基于响应曲面法的齿轮轴高精磨削加工参数优化研究

Study of Gear Shafts High Precision Grinding Process Parameters Optimize Based on Response Surface Method

针对某变速器发生异响展开研究,锁定问题发生的根本原因是圆度不合格,进而将故障发生时间锁定在齿轮轴的外圆高精磨削加工过程中。识别出5个对圆度影响显著的因子。通过中心复合响应曲面方法设计出因子及因子的水平,利用Minitab软件,生成108次随机试验矩阵。对108次试验结果进行分析发现,模型一阶项、二阶平方项对异响的影响显著,二阶交互的作用不显著。通过残差分析验证了模型符合假设,进而得到模型回归方程的最优解。同时,基于模型,调整了因子参数,缩短了加工时间,提升了生产效率,解决了高精磨削加工过程中的圆度不合格问题。研究表明,该方法可以识别出模型中弯曲、非线性关系,进而得到全局最优。同时,所建立的模型为零件加工过程参数调整提供了依据。

The study starts from the abnormal noise of the transmission.The root cause of the noise is the unqualified roundness.The unqualified roundness is locked in the high-precision grinding process of the gear shaft outer circle.Identify five factors which are significantly affect roundness.The factors and their levels are designed by the central composite response surface method,and 108 random test matrix are generated by Minitab software.Through the analysis of 108 test results which are proved that the first-order and second-order square of the model have significant influence,while the second-order interaction is not significant.Through the residual analysis proved that the model conforms to the hypothesis and then get the regression equation and the optimal solution of the model.Based on the model,by adjusting the factor parameters,reducing the machining time.So the production efficiency is improved.And the problem of unqualified roundness in the high-precision grinding process is solved.The research shows that this method can identify the bending and nonlinear relationship of the model,and then optimize the model.At the same time,the established model provides a basis for the parameter adjustment of the component machining process.