本文關(guān)鍵詞： 冷沖擊成形 大模數(shù)花鍵 機床振動 金屬流動規(guī)律 成形成性一體化調(diào)控　出處：《太原科技大學》2017年碩士論文　論文類型：學位論文

【摘要】：大模數(shù)花鍵連續(xù)冷沖擊精密成形是一種新型冷體積成形技術(shù),基本原理是在室溫下利用一對滾打輪對工件進行快速擊打,迫使工件表面金屬發(fā)生塑性變形,形成花鍵齒槽。與傳統(tǒng)的切削加工相比,通過連續(xù)冷沖擊成形的花鍵軸具有力學性能好,成形精度高,材料利用率高等顯著優(yōu)點。為提高花鍵成形質(zhì)量,改善機床受力,本文對高速冷沖擊精密成形大模數(shù)花鍵制造過程中打擊力的影響因素進行理論分析和仿真分析,確定出機床結(jié)構(gòu)參數(shù)和生產(chǎn)工藝參數(shù)等因素對成形過程打擊力影響的特點和程度。研究了制造過程中的振動,分析機床本身運行時的振動特征,應用ABAQUS有限元軟件分析模擬了沖擊成形過程,獲得打擊瞬間的載荷特征,從而給出減振建議,減小機床振動對加工質(zhì)量的影響。對高速冷沖擊精密成形的花鍵零件表面硬度進行測試,通過對成形零件金相組織分析,探索花鍵軸宏觀性能與微觀組織特征之間的關(guān)系。利用不同的加工工藝參數(shù)加工花鍵試樣,分析成形工藝參數(shù)對冷沖擊成形花鍵表面硬度的影響,獲得控制表面硬度的方法。控制冷沖擊成形過程中的金屬流動是保證零件精度和性能的關(guān)鍵,本文通過ABAQUS軟件仿真連續(xù)冷沖擊成形過程,對典型位置的節(jié)點進行追蹤,輸出節(jié)點的位移,結(jié)合實驗從宏觀角度分析變形,總結(jié)成形過程的金屬流動規(guī)律。通過研究得出了機床結(jié)構(gòu)參數(shù)(滾打輪尺寸,滾打輪回轉(zhuǎn)半徑),成形工藝參數(shù)(主軸轉(zhuǎn)速,進給速度),花鍵軸幾何參數(shù)(花鍵模數(shù))等對成形過程打擊力的影響。高速冷沖擊精密成形過程中,機床所受載荷為脈沖式,在制造過程中會引起的機床振動,對花鍵成形質(zhì)量的影響顯著,針對高速冷沖擊成形的載荷特點設(shè)計減振結(jié)構(gòu),提高零件成形精度。成形工藝參數(shù)的變化使得冷沖擊變形速率變化,從而影響成形零件的微觀組織和宏觀性能,對不同主軸轉(zhuǎn)速和進給速度等工藝參數(shù)下成形的花鍵表面質(zhì)量進行了分析,得到高速冷沖擊成形花鍵輪軸齒部的硬度分布,給出提高成形質(zhì)量的工藝優(yōu)化方案。應用仿真與實驗結(jié)合的方法研究了成形過程的金屬流動規(guī)律,通過仿真分析對節(jié)點追蹤,并經(jīng)過高速冷沖擊成形試驗得出了花鍵齒典型位置的流動特點,發(fā)現(xiàn)高速冷沖擊成形的花鍵齒頂位置突出,齒側(cè)位置被壓向工件內(nèi)部,齒根壓下量最大,軸向位置金屬向打輪打出方向流動,形成端面突出,使得靠近端面處的齒頂成形不飽滿。
[Abstract]:Large modulus spline continuous cold impact precision forming is a new cold volume forming technology. The basic principle is to use a pair of rolling wheels to beat the workpiece quickly at room temperature, forcing the metal on the surface of the workpiece to produce plastic deformation. Compared with the traditional machining, the spline shaft formed by continuous cold impact has the advantages of good mechanical properties, high forming precision and high material utilization ratio, etc. In order to improve the quality of spline forming and improve the force of machine tool, In this paper, the factors influencing the impact force in the manufacturing process of high speed cold impact precision forming large modulus spline are analyzed theoretically and simulated. The characteristics and extent of the influence of structural parameters and production process parameters on the impact force of the forming process are determined. The vibration in the manufacturing process is studied, and the vibration characteristics of the machine tool when it is running are analyzed. The impact forming process is analyzed and simulated by using ABAQUS finite element software, and the load characteristics of the impact moment are obtained, and the vibration reduction suggestion is given. To reduce the influence of machine tool vibration on machining quality, the surface hardness of spline parts formed by high speed cold impact precision forming was tested, and the metallographic structure of formed parts was analyzed. The relationship between the macroscopic properties of spline shaft and the microstructure of spline shaft was explored. The effect of forming parameters on the surface hardness of cold impact forming spline was analyzed by using different processing process parameters. The method of controlling surface hardness is obtained. Controlling the metal flow during cold impact forming is the key to ensure the precision and performance of parts. In this paper, the continuous cold impact forming process is simulated by ABAQUS software, and the nodes in typical position are tracked. The displacement of the output node is analyzed from the macroscopic angle of the experiment, and the metal flow law in the forming process is summarized. Through the research, the structure parameters of the machine tool (the size of the roller, the radius of rotation of the rolling wheel, the technological parameters of the forming process (spindle rotation speed), and the parameters of the forming process are obtained. The influence of feed speed, spline shaft geometry parameters (spline module) on the impact force in the forming process. In the process of high speed cold impact precision forming, the load on the machine tool is pulse type, and the vibration of the machine tool will be caused during the manufacturing process. According to the load characteristics of high speed cold impact forming, the vibration absorption structure is designed to improve the forming accuracy of parts. The change of forming process parameters makes the change of cold impact deformation rate. Thus, the microstructure and macroscopic properties of the forming parts are affected. The surface quality of the spline formed under different spindle speed and feed speed is analyzed, and the hardness distribution of the gear teeth of the spline is obtained by high speed cold impact forming. The process optimization scheme to improve the forming quality is given. The metal flow law of the forming process is studied by the method of simulation and experiment, and the node is tracked by simulation analysis. The flow characteristics of the typical position of spline teeth are obtained by high speed cold impact forming test. It is found that the top position of spline teeth in high speed cold impact forming is prominent, the side position of tooth is pressed to the inner part of the workpiece, and the reduction of tooth root is the largest. In axial position, the metal flows in the direction of striking wheel, forming the end face protruding, which makes the tooth top near the end face not full.
【學位授予單位】：太原科技大學
【學位級別】：碩士
【學位授予年份】：2017
【分類號】：TG386.3

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