齿形轴类零件冷敲成形机原理与装备实现

The toothed shafts such as large modulus splines and clutch hubs are the key mechanical elements for transmission and load carrying in industry. The cutting technology is employed to manufacture these parts now. However, this method has many disadvantages such as low productivity and material wastage. Especially, the produced products don't possess good surface quality and sound mechanical properties, and then could not meet the product requirements for high quality and strength. To address the above problems, a new technology, cold strike forming, is put forward. Based on years of studies of the theory, technology and machine of shafts cold rolling precision forming and studies of cold strike forming technology of large modulus splines, the cold strike forming machine for toothed shafts is designed and created in this project. The study is to research the working principle of cold strike forming machine, to settle the problems of the precise synchrodrive and coordinated control between high speed rotation of strike wheels and intermittent rotation indexing of work-piece axle, and between high speed rotation of strike wheels and axial microfeed of work-piece by means of kinematic and dynamic analysis, to find the way of precise intermittent rotation of work-piece axle, to probe the influence of structural stiffness on forming accuracy and corresponding compensation measures, and finally to overcome the 4-axes linkage and precise control technique of high speed rotation of strike wheels, radial feed of strike wheel axle, intermittent rotation indexing of work-piece axle and axial microfeed of work-piece. The development of domestic cold strike forming machine for toothed shafts will be significant in efficient, low-carbon, saving material, green and high properties manufacturing.

齿形轴类零件如大模数花键和汽车离合器齿毂等是工业领域常用的传动、承载关键机械零件，传统的齿形轴类零件生产主要采用切削加工方法，效率低、浪费材料、表面质量和机械性能差，尤其是无法满足高质量、高强度零件和装备生产要求。利用冷敲成形原理生产齿形轴类件，生产效率大大提高，节约材料，表面质量和机械性能大大改善。本项目在多年研究轴类件冷滚压精确成形理论、工艺、装备和大模数花键冷敲成形理论、工艺的基础上，研究齿形轴类零件冷敲成形机新原理；通过运动学和动力学分析，解决冷敲机滚打轮主轴高速旋转敲击和工件轴间歇旋转分度及轴向微量进给高精度同步传动与协调控制难题；探索工件轴准确旋转分度方法和高冲击载荷下结构刚度对成形精度的影响及补偿措施；突破滚打轮高速旋转敲击、滚打轮主轴径向进给、工件轴旋转分度和轴向微量进给四轴精确联动与控制技术。开发出国产齿形轴类零件精确成形冷敲机，实现高效、低碳、节材、绿色和高性能制造。

随着我国装备制造业的飞速发展，对高性能、高精度齿形轴类零件的需求量日益增加。传统切削方式加工的花键轴类件已经不能满足要求。现阶段我国的冷体积成形工艺装备仅能生产模数小于1.5mm的花键轴。高性能、高精度大模数花键轴类零件及装备长期依赖进口，严重制约了我国相关行业的发展。.鉴于以上研究背景，本项目在冷敲成形设备方面，对冷敲成形机工作原理和结构进行了系统分析，建立了成形设备的多轴运动学模型、工作机构和工件运动参数计算理论和方法；对关键部件进行了运动学仿真、模态分析及结构优化设计。研究了冷敲成形过程的动态载荷特征以及变化特点，得出在该种载荷情况下对花键质量精度的影响，提出相关控制以及补偿方法；对多轴高速运动协调控制理论和方法进行了研究，提出了各种运动不发生干涉条件下的工艺参数并设计了具体的传动系统。通过机、电、液一体化控制系统集成，实现了冷敲机滚打轮的高速旋转运动，滚打轮进给运动，工件的间歇分度以及轴向微量进给运动等。设计了冷敲成形机无级分度系统，实现了滚打轮高速旋转敲击与工件轴间歇分度高精度多轴协调控制。在以上理论分析的基础上最终完成设计了国内首台具有独立自主知识产权的LQ200型花键冷敲机。通过试验研究完成了冷敲花键质量分析并根据性能分布特点揭示了冷敲花键性能提高机理以及影响花键性能质量的关键工艺参数。开发的LQ200型冷敲机技术参数：花键加工模数达到3.5mm，花键齿面加工精度达到 Ra0.4，可安装工件最大长度1000mm，可加工工件花键最大长度200mm，可加工工件直径范围80～260mm，可加工工件齿数范围12～36，齿轧辊最大回转速度：1450r／min，轧辊回转直径：205mm，轧辊主轴中心距：290～470mm。.该项目的完成形成了齿形轴类零件冷敲精密成形控形/控性方面的基础理论、工艺方法和技术，冷敲成形相关设备的研制成功打破国外垄断，对提升我国制造业水平具有深远意义。