mechanical properties, and the flow characteristic of themetal on tooth surface was analyzed, and the effective range of the deformation duringthe practical cold rolling precision forming was marked out. Then, the strengthening andhardening mechanisms in tooth surface was obtained based on the theoretical analysisand experimental study on the machining accuracy and the performance of the splineshafts which were made out by cold rolling precision forming press. The experimentalso verified this forming technology could been applied to make components withcomplex shape and high precision and could improve the microstructure then toenhanced the performance. It could be considered that the processing meet the shapeand performance requirement simultaneously and especially meet high quality, highprecision requirement of axial parts production needed by national defense industry.
The relationship was carried out between the cumulative pitch error and everyprocess parameters according to analysis on the cumulative pitch error brought out incold rolling precision forming process of free-indexing spline shafts, then a rollingmethod controlled by speed synchronization was put up to realize the dynamic indexingin cold rolling and to improve the forming accuracy. In addition, the cause brings aboutthe usual forming defects was analyzed, and then a quality control method was putforward. This work has theoretic value and practical meaning for extension andapplication of the cold rolling precision forming process of spline shafts because that itsolves the key technical problems in the industrial application and it expands thetechnology theory in cold rolling precision forming press of spline shafts.
花键轴冷滚压精密成形是一种无切屑的先进制造技术，具有成形效率高、零件综合性能好等优点。冷滚压成形是一种冷体积塑性变形过程，变形机理复杂，迄今还缺乏一套系统的理论和计算依据，因而影响了该工艺在生产实践过程中的推广和应用。本论文针对成形工艺与装备理论、成形零件精度控制中存在的问题，采用理论分析与试验研究相结合的方法，对花键轴冷滚压精密成形机理、力能参数计算、齿面强化机理、成形精度与质量控制等进行了系统的研究。主要研究内容和结论如下：
通过花键轴冷滚压精密成形过程的理论分析，得到分齿阶段的旋转条件和成形几何条件，提出了限定滚压轮最小齿数和齿顶涂层增加摩擦改善旋转条件的滚压轮设计方案；基于双面无侧隙啮合运动，获得了冷滚压齿部成形时滚压轮和工件接触区特征和接触点的滑动方式；应用滑移线场理论，精确分析了花键轴冷滚压成形过程的单位平均应力，给出了滚压轮和工件齿部接触面积的计算方法和影响因素，并对冷滚压成形过程滚压力和滚压力矩进行了计算。为成形工艺参数的确定、机床及滚压轮的设计提供了理论依据。
在理论分析的基础上，提出冷滚压机床主轴阻尼减振方案，与企业合作研制了专用数控冷滚压机床，解决了冷滚压成形变形力剧烈波动导致零件成形精度低等关键问题；自主设计研制了花键轴冷滚压精密成形过程的力能参数测试系统，实现了对实际零件成形过程中动态滚压力和滚压力矩变化的在线测试，研究了滚压轮转速、进给速度对最大滚压力和最大滚压力矩的影响，并对力能参数的理论计算结果进行了验证；首次对冷滚压精密成形精度、表面质量和力学性能进行了综合试验，分析了花键零的齿面金属的流动特征，得到了变形区的作用范围。揭示了冷滚压成形及工艺参数对零件精度、质量和性能的影响，获得了齿面强化和硬化机理。结果表明，花键轴冷滚压精密成形不仅能赋予零件复杂形状与精确尺寸，而且使成形零件原有微观组织得到改善，提高了花键的综合性能，达到了零件的“成形/成性”的一体化调控，尤其适合国防等工业对于高质量、高精度轴类件生产的需求。
通过对自由分度式花键轴冷滚压精密成形齿距累积误差的分析，建立了齿距累积误差与各工艺参数之间的关系，提出了一种速度强制同步控制滚压方案，实现了冷滚压过程的动态分度，提高了零件的成形精度。分析了常见成形缺陷产生的原因，提出了花键轴冷滚压成形质量的控制措施，解决了花键轴冷滚压精密成形工艺走向工业应用的关键技术问题，丰富了花键轴冷滚压精密成形工艺理论，对花键轴冷滚压精密成形技术的推广和应用具有一定的理论价值和实际指导意义。
This work is supported by the National Natural Science Foundation ofChina(NO.50675145, Theoretical and Experimental Study on the Cold RollingPrecision Forming Process of Thread or Spline) and the Key Scientific Project ofShanxi Province(NO.50675145, Study on New Technology and EquipmentDevelopment for the Cold Rolling Precision Forming Process of Shaft).
Cold rolling precision forming process of spline shafs is one of the non-chipforming advanced manufacturing technologies. It has the characteristics such as havinghigh forming efficiency, forming components with better property and so on. But it hasnot been widely used in the practical production because of the lack of knowledge aboutthe complex cold rolling forming mechanism as a kind of cold volume plasticdeformation. Aiming at those problems exited in the theoretical and equipment researchon forming process and in the precision control on component forming, this work givesa systematic study on the precision forming mechanism of cold rolling process of splineshafts, the calculation of force and energy parameters, the strengthening mechanism ofgear tooth surface, the forming precision and quality control based on the combinationof theoretical analysis and experimental study. The following main research contentsand conclusions have been made.
According to the theoretical analysis on the cold rolling precision forming processof spline shafts, the revolving condition and the geometric condition to form on theindexing stage were worked out, moreover, the rolling wheel design was schemed outwhich limits the minimum number of teeth and requests addendum electroplating toimprove the revolving condition. Based on the analysis of the double-sidednon-backlash meshing, the characteristics of contact area between rolling wheel andworkpiece and the sliding mode of the contact point were brought out. On the basis ofslip line field theory, the unit average stress at the cold rolling forming process of splineshaft was worked out precisely, the method and influencing factors to calculate thecontact area between rolling wheels and tooth was presented, meanwhile, the rollingpressure and rolling moment in the cold rolling process were calculated. The theoreticalanalysis is the support for both the determination of process parameters and the designof machine or rolling wheels.
According to the theoretical analysis, a vibration damping design applied to the spindle of the cold rolling machine has been brought out and has been used in thedevelopment of special NC cold rolling machine which is co-developed with enterprise.As the result, the key problem has been solved which is the deformation force variationleading to the low forming precision during the cold rolling forming. A system wasinnovatively constructed for testing the force and energy parameters during the coldrolling precision forming of spline shafts, and the variation of rolling pressur and rollingmoment were in-circiut tested. The effect of the rotational speed and feed rate of therolling wheel on the maximal rolling pressur and the maximal rolling moment wasanalyzed and the theoretical calculation of the force and energy parameters was verified.A comprehensive test system was firstly designed to obtain cold rolling deformationaccurary, surface quality and mechanical properties, and the flow characteristic of themetal on tooth surface was analyzed, and the effective range of the deformation duringthe practical cold rolling precision forming was marked out. Then, the strengthening andhardening mechanisms in tooth surface was obtained based on the theoretical analysisand experimental study on the machining accuracy and the performance of the splineshafts which were made out by cold rolling precision forming press. The experimentalso verified this forming technology could been applied to make components withcomplex shape and high precision and could improve the microstructure then toenhanced the performance. It could be considered that the processing meet the shapeand performance requirement simultaneously and especially meet high quality, highprecision requirement of axial parts production needed by national defense industry.
The relationship was carried out between the cumulative pitch error and everyprocess parameters according to analysis on the cumulative pitch error brought out incold rolling precision forming process of free-indexing spline shafts, then a rollingmethod controlled by speed synchronization was put up to realize the dynamic indexingin cold rolling and to improve the forming accuracy. In addition, the cause brings aboutthe usual forming defects was analyzed, and then a quality control method was putforward. This work has theoretic value and practical meaning for extension andapplication of the cold rolling precision forming process of spline shafts because that itsolves the key technical problems in the industrial application and it expands thetechnology theory in cold rolling precision forming press of spline shafts.
引文
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