基于旋风铣削和多光纤传感器检测的高负载滚珠丝杠疲劳寿命研究

As a key rolling component of CNC machine, the screw under high load conditions is required to keep good functional reliability, which is an urgent problem to be solved. Targeted at whirlwind milling screw, the failure mechanism and fatigue life under high load conditions were studied through the screw surface quality analysis, failure test and failure analysis. First, the influence of different cutting parameters on the surface quality of whirlwind milling was analyzed. As a source of of failure, a prediction model aimed at reducing the microcracking initiation was based on cutting parameters. Secondly, on the basis of multi-fiber sensor, the real-time intelligent testing method was explored to study the influence law and evolution mechanism, and to establish a prediction model of the dominant failure mode. Finally, combining the study of the cutting mechanism and failure mechanism, a prediction model of the fatigue life under high load conditions was established and verified by experiments. For the fatigue life of ball screw, the study provides all-round technical support and research ideas for processing technology improvement, operation monitoring and life prediction, which strives to achieve its high performance and long life.

作为数控机床的关键滚动功能部件，丝杠在高负载工况下的功能可靠性是亟待解决的问题。本项目拟以旋风铣削的丝杠为研究对象，贯穿丝杠的加工表面质量分析、失效实验检测和失效分析全过程，开展旋风铣削丝杠在高负载工况下的失效机理和疲劳寿命研究。首先，研究旋风铣削不同工艺参数对表面质量的影响规律，以失效源头微裂纹萌生为出发点，建立以减少微裂纹萌生为目标的加工多因素预报模型；其次，研究基于多光纤传感器的全程实时智能测试方法，探索失效模式的影响规律和演变机理，建立基于检测过程的主导失效模式预报模型；最后，综合加工机理和失效机理研究，建立高负载丝杠的疲劳寿命预报模型，并结合实验修正或验证。本项目为丝杠提供了工艺改进、过程监测和寿命预报的全方位技术支撑和研究思路，力求实现滚珠丝杠的高性能和高寿命。

本项目为实现滚珠丝杠的高性能和高寿命，以旋风铣削的丝杠为研究对象，贯穿丝杠的加工表面质量分析、失效实验检测和失效分析全过程，开展了旋风铣削丝杠在高负载工况下的失效机理和疲劳寿命研究。首先，研究了旋风铣削不同工艺参数对表面质量的影响规律，以失效源头微裂纹萌生为出发点，进行了减少微裂纹的方法研究；其次，基于多光纤传感器，分析了失效模式的影响规律和演变机理；最后，综合加工机理和失效机理研究，探索了延长丝杠工作寿命的方法，并将结合后期的实验进行调整。本项目为丝杠提供了工艺改进、过程监测和寿命延长的全方位技术支撑和研究思路。