Cylindrical rollers are important elements of bearings,and their machining accuracy and consistency affect the bearing quality.Using a GCr15 cylindrical roller ofФ11×12 as the processing object in this study,the...Cylindrical rollers are important elements of bearings,and their machining accuracy and consistency affect the bearing quality.Using a GCr15 cylindrical roller ofФ11×12 as the processing object in this study,the effects of loading pressure,abrasive concentration,and speed combination on cylindrical roller machining precision were investigated using the orthogonal experimental design method on a double-side eccentric pendulum lapping and polishing machine.The machining parameters of the lapping stage were optimized,and the lapping optimal process parameters were determined by S/N response analysis and analysis of variance(ANOVA).The results show that when the experiment was optimized using loading pressure of 10 N/roller,abrasive concentrationof 20.0 wt%,and rotational speed combination,the material removal rate(MRR)of cylindrical roller reached 0.0896μm/min;the average roughness of the batch decreased from 0.056μm to 0.027μm,51.8%lower than the original batch average roughness,and the deviation decreased from the initial 0.022μm to 0.014μm;the batch average roundness error decreased from 0.47μm to 0.28μm,40.4%lower than the original batch average roundness error,and the deviation decreased from the initial 0.19μm to 0.038μm;and the batch average diameter variation decreased from 4.5μm to about 3.6μm,20%lower than the original batch average diameter variation.The double-side eccentric lapping of cylinder rollers does not only lead to improvement in the surface quality and shape accuracy of rollers,but also improvement in the batch consistency.展开更多
双盘直槽(double-disc and linear-groove,DDLG)研磨方法是以1个平端面研磨盘和1个具有多条直沟槽的研磨盘为对磨研具,对圆柱滚子的滚动面进行精密加工的新方法。在加工过程中,圆柱滚子沿直沟槽连续供料,在2个研磨盘的摩擦力矩驱动下连...双盘直槽(double-disc and linear-groove,DDLG)研磨方法是以1个平端面研磨盘和1个具有多条直沟槽的研磨盘为对磨研具,对圆柱滚子的滚动面进行精密加工的新方法。在加工过程中,圆柱滚子沿直沟槽连续供料,在2个研磨盘的摩擦力矩驱动下连续自转。研磨盘材料的选择是搭建双盘直槽研磨设备的基础。为了确定适用于双盘直槽研磨方法的研磨盘材料组合,基于摩擦磨损实验展开相关研究。首先,基于摩擦原理,分析了圆柱滚子的运动状态和研磨盘材料的摩擦特性对研磨效果的影响,并确定了研磨盘材料摩擦系数的筛选条件。然后,通过销-盘摩擦磨损实验测试了铸铁、45钢、黄铜、聚四氟乙烯(polytetrafluoroethylene,PTFE)、有机玻璃(polymethyl methacrylate,PMMA)、125%铸铁基固结磨料和125%树脂基固结磨料等多种备选材料在研磨条件下的摩擦系数、耐磨性和排屑性能。最后,搭建了双盘直槽研磨试验台,通过观察圆柱滚子的自转情况来验证基于摩擦磨损实验的研具选材方法的合理性。通过摩擦磨损实验测得,铸铁和45钢的滑动摩擦系数大,磨削效率高,但耐磨性差,适合用作大去除量场合的上研磨盘材料;有机玻璃的滑动摩擦系数大,耐磨性好,磨削效率高,适合用作小去除量场合的上研磨盘材料;聚四氟乙烯的滑动摩擦系数小,耐磨性好,可用作下研磨盘直沟槽材料;固结磨料的滑动摩擦系数变化大且易堵塞,不适合用作研磨盘材料。研究结果可为双盘直槽研磨设备的设计提供可行的研具选材依据。展开更多
基金supported by National Natural Science Foundation of China (Grant No.51175468,U1401247)Public Welfare Industry Project of Zhejiang Provincial Science and Technology Department (Grant no.20160069)
文摘Cylindrical rollers are important elements of bearings,and their machining accuracy and consistency affect the bearing quality.Using a GCr15 cylindrical roller ofФ11×12 as the processing object in this study,the effects of loading pressure,abrasive concentration,and speed combination on cylindrical roller machining precision were investigated using the orthogonal experimental design method on a double-side eccentric pendulum lapping and polishing machine.The machining parameters of the lapping stage were optimized,and the lapping optimal process parameters were determined by S/N response analysis and analysis of variance(ANOVA).The results show that when the experiment was optimized using loading pressure of 10 N/roller,abrasive concentrationof 20.0 wt%,and rotational speed combination,the material removal rate(MRR)of cylindrical roller reached 0.0896μm/min;the average roughness of the batch decreased from 0.056μm to 0.027μm,51.8%lower than the original batch average roughness,and the deviation decreased from the initial 0.022μm to 0.014μm;the batch average roundness error decreased from 0.47μm to 0.28μm,40.4%lower than the original batch average roundness error,and the deviation decreased from the initial 0.19μm to 0.038μm;and the batch average diameter variation decreased from 4.5μm to about 3.6μm,20%lower than the original batch average diameter variation.The double-side eccentric lapping of cylinder rollers does not only lead to improvement in the surface quality and shape accuracy of rollers,but also improvement in the batch consistency.
文摘双盘直槽(double-disc and linear-groove,DDLG)研磨方法是以1个平端面研磨盘和1个具有多条直沟槽的研磨盘为对磨研具,对圆柱滚子的滚动面进行精密加工的新方法。在加工过程中,圆柱滚子沿直沟槽连续供料,在2个研磨盘的摩擦力矩驱动下连续自转。研磨盘材料的选择是搭建双盘直槽研磨设备的基础。为了确定适用于双盘直槽研磨方法的研磨盘材料组合,基于摩擦磨损实验展开相关研究。首先,基于摩擦原理,分析了圆柱滚子的运动状态和研磨盘材料的摩擦特性对研磨效果的影响,并确定了研磨盘材料摩擦系数的筛选条件。然后,通过销-盘摩擦磨损实验测试了铸铁、45钢、黄铜、聚四氟乙烯(polytetrafluoroethylene,PTFE)、有机玻璃(polymethyl methacrylate,PMMA)、125%铸铁基固结磨料和125%树脂基固结磨料等多种备选材料在研磨条件下的摩擦系数、耐磨性和排屑性能。最后,搭建了双盘直槽研磨试验台,通过观察圆柱滚子的自转情况来验证基于摩擦磨损实验的研具选材方法的合理性。通过摩擦磨损实验测得,铸铁和45钢的滑动摩擦系数大,磨削效率高,但耐磨性差,适合用作大去除量场合的上研磨盘材料;有机玻璃的滑动摩擦系数大,耐磨性好,磨削效率高,适合用作小去除量场合的上研磨盘材料;聚四氟乙烯的滑动摩擦系数小,耐磨性好,可用作下研磨盘直沟槽材料;固结磨料的滑动摩擦系数变化大且易堵塞,不适合用作研磨盘材料。研究结果可为双盘直槽研磨设备的设计提供可行的研具选材依据。
