目的 针对齿轮滚磨光整加工表面完整性基础数据缺乏、工艺控制规律不清的问题,探索主轴式滚磨光整工艺参数对齿轮表面完整性的影响规律,并进行预测建模和工艺参数优化。方法 采用单因素和响应曲面试验方法,对8620RH齿轮钢直齿圆柱齿轮进行主轴式滚磨光整工艺试验,测试加工后齿面表面粗糙度、表面几何形貌、残余应力场、显微硬度场和表层微观组织,讨论工艺参数对表面完整性的影响规律;采用多元线性回归方法,建立表面完整性特征与工艺参数的映射关系模型;基于改进的灰色关联度分析方法,以最大灰色关联度为目标优化滚磨光整工艺参数,并进行试验验证。结果 主轴式滚磨光整加工后齿面三维表面粗糙度Sa由0.280 μm降低至0.089 μm,表面几何形貌和表面纹理均匀一致;随着埋入深度、主轴转速和加工时间的增大,表面粗糙度逐渐减小并趋于稳定;齿高方向残余压应力大于齿宽方向残余压应力,残余压应力影响层深度约为40 μm;表面显微硬度最大硬化程度约为9.9%,硬化层深度约为40 μm,表层微观组织塑性变形层深度约为5 μm。表面完整性预测模型的P值小于0.000 1,决定系数R2大于0.94;最佳主轴式滚磨光整工艺参数组合为埋入深度166 mm、主轴转速130 r/min、加工时间80 min,该工艺参数下模型预测误差在7%以内。结论 主轴式滚磨光整可去除齿轮磨削纹理,降低表面粗糙度,提高表面下20 μm范围内的残余压应力和显微硬度。获得了主轴式滚磨光整工艺参数对表面完整性的影响规律,建立了表面完整性特征预测模型,为齿轮高表面完整性控制提供了基础数据和工艺方法支撑。
Abstract
Gear parts are the core basic components in many different application areas, such as aviation, aerospace, shipbuilding, rail transportation and marine equipment. The surface integrity characteristics of gears are crucial for their long life, low noise, and high operational performance. Barrel finishing is widely used as the last process to improve the surface integrity of gear parts. Regarding the issue of the lack of basic data on surface integrity and unclear process control rules in spindle barrel finishing, the work aims to explore the effects of different spindle barrel finishing parameters on the surface integrity of gears, and optimize the process parameters. With single factor and response surface methodology, the spindle barrel finishing experiments were carried out to 8620RH cylindrical spur gears. Then, the surface roughness, surface topography, residual stress, microhardness, and microstructure of the tooth surface were measured and the effects of spindle barrel finishing parameters on the surface integrity characteristics were discussed. The relationship between the surface integrity characteristics and the spindle barrel finishing parameters was established through multiple linear regression analysis. Spindle barrel finishing parameters were optimized with improved grey correlation degree analysis method, and verified by experiments. The 3D surface roughness Sa of the tooth surface after spindle barrel finishing was reduced from 0.280 μm to 0.089 μm. The surface roughness decreased and tended to be stable with the increase of the embedding depth, spindle speed, and finishing time. The surface topography and surface texture were uniform and consistent after spindle barrel finishing process. The residual stress states of processed gears were compressive, with the maximum value on the surface. The compressive residual stress along the tooth height direction was larger than that along the tooth width direction, and the depth of the compressive residual stress affected layer was approximate 40 μm. The surface of gear was hardened and the maximum degree of hardening was 9.9%. The depth of the hardened layer and plastic deformation layer was appropriate 40 μm and 5 μm, respectively. Spindle barrel finishing could enlarge the compressive residual stress and microhardness values within a range of 20 μm below the surface, but had not significant effect on the depth of the affected layer. Prediction models of surface integrity characteristics were established through multiple linear regression analysis, the P value of these models was less than 0.000 1, and the coefficient of determination R2 was more than 0.94. Based on the grey correlation analysis method, an improved model of the relationship between grey correlation and process parameters was established. The optimal combination of spindle barrel finishing parameters was obtained with the goal of maximizing grey correlation, which was the embedding depth of 166 mm, spindle speed of 130 r/min, and finishing time of 80 min. The optimized parameters were experimentally validated, and the prediction error of the surface integrity characteristics was less than 7%. It can be seen that spindle barrel finishing can remove the gear grinding traces, reduce the surface roughness and improve the compressive residual stress and microhardness in the range of 0~20 μm below the surface. The effects of spindle barrel finishing process parameters on the surface integrity characteristics and establishes the prediction models of surface integrity characteristics are clarified, which can provide basis data and process method for controlling high surface integrity of gears.
关键词
齿轮 /
主轴式滚磨光整 /
表面完整性 /
表面粗糙度 /
残余应力 /
灰色关联度 /
工艺参数优化
Key words
gear /
spindle barrel finishing /
surface integrity /
surface roughness /
residual stress /
grey correlation degree /
optimization of parameters
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基金
陕西省重点研发计划（2024PT-ZCK-63,2021ZDLGY10-06）
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