【作者】 张大伟；

【导师】 李永堂； 付建华；

【作者基本信息】 太原科技大学 ， 材料加工工程， 2007， 硕士

【摘要】 摘要:随着我国综合国力的快速增长,机械制造业进入一个迅速发展阶段。航空、航天、汽车及机械工业对高强度、高精度的轴类零件的需求量日益增加。采用无切削冷滚压成形花键轴,具有生产效率高、齿面金属纤维连续性好、齿面强度高、耐磨性好等优点,在高强度、高精度的花键类零件生产中得到越来越多的重视与应用。但由于冷滚压成形工件变形机理复杂,且国内外在花键冷滚压成形工艺理论和力学分析方面的研究较少,现有的成形工艺和生产基本上是依靠经验,缺乏系统的理论指导。本文通过对花键冷滚压成形工艺力学进行分析,用图解法建立塑性变形区的滑移线场。在不同接触区域采用不同的摩擦条件,真实地反映了成形过程实际情况。并根据滑移线场的应力场理论得到冷滚压成形过程中接触面上单位压力的封闭解。运用共轭曲线及包络线理论建立滚压过程滚轮齿廓、工件齿廓数学模型,并在此基础上编写了接触面积的计算程序。以单位压力、接触面积求解为基础,编写了滚压成形过程滚压力、滚压力矩的求解计算程序,研究了工件模数、压力角、压缩量、滚轮及工件的齿数等工艺参数的影响因素,确定了主要滚压工艺参数。通过简化建立了用于指导实际生产的滚压力、滚压力矩计算公式。建立了花键冷滚压有限元模型,应用有限元软件DEFORM对成形过程进行了数值模拟。将不同参数条件下单位压力的数值模拟结果与理论分析结果进行了比较,二者吻合较好。采用后继屈服的修正模型计算所得的滚压力值与数值模拟值的误差小于1.5%。本文建立的花键冷滚压成形工艺基本理论,为开发研制花键类零件冷滚压成形设备及花键类零件冷滚压成形生产提供理论依据,对于花键类零件冷滚压成形技术的推广应用、设备的研发具有重要意义。更多还原

【Abstract】 With the rapid growth in synthetic national-power of China, a speedily development phase with mechanical manufacturing has arrived. The quantity- demanded of high-strength and high-precision shaft-part is gradually increasing in aviation, astronavigation and mechanical industry. Because there are many advantages such as high productivity, good continuity of metal wool in tooth face, high strength and better wear resisting property of tooth face, the non-cutting forming technology by cold rolling is more and more regarded and widely used in production of high-strength and high-precision spline. The denformation mechanism of spline cold rolling is complexity. So the research of the theory and mechanics analysis on process of spline cold rolling is few in the world. The existing forming technology and the production often depend on experience. The systemic theory instructing the production is lack.The processing mechanics of spline cold rolling is analyzed. The slip-line field of plastically deforming area in process of spline cold rolling is founded combined with the methods of the analysis-inference and the graphics. Different friction-conditions are used in different contact areas in order to realistically reflect the factual situation. The unit pressure on contact surface of the rolling process was solved according to the stress filed theory of the slip-line. According to theory of the conjugate curves and the envelope curve, the mathematic model of roller-tooth-curve and workpiece-tooth-curve was established. And according to the mathematic models, the calculation-program of entire contact area in rolling process is compiled.Based on the solving of unit pressure and contact area, the calculation-program of rolling-force and rolling-moment is compiled. The influencing causes of module, pressure angle, decrement, number of roller teeth and workpiece have been studied, and the rolling parameters may be obtained. The mathematic models have been simplified and the instructing formulae of rolling-force and rolling-moment are established.The model of finite element is setted up. Forming process of spline cold rolling is simulated by DEFORM. The theoretical results of unit pressure are consistent with the finite element analysis. The theoretical result of rolling-force which is calculated by modified model that considered successor yield is consistent with the result of numerical simulation, and the error percentage is less than 1.5%.In this paper, the elementary theory is established. The result of research provides the theory-basis for developing the special cold rolling machine in spline and industrial process. It is significant to use and to improve the new technology of the cold rolling and it is also significant to research and to develop the equipments of the cold rolling.更多还原