系统参数对花键轴轴向推进滚轧成形工艺过程的影响分析及试验

为实现花键轴零件高效高性能精确成形制造，介绍一种花键轴轴向推进滚轧成形工艺的系统组成、工艺过程以及特点，分析滚轧过程中滚轧模具与花键轴间的啮合传动规律，利用ADAMS系统动力学软件研究系统参数(滚轧模具个数Nd、滚轧模具齿数z1)对滚轧过程的影响特点，并通过研制的花键轴轴向推进滚轧成形工艺系统开展滚轧过程中花键轴实时转速的测试以及花键轴的滚轧成形试验。结果表明，滚轧过程中滚轧模具与花键轴间的啮合传动重合度小于1；Nd=3时滚轧模具与花键轴间的啮合传动稳定性明显优于Nd等于2和4的方式，当z1与花键轴齿数z2相等时滚轧模具与花键轴间的啮合传动稳定性较差，而当z1>z2时二者的啮合传动稳定性显著提高，确定的合理工艺系统参数为Nd=3、z1=120。滚轧试验过程中滚轧模具与花键轴啮合传动平稳，成形的花键轴齿数准确、齿形分布整齐、精度高。

Analysis and Experiment on the Effect of System Parameters on the Axial-infeed Rolling Forming Process of Spline Shaft

Aiming to realize the high efficiency, performance and precision forming manufacture for spline shaft, the process system, forming process and characteristic of an axial-infeed rolling forming process are introduced; The meshing transmission rule between the rolling die and spline shaft during the rolling process is investigated; The effects of system parameters(the number of rolling die Nd, the tooth number of rolling die z1) on the rolling process are analyzed utilizing the ADAMS software, and then the reasonable system parameters are determined; the practical axial-infeed rolling process system is established, the real-time rotational speed of spline shaft during the rolling process is tested, and the rolling forming process of spline shaft is conducted. The results show that the meshing transmission contact ratio between the rolling die and spline shaft is less than 1; the meshing transmission stability between the rolling die and spline shaft under Nd of 3 is better than those under Nd of 2 and 4, besides, the meshing transmission stability would be improved obviously when z1 is larger than the tooth number z2 of spline shaft; the meshing transmission between the rolling die and spline shaft is stable during the rolling experiment, the tooth number of the formed spline shaft is correct, and the formed tooth profiles are uniform and accurate.