目的 优化套圈浮动装夹回转式抛磨工艺,提升其抛磨效率及表面质量。方法 提出叠加水平激振辅助的抛磨工艺,设计搭建了水平激振辅助抛磨实验装置。通过使用DEM（离散单元法）对该工艺进行仿真分析,研究振幅、频率（振动加速度）对颗粒介质流动行为的影响,进而分析了颗粒介质流动行为对工件内、外表面冲蚀作用的影响规律,通过接触压力分布测试对上述结果进行了验证,选取具有代表性的工艺参数进行抛磨实验,并测量表面形貌和表面硬度以分析抛磨效果。结果 水平激振辅助下颗粒介质流中的静止区和低速区减小,活跃区增加,颗粒介质的分布均匀性改善,该趋势随激振参数的增加而增加。振动加速度越大,抛磨介质对套圈内、外表面的冲蚀作用也越大。在抛磨时间为60 min、振幅为6 mm、频率为15 Hz（振动加速度为5.44 g）的条件下,工件内、外表面的表面三维粗糙度分别由Sa=0.483 μm和Sa=0.611 μm下降至Sa=0.261 μm和Sa=0.488 μm;内、外表面硬度分别由3.71 GPa和3.22 GPa提升至6.12 GPa和4.74 GPa;内、外表面的弹性模量分别由113 GPa和120 GPa提升至153 GPa和152 GPa。结论 水平激振辅助套圈浮动装夹回转抛磨工艺可有效提高抛磨效率,提升工件表面质量。
Abstract
The work aims to enhance the rotary barrel finishing for bearing rings in floating clamp (RBF-FC) process through superposition to the horizontal vibration assistance. With the rapid development of modern high-end equipment such as automotive, aerospace and high-end machine tools, there is an urgent need for processing and manufacturing high-performance bearing rings, which can support the normal operation of rotating machinery. RBF-FC, an overall finishing process, has a low processing efficiency and poor surface quality although it can realize surface finishing simultaneously and clamping without damage. During the RBF-FC process, the granular media flow relatively stereotypes due to the simple rotational motion of barrel wall, which is difficult to affect the inactive region in media flow. In this work, horizontal vibration-assisted finishing is employed to improve the finishing efficiency of the RBF-FC process. This configuration induces great variations in the granular media flow, allowing the granular media to exhibit more active status. Consequently, the relative motion between media and workpiece surfaces is enhanced, ultimately increasing the finishing capability.
The objective of optimizing the RBF-FC process is to elevate surface quality and enhance the finishing efficiency. A comprehensive analysis is performed to evaluate the effects of vibration parameters within the horizontal vibration-assisted RBF-FC. Vibration parameters under scrutiny include amplitude and frequency, which are assessed for their effects on granular media flow behavior by Discrete Element Method (DEM) simulation. It is observed that an increase in the amplitude or frequency leads to a gradual reduction in static region and low-speed region, while simultaneously increasing the active region. The movement of the media is more complex and activated, which can obtain greater kinetic energy. Furthermore, the erosion effect of media flow on inner surface and outer surface is also explored under different vibration strength, which can be defined as the ratio of vibration acceleration to that of gravity. An increase in vibration strength induces a gradual rise in both impact velocity and impact angle of the media on the surfaces. The above corresponding simulation results are verified by the contact pressure measurement with pressure-sensitive paper. The device of horizontal vibration-assisted RBF-FC is designed and built. Optimal process parameters are attained with an amplitude of 6 mm, a frequency of 15 Hz (vibration acceleration of 5.44 g), and a finishing duration of 60 min. Under these conditions, the surface roughness of inner surface and outer surface is reduced from Sa=0.483 μm and Sa=0.611 μm to Sa=0.261 μm and Sa=0.488 μm, respectively. The hardness of inner surface and outer surface increases from 3.71 GPa and 3.22 GPa to 6.12 GPa and 4.74 GPa, respectively. The elasticity modulus of inner surface and outer surface increases from 113 GPa and 120 GPa to 153 GPa and 152 GPa, respectively.
The horizontal vibration-assisted RBF-FC process has been demonstrated to significantly improve the finishing efficiency and to augment the surface quality of workpieces, providing a new approach and theoretical basis for the processing of high-performance bearing rings.
关键词
整体抛磨 /
激振辅助 /
DEM仿真 /
颗粒介质流 /
冲蚀行为 /
表面质量
Key words
overall finishing /
vibration-assisted /
DEM simulation /
granular media flow /
erosion behavior /
surface quality
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基金
山西省高等学校科技创新项目（2025L067）; 太原科技大学科研启动基金（20252093）; 山西省基础研究计划青年基金项目（202303021212218）; 山西省来晋工作优秀博士奖励资金（20232072）
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