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针对高速干切滚齿过程中切屑的形变规律及切屑挤压行为,基于DEFORM-3D建立了高速干切滚齿工艺仿真实验模型,通过对不同工艺参数下高速干切滚齿工艺实验仿真,实现了高速干切滚齿过程中齿轮材料去除过程的可视化,获得了高速干切滚齿过程中切屑的形变规律以及干切滚刀的磨损状态。结合实际高速干切滚齿加工实验,对比切屑形貌及干切滚刀损伤情况,进一步验证了切屑在生成及流动过程中的形变规律以及切屑对干切滚刀的挤压损伤行为。研究结果可为高速干切滚齿工艺参数优化以及高速干切滚刀的寿命延长和性能控制提供参考。 相似文献
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齿轮高速干式滚切工艺取消了切削油/液的使用,是一种绿色高效的齿轮制造工艺,其成形过程分析是提升该滚齿工艺性能的有效途径。基于金属切削工艺仿真软件Deform3D建立了齿轮高速干式滚切过程的有限元仿真模型;进行了齿轮高速干式滚切材料去除过程的数值仿真分析,获得了不同参数条件下齿轮高速干式滚切过程中切屑的变形规律,以及切削力与切削温度的分布规律,分析并确定了影响滚切性能的主要参数。研究结果为齿轮高速干式滚切工艺参数优化提供了理论和方法支撑。 相似文献
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《机械工程学报》2017,(1)
齿轮滚切工艺是应用最广泛的齿部成形加工工艺,高速干切工艺的出现和逐步成熟为齿轮滚切实现绿色环保加工以及高效自动化生产提供了技术条件。但由于高速干切工艺切削速度高且缺少切削油/液的冷却润滑,因而工艺参数对机床热变形误差、刀具寿命和工件质量等影响很大,需要开展深入研究。以自动化加工效率、齿轮单件成本为目标,工件材料、刀具涂层以及切削速度、进给量和滚刀顶刃最大切屑厚度等因素为变量,建立一种齿轮高速干式滚切工艺参数优化模型。通过数据分析和试验验证,基于工件材料的抗拉强度,得出齿轮高速干切滚齿工艺切削速度和滚刀顶刃最大切屑厚度推荐值;同时,为实现模型在齿轮自动化生产线上的应用,建立了高速干切滚齿工艺参数在机自适应优化修正模型,并基于西门子840D数控系统开发了高速干切滚齿工艺参数优化支持系统。该系统在某轿车齿轮自动生产线的生产实践中得到应用,取得了良好的效果。 相似文献
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圆柱齿轮滚切多刃断续切削空间成形模型及应用 总被引:2,自引:0,他引:2
滚切加工作为当前圆柱齿轮制造应用最为广泛的工艺具有高效但成形过程复杂的特点。基于展成原理,由规则分布在滚刀基本蜗杆螺旋面上的一系列切削刃相继从圆柱齿坯上切除材料,最终包络形成渐开线齿面。研究其成形原理可以为提升该工艺性能提供有效指导。针对齿轮滚切工艺过程多刃切削成形特征,建立圆柱齿轮滚切的空间成形模型。基于滚刀几何结构参数的理论约束关系,建立滚刀切削刃序列的参数方程;根据滚刀和工件的几何参数以及切削参数确定滚切过程中滚刀与工件的空间位置和运动关系,并基于空间运动学方法推导求得滚刀刀刃序列形成的空间成形曲面参数模型;采用离散数值方法获得滚切过程中的切屑几何形态及切屑厚度,并根据切屑几何计算各刀刃去除材料时的瞬时主切削力。该模型可以为滚切工艺参数优化、滚刀几何设计等研究提供支撑。 相似文献
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滚挤压是一种金属表面微塑性连续变形精加工工艺,现在日益被用作切削加工后的表面强化终处理工艺以获得具有压缩残余应力的高性能低粗糙度的镜面零件表面。本文分析了车削前处理工艺对后续滚挤压加工效果的影响,采用考虑交互作用的L27(313)正交试验设计与分析方法研究了车削滚挤压复合工艺中车削三要素(即车削速度v、车削进给量f、车削深度ap)和滚挤压三要素(即滚挤压速度vb、滚挤压进给量fb、滚挤压深度ab)对滚轮滚挤压45号钢的滚挤压效果(即表面粗糙度Ra、小负荷维氏硬度Hv的影响规律),其中考虑了对滚挤压效果影响最显著的车削进给量f、滚挤压深度ab与滚挤压进给量fb两两之间的交互作用,分析得出了对滚挤压效果影响最显著的主要因素及其规律。从试验的角度发现车削进给量对滚挤压效果有显著影响,与理论分析和预测相吻合。 相似文献
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P. Senthil K. S. Amirthagadeswaran 《Journal of Mechanical Science and Technology》2012,26(4):1141-1147
This paper reports a research in which an attempt was made to prepare AC2A aluminium alloy castings of a non symmetrical component
through squeeze casting process. The primary objective was to investigate the influence of process parameters on mechanical
properties of the castings. Experiments were conducted based on orthogonal array suggested in Taguchi’s offline quality control
concept. The experimental results showed that squeeze pressure, die preheating temperature and compression holding time were
the parameters making significant improvement in mechanical properties. The optimal squeeze casting condition was found and
mathematical models were also developed for the process. 相似文献
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P. Vijian V. P. Arunachalam 《The International Journal of Advanced Manufacturing Technology》2007,33(11-12):1122-1127
Squeeze casting is a hybrid metal forming process combining features of both casting and forging in one operation. This paper reports a research in which an attempt was made to prepare solid cylindrical components of LM24 aluminum alloy through squeeze casting. The primary objective was to investigate the effect of process parameters on the mechanical properties exhibited by the castings produced though squeeze casting process. A set of trials were conducted based on parameters settings suggested in Taguchi’s offline quality control concept. The experimental results indicate that the squeeze pressure and the die-preheating temperature were the parameters making significant contribution toward improvement in mechanical properties of squeeze cast LM24 aluminum alloy. 相似文献
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基于模糊控制的挤压铸造模温控制系统研究 总被引:2,自引:0,他引:2
针对挤压铸造模具温度难于控制的特性,分析了挤压铸造工艺及挤铸模具温度影响因素。根据现有挤铸模具加热及冷却方式,结合分析研究影响挤铸模温的多因素与多变性,建立了新的挤铸模具温度控制模型,并运用模糊控制方法来实现温度控制。在设计好模糊控制器后,利用Matlab软件中的Simulink模块建立了模温控制系统模型并实现了仿真分析。仿真结果表明:与传统的PID控制相比,模糊控制系统具有良好的控制特性。 相似文献
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针对求解MEMS挤压膜阻尼过程中存在的问题,采用了多重网格方法进行求解,与传统方法相比,应用于挤压膜中流体问题的求解具有收敛速度快,数值稳定性好的优点,求得了谐振器平板间的压力分布函数以及微谐振器的各个性能指标的值,研究了挤压膜中流体阻尼力的特性以及与谐振器件幅—频特性的关系。 相似文献
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Ming Li Wei Tian Junshan Hu Changrui Wang Wenhe Liao 《Microscopy research and technique》2022,85(3):1075-1088
In the automatic drilling and riveting process, the perpendicular error of the hole is inevitable, which has a great influence on the assembly quality. In the current research, the shear and pull-out behaviors of riveted joints under different perpendicularity errors and squeeze forces were investigated and compared by the quasi-static tests. The fracture of the failed samples was characterized by a scanning electron microscope and the formation process of fracture was discussed. The failure mechanisms of riveted joints were analyzed in detail to guide engineering applications. The test results demonstrated that the shear load and pull-out load of riveted joints increased slightly with the increase of the tilt angle from 0° to 4°. The perpendicularity error did not affect the shear and pull-out failure modes of the riveted joints. However, the squeeze force had a significant effect on the failure modes of the pull-out samples. Fracture analysis showed that the failure of all shear samples occurred at the rivet shaft. Besides, when the squeeze force increased from 15 kN to 23 kN, the failure modes of the pull-out samples changed from the sheet to the rivet itself. 相似文献