球轴承的失效分析

通过宏观分析、金相检验、断口分析、化学分析和硬度检测等手段,对球轴承的钢球和内圈进行分析,并对其接触应力及有关参数进行计算,对接触疲劳的失效原因进行探讨。结果表明,钢球存在严重的材料冶金缺陷,引起钢球和内圈的早期接触疲劳失效。     

连铸滚珠轴承钢的质量

介绍夹杂物的种类和大小对滚珠钢接触疲劳的影响.对含Al和不含Al两种滚珠钢的质量进行对比.描述了神户、POSCO、Saar几家钢厂生产滚珠钢的情况.讨论钢中MgO·Al2O3夹杂的来源.     

基于小波神经网络的滚动轴承故障诊断

根据滚动轴承振动信号的频域变化特征,采用小波包分析对其建立频域能量特征向量,利用径向基函数神经网络完成滚动轴承故障状态的识别.理论和试验证明了该方法的有效性和实用性.     

Damping models for machine tool components of linear axes

To simulate the dynamic behaviour of machine tools, the stiffness, damping and inertia parameters of the structure are needed. While masses and stiffness parameters of structural parts can be obtained with a static measurement, the determination of damping parameters requires a thorough methodology. In this paper the common methodology for the identification of local damping parameters of machine components was extended by an additional step to isolate the damping of the test object more precisely. Furthermore test benches as well as the identified damping models for components of an exemplary linear axis are presented.     

精密立式加工中心运动轴的定位误差补偿研究

以某精密立式加工中心为对象,在西门子840D(Sinumerik 840D)数控系统平台下,基于分段补偿算法,利用Renishaw激光干涉仪对机床运动轴的位置精度进行定点测量,实现了对定位误差的补偿。实验结果表明了所述方法的有效性。     

Prediction and identification of rotary axes error of non-orthogonal five-axis machine tool

This paper proposes an efficient and automated scheme to predict and identify the position and motion errors of rotary axes on a non-orthogonal five-axis machining centre using the double ball bar (DBB) system. Based on the Denavit-Hartenberg theory, a motion deviations model for the tilting rotary axis B and rotary C of a non-orthogonal five-axis NC machine tool is established, which considers tilting rotary axis B and rotary C static deviations and dynamic deviations that total 24. After analysing the mathematical expression of the motion deviations model, the QC20 double ball bar (DBB) from the Renishaw Company is used to measure and identify the motion errors of rotary axes B and C, and a measurement scheme is designed. With the measured results, the 24 geometric deviations of rotary axes B and C can be identified intuitively and efficiently. This method provides a reference for the error identification of the non-orthogonal five-axis NC machine tool.     

Modeling of vial and ball motions for an effective mechanical milling process

Mechanical milling (MM) is referred to a solid state size reduction process where work materials in the form of coarse particulates are broken into the ultimate fineness by means of mechanical impact created by collisions of the work materials and the milling media which are placed inside a reciprocating vial. Many milling techniques have been so far developed to improve the process. However, the efficiency of MM process is still below satisfactory in terms of energy balance, where the energy consumed by the process of reduction is still very low compared to the energy supplied to perform the milling process itself. This contributes to high energy losses and proportionally to the span of processing time. Other major problems inherent in the process are contamination by the balls and the vial materials into the work materials, and process temperature that could influence the properties of milled materials. Since MM process utilizes the energy generated by impact upon the collisions of the balls against the work materials, it is important to understand the motions of the balls, the work materials, and the vial, which are the sources of the generation of impact energy. To obtain an optimized processing condition, the motions of vial and ball in relationship with the work materials should be designed in such a way to ensure the optimum impact energy is consumed by the work materials for the size reduction purposes. This paper presents a physical model for work materials, balls, and vial collisions based on different ways of motions. Using this model, higher impact could be achieved. These would lead to the reduction of milling time, contamination, as well as milling temperature.     

Analysis of error motions of ultra-high-speed (UHS) micromachining spindles

This paper presents an experimental approach to analyze radial and axial error motions of miniature ultra-high-speed (UHS) spindles. The present work focuses on identifying the sources of error motions and quantifying them, specifically for the UHS spindles with hybrid ceramic bearings. Since effective application of micromachining processes, which commonly utilize miniature UHS spindles, require a high level of dimensional accuracy, form accuracy, and surface finish, the (unwanted) motions of the UHS spindles (and the associated tool-tip runout) must be well-understood. In this work, a laser Doppler vibrometer (LDV)-based measurement technique is used to measure radial and axial motions of the spindle from a sphere-on-stem precision artifact. The influence of temperature fluctuations, dynamically-induced effects, contact-bearing defects, and tool-attachment errors are analyzed. The spindle speeds are varied from 40 krpm to 160 krpm, and the over-hang lengths of 15 mm and 7.5 mm are considered. The variations arising from tool attachment to the collet are also studied. It is seen that (1) the thermal state of the spindle exhibits a cyclic behavior that results in significant changes to the spindle motions, (2) spindle speed and over-hang length significantly affect the spindle motions, and (3) the variations arising from the tool attachment to the collet can be described using a normal distribution, and may cause more than ±50% amplitude variations to the spindle motions.     

Construction of an error map of rotary axes on a five-axis machining center by static R-test

This paper proposes an efficient and automated scheme to calibrate error motions of rotary axes on a five-axis machining center by using the R-test. During a five-axis measurement cycle, the R-test probing system measures the three-dimensional displacement of a sphere attached to the spindle in relative to the machine table. Location errors, defined in ISO 230-7, of rotary axes are the most fundamental error factors in the five-axis kinematics. A larger class of error motions can be modeled as geometric errors that vary depending on the angular position of a rotary axis. The objective of this paper is to present an algorithm to identify not only location errors, but also such position-dependent geometric errors, or “error map,” of rotary axes. Its experimental demonstration is presented.     

基于功能进化的滚动直线导轨创新设计

根据机械产品功能进化的要求,将进化思想运用于创新设计过程,通过结构特征单元的提取与变换,对滚动直线导轨的结构进行了创新设计,实现了基于功能设计产品结构的过程.     

Derivation of machine tool error models and error compensation procedure for three axes vertical machining center using rigid body kinematics

Volumetric positional accuracy constitutes a large portion of the total machine tool error during machining. In order to improve machine tool accuracy cost-effectively, machine tool geometric errors as well as thermally induced errors have to be characterized and predicted for error compensation. This paper presents the development of kinematic error models accounting for geometric and thermal errors in the Vertical Machining Center (VMC). The machine tool investigated is a Cincinnati Milacron Sabre 750 3 axes CNC Vertical Machining Center with open architecture controller. Using Rigid Body Kinematics and small angle approximation of the errors, each slide of the three axes vertical machining center is modeled using homogeneous coordinate transformation. By synthesizing the machine's parametric errors such as linear positioning errors, roll, pitch and yaw etc., an expression for the volumetric errors in the multi-axis machine tool is developed. The developed mathematical model is used to calculate and predict the resultant error vector at the tool–workpiece interface for error compensation.     

球化剂种类对BGA焊球质量的影响

钎焊球是BGA及μBGA等高密封装技术中凸点制作的关键材料,球化剂种类是影响钎焊球质量的关键因素.在预热温度为500℃和球化温度为280℃,球化剂分别采用机油、重油、硅油和花生油时,采用切丝重熔法制作高密封装用钎焊球.研究了不同球化剂种类对63Sn37Pb钎焊球的球形度和外观形貌的影响.结果表明,花生油作为球化剂时,63Sn37Pb钎焊球的真球度系数值最小,钎焊球越接近真球形状,球形度越好,外观形貌也最好,球化效果最好.重油、硅油次之,机油最差.     

Design to limit thermal effects on linear motion bearing performance

By tuning the geometry of a linear motion bearing to the metallurgical and geometric properties of a structure, the effects of temperature changes on bearing geometry and performance can be minimized. This is illustrated in the design of a recirculating-roller, linear motion bearing that was designed for use on a flexible automated fixturing system. The main structure of the fixturing system was made of aluminium and steel and powered by hydraulics. Due to temperature rise caused by the hydralics, thermal growth effects on bearing preload had to be controlled in order to maintain accuracy of the system.     

Influence of turning parameters on distortion of bearing rings

The turning of bearing rings often leads to undesired form and dimensional changes after heat treatment which are referred to as distortion. In order to investigate the influence of cutting parameters on distortion, external longitudinal turning experiments were conducted. After machining the ring geometry and the residual stresses around the rings’ circumference were measured. The residual stresses were then released by a subsequent heat treatment. After the heat treatment the ring geometry was measured again. The results show that the residual stresses induced by the machining process correlate well with the dimensional changes after heat treatment. The cutting parameters that have the highest influence on the dimensional changes are the feed rate and the depth of cut. Residual stresses induced by soft-machining lead to an increase of the ring diameter, depending on the machining parameters.     

Influence of material microstructure on grindability of bearing steel

Innovative new materials and microstructures are being continually developed to meet increasingly challenging applications. These newly developed microstructures pose significant challenges in terms of grindability and component distortion. This fundamental study sheds light on the grindability of microstructure variations of through hardened A485–1 grade steel. Results indicate that the phase composition and carbide distribution significantly influence grindability which is characterized in terms of specific grinding energy, G-ratio and part distortion. The study also demonstrates that the numerically quantified carbide distribution exhibits a strong correlation to grindability when phase compositions are similar.     

CBN砂轮磨削薄壁球轴承内圈滚道的试验研究

提出了用立方氮化硼(CBN)砂轮代替传统的微晶刚玉砂轮磨削薄壁球轴承内圈滚道的方法,探讨了不同工艺参数对工件表面粗糙度和圆度精度的影响.试验结果表明,当CBN砂轮粒度变细时,可以明显改善磨削表面粗糙度,而对工件圆度值的影响较小;随着进给量增大,加工表面粗糙度值和滚道圆度误差值均增大;随着磨削速比降低加工表面粗糙度值增大.得出了最佳工艺参数为:磨削速比值ν工/ν砂=1/24,磨削进给量0.6 mm/min,砂轮粒度80#;其加工效果为:滚道圆度值由4μm稳定降低至2.5μm范围内,表面粗糙度由Ra 0.42 μm降低至Ra 0.28μm,尺寸一致性提高37%,无烧伤现象;生产率比微晶刚玉磨削提高40倍以上,砂轮耐用度提高50倍以上.