Zhang Huan, Niu Ying, Jia Xiaofeng, Chu Shuaizhen, Niu Jingjing
School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo 454000, China.
School of Mechanical Engineering, Anyang Institute of Technology, Anyang 455000, China.
Micromachines (Basel). 2023 Aug 17;14(8):1626. doi: 10.3390/mi14081626.
The common material of bearing rings is GCr15 bearing steel which is a typical difficult-to-machine material. As an important working surface of the bearing, the inner surface of the raceway plays a vital role in the performance of the bearing. As an important means to solve the high-performance manufacturing of difficult-to-machine materials, longitudinal-torsional ultrasonic processing is widely used in various types of processing. In the presented work, the basic size of the horn is obtained from the wave equation of the forced vibration, and the modal analysis and amplitude test are carried out to verify the rationality of the LUTG structure. Then, according to the probability density function of cutting thickness and the overlapping effect of adjacent abrasive trajectories, the LUTG surface topography prediction model is established by using the height formula of the surface residual material, and the model reliability is verified by using the orthogonal test. The error between the test results and the prediction model is within 13.2%. Finally, based on the response surface method, the optimal process parameters that can meet the requirements of low roughness (Ra) and high material removal rate (MRR) are screened, and the optimal combination of process parameters is obtained as follows: A = 4.5 μm, n = 6493.3 r/min, ap = 28.4 μm, and vf = 21.1 mm/min.
轴承套圈的常用材料是GCr15轴承钢，它是一种典型的难加工材料。作为轴承的重要工作表面，滚道内表面对轴承性能起着至关重要的作用。作为解决难加工材料高性能制造的重要手段，纵向扭转超声加工在各类加工中得到广泛应用。在本研究中，变幅杆的基本尺寸由受迫振动波动方程得出，并进行模态分析和振幅测试以验证纵向扭转超声磨削（LUTG）结构的合理性。然后，根据切削厚度概率密度函数和相邻磨粒轨迹重叠效应，利用表面残余材料高度公式建立LUTG表面形貌预测模型，并通过正交试验验证模型可靠性。试验结果与预测模型之间的误差在13.2%以内。最后，基于响应面法筛选出能满足低粗糙度（Ra）和高材料去除率（MRR）要求的最优工艺参数，得到的工艺参数最优组合如下：A = 4.5μm，n = 6493.3 r/min，ap = 28.4μm，vf = 21.1 mm/min。
