冷滚打滚珠丝杠理论研究
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摘要
滚珠丝杠具有传动效率高、运动平稳性好以及使用寿命长等特点,因而被广泛的应用于机械、航天、航空、核工业等领域。随着产品的应用范围不断扩大以及滚珠丝杠自身的优点,使得它将始终占领直线运动领域的绝大部分市场。但目前由于受国内加工能力的限制,使得大量国外产品占有国内较大一部分市场。因而,非常有必要研究和开发一种新的滚珠丝杠加工方法。
本文主要研究工作包括以下几点:
1.根据零件表面成形原理,建立了滚珠丝杠冷滚打运动关系模型,借助于机械动力学分析软件MSC.ADAMS,对滚打轮自转角速度进行了运动仿真,对比分析了仿真结果与理论计算结果,验证了冷滚打运动关系模型建立的正确性。
2.根据冷滚打运动关系,建立了冷滚打坐标系和冷滚打数学模型,运用啮合原理建立了冷滚打接触面数学模型及接触线数学模型;对接触面数学模型和接触线数学模型进行了分析,揭示了冷滚打运动成形原理。
3.根据误差计算原理,建立了滚珠丝杠螺旋滚道法向截形误差、滚珠中心轨迹螺旋线误差和滚珠丝杠螺旋线表面粗糙度的数学模型。通过对螺旋滚道法向截形误差的分析,揭示了误差变化规律、造成误差的原因,给出了消除误差的方法;通过对滚珠中心轨迹螺旋线误差的分析,揭示了产生误差的原因,提出了减小误差的措施;通过对冷滚打滚珠丝杠底径螺旋线表面粗糙度的分析,给出了影响螺旋滚道表面质量的因素及提高螺旋滚道表面质量的有效途径。
4.根据滚珠丝杠冷滚打运动关系和啮合原理,建立了滚打轮轴向截形数学模型,通过对所设计的滚打轮轴向截形与成形法设计的滚打轮轴向截形进行对比,对比结果验证了滚打轮轴向截形数学模型建立的正确性
5.根据冷滚打前后毛坯横截面面积不变原理,建立了毛坯直径计算方法;并对不同工艺参数下的滚珠丝杠冷滚打过程进行了有限元模拟,通过对模拟结果进行分析,给出了合理的冷滚打工艺参数;并通过对合理参数下的有限元模拟结果进行的分析,揭示了在冷滚打过程中毛坯所受应力、应变、速度以及法向截形的变化规律。通过对理论法向截形与冷滚打法向截形进行的对比分析,得出了有限元模拟法向截形比理论法向截形大的结论,这与法向截形误差的分析结果是一致的。
6.采用改进后的CA6140车床,分别对铜棒和铝棒进行了冷滚打试验,试验结果表明冷滚打加工技术在滚珠丝杠的加工上是可行的。
Because the ballscrew hitherto has the following characteristics: high transmission efficiency, good smoothness of motion, high reliability etc., it has been applied to machinery, aviation, nuclear industry and other fields. With product application range expanded and its own advantages which makes the ballscrew occupy the vast majority of the market. Because the domestic processing capacity is limited, the large number of foreign products occupies a large part of the domestic market. So the study and development on new processing methods of ballscrew is necessary.
In this paper the main research contents are as follows:
1. The motional relation model of ballscrew manufacture by cold rolling has been investigated based on the kinematics theory of part surface forming motion. The simulation of rotation angular velocity is made by means of ADAMS. The correct motion relationship can be got through comparison between theoretical value and simulation result.
2. According to the movement relationship of cold rolling, the coordinate of cold rolling and mathematical model of cold rolling have been established. On the basis of mathematical model of cold rolling, the flank equation and contact line equation have been built. The objective moving laws between the roller and the workpiece has been revealed by analyzing the flank and contact line.
3. According to error theory the error models of normal profile and the actual helix of the center track of ball and surface roughness have been built. The change of error and the error cause and the method of error elimination have been obtained through analysis of the normal profile error. By analyzing of the ball center track error the error generation causes and the measures of error elimination can be got. By analyzing of surface roughness of spiral race the factors of influencing surface quality have been got. The effective ways of improving processing quality can also be got.
4. According to the relationship of cold rolling and the engagement principle, the model of the axial section has been built. Through comparing the design normal profile and forming normal profile the comparison result proves that the design of roller has been proved correctly.
5. On the principle of the constancy of volume the calculation of the blank diameter has been derived. Using that roller of shaping method design makes finite element simulation of ballscrew under different process parameters; the reasonable process parameter can be got. Through analysis of simulation result the forming law of blank can be obtained in the process of cold rolling. The error law can be obtained through comparing process tooth profile to theoretic normal profile, which can be shown correctly once again.
6. The tests of cold rolling are done to copper rod and aluminum rod using the improved CA6140. The test results indicate the technology of cold rolling applied to ballscrew machining is feasible. KEY WORDS: ballscrew; superficial shaping of parts; cold rolling; surface roughness;
本文主要研究工作包括以下几点:
1.根据零件表面成形原理,建立了滚珠丝杠冷滚打运动关系模型,借助于机械动力学分析软件MSC.ADAMS,对滚打轮自转角速度进行了运动仿真,对比分析了仿真结果与理论计算结果,验证了冷滚打运动关系模型建立的正确性。
2.根据冷滚打运动关系,建立了冷滚打坐标系和冷滚打数学模型,运用啮合原理建立了冷滚打接触面数学模型及接触线数学模型;对接触面数学模型和接触线数学模型进行了分析,揭示了冷滚打运动成形原理。
3.根据误差计算原理,建立了滚珠丝杠螺旋滚道法向截形误差、滚珠中心轨迹螺旋线误差和滚珠丝杠螺旋线表面粗糙度的数学模型。通过对螺旋滚道法向截形误差的分析,揭示了误差变化规律、造成误差的原因,给出了消除误差的方法;通过对滚珠中心轨迹螺旋线误差的分析,揭示了产生误差的原因,提出了减小误差的措施;通过对冷滚打滚珠丝杠底径螺旋线表面粗糙度的分析,给出了影响螺旋滚道表面质量的因素及提高螺旋滚道表面质量的有效途径。
4.根据滚珠丝杠冷滚打运动关系和啮合原理,建立了滚打轮轴向截形数学模型,通过对所设计的滚打轮轴向截形与成形法设计的滚打轮轴向截形进行对比,对比结果验证了滚打轮轴向截形数学模型建立的正确性
5.根据冷滚打前后毛坯横截面面积不变原理,建立了毛坯直径计算方法;并对不同工艺参数下的滚珠丝杠冷滚打过程进行了有限元模拟,通过对模拟结果进行分析,给出了合理的冷滚打工艺参数;并通过对合理参数下的有限元模拟结果进行的分析,揭示了在冷滚打过程中毛坯所受应力、应变、速度以及法向截形的变化规律。通过对理论法向截形与冷滚打法向截形进行的对比分析,得出了有限元模拟法向截形比理论法向截形大的结论,这与法向截形误差的分析结果是一致的。
6.采用改进后的CA6140车床,分别对铜棒和铝棒进行了冷滚打试验,试验结果表明冷滚打加工技术在滚珠丝杠的加工上是可行的。
Because the ballscrew hitherto has the following characteristics: high transmission efficiency, good smoothness of motion, high reliability etc., it has been applied to machinery, aviation, nuclear industry and other fields. With product application range expanded and its own advantages which makes the ballscrew occupy the vast majority of the market. Because the domestic processing capacity is limited, the large number of foreign products occupies a large part of the domestic market. So the study and development on new processing methods of ballscrew is necessary.
In this paper the main research contents are as follows:
1. The motional relation model of ballscrew manufacture by cold rolling has been investigated based on the kinematics theory of part surface forming motion. The simulation of rotation angular velocity is made by means of ADAMS. The correct motion relationship can be got through comparison between theoretical value and simulation result.
2. According to the movement relationship of cold rolling, the coordinate of cold rolling and mathematical model of cold rolling have been established. On the basis of mathematical model of cold rolling, the flank equation and contact line equation have been built. The objective moving laws between the roller and the workpiece has been revealed by analyzing the flank and contact line.
3. According to error theory the error models of normal profile and the actual helix of the center track of ball and surface roughness have been built. The change of error and the error cause and the method of error elimination have been obtained through analysis of the normal profile error. By analyzing of the ball center track error the error generation causes and the measures of error elimination can be got. By analyzing of surface roughness of spiral race the factors of influencing surface quality have been got. The effective ways of improving processing quality can also be got.
4. According to the relationship of cold rolling and the engagement principle, the model of the axial section has been built. Through comparing the design normal profile and forming normal profile the comparison result proves that the design of roller has been proved correctly.
5. On the principle of the constancy of volume the calculation of the blank diameter has been derived. Using that roller of shaping method design makes finite element simulation of ballscrew under different process parameters; the reasonable process parameter can be got. Through analysis of simulation result the forming law of blank can be obtained in the process of cold rolling. The error law can be obtained through comparing process tooth profile to theoretic normal profile, which can be shown correctly once again.
6. The tests of cold rolling are done to copper rod and aluminum rod using the improved CA6140. The test results indicate the technology of cold rolling applied to ballscrew machining is feasible. KEY WORDS: ballscrew; superficial shaping of parts; cold rolling; surface roughness;
引文
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[2] Dominic S. Guevarra, Akira Kyusojin, Hiromi Isobe, Yoshiaki Kaneko. Development of a new lapping method for high precision ball screw (1st report)-feasibility study of a prototyped lapping tool for automatic lapping process [J]. Precision Engineering, 2001, (25):63–69.
[3] Mei Xuesong, Tsutsumi Masaomi, Tao Tao, etc., Study on the load distribution of ball screws with errors [J]. Mechanism and Machine Theory, 2003, (38):1257-1269.
[4] Liu Jenyu, Meng-Hui Hsu, Fu-Chen Chen. On the design of rotating speed functions to improve the acceleration peak value of ball-screw transmission mechanism [J]. Mechanism and Machine Theory, 2001, (36):1035-1049.
[5] Xia Junyong, Wu Bo, Hu Youmin, etc., Experimental research on factors influencing thermal dynamics charateristics of feed system [J]. Precision engineering, 2010, (34):357-368.
[6] Stoppler Guido, Douglas Steve. Adaptronic gantry machine tool with piezoelectric actuator for active error compensation of structural oscillations at the tool centre point [J]. Mechatronics, 2008, (18):426-433.
[7] Maeda Guilherme Jorge, Sato Kaiji. Practical control method for ultra-precision positioning using a ballscrew mechanism [J]. Precision Engineering, 2008, (32):309-318.
[8]赵慧丽,朱彦军.超长数控滚珠丝杠磨床砂轮振动分析及防治措施[J].机械设计与制造,2010, (3):178-179.
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