A processing method for conical or cylindrical rollers

Abstract

A processing method for conical or cylindrical rollers, which relates to the technical field of bearing processing. Through the process route of hard turning - fine grinding of the rolling surface - final grinding of the rolling surface - superfinishing, turning is used instead of grinding, saving a large amount of manpower and material resources, reducing the labor intensity, shortening the processing cycle. By implementing the present invention, both the product quality can be guaranteed and the production efficiency can be improved, having good social and economic benefits, etc., and is suitable for large-scale promotion and application.

Description

Technical Field

[0001] The present invention relates to the technical field of bearing processing, and particularly relates to a processing method for conical or cylindrical rollers, and specifically relates to the processing of rollers with requirements for logarithmic modification convexity profile of the rolling surface and spherical base surface arc curvature requirements. Background Art

[0002] Taking conical rollers as an example, with the gradual popularization of logarithmic curve modification of the working surface of conical rollers, customers have increasingly strict requirements for logarithmic modification of the rolling surface of the rollers, spherical base surface curvature, and surface finish. The existing roller processing technology mainly relies on the generating grinding method to achieve the requirements of logarithmic modification of the rolling surface and spherical base surface curvature; however, this processing method is difficult to meet the roller quality requirements; on the one hand, after grinding the spherical base surface, it is difficult to control the curvature and the scatter is large, which cannot meet the process requirements; on the other hand, the surface roughness after grinding reaches more than 0.25 μm, which cannot meet the requirement of the spherical base surface roughness of 0.16 μm; the logarithmic modification of the rolling surface is realized by converting the logarithmic curve into several arcs on the CNC grinding machine, and there is a large error between the actual logarithmic curve shape, the profile is large, and the convexity profile repaired cannot meet the process requirements;

[0003] The existing processing technology "rough grinding the rolling surface I - rough grinding the rolling surface II - grinding the spherical base surface - grinding the small end face - turning the chamfer - fine grinding the rolling surface - magnetic particle inspection - polishing the spherical base surface - final grinding the rolling surface - grinding the slope - superfinishing the rolling surface", the process route is complex and the processing cycle is long.

[0004] Therefore, there is an urgent need to provide a new processing method for conical or cylindrical rollers to solve the problems of unguaranteed processing quality and low processing efficiency in current roller processing, so as to meet the requirements of rolling surface modification and spherical base surface arc curvature, shorten the process route, improve the processing efficiency, etc. Summary of the Invention

[0005] To overcome the deficiencies in the background art, the present invention provides a processing method for conical or cylindrical rollers, which is used to realize the logarithmic curve modification of the rolling surface of conical or cylindrical rollers and the processing requirements of spherical base surface arc curvature, etc.

[0006] To achieve the above-mentioned invention purpose, the present invention adopts the following technical solutions:

[0007] A processing method for conical or cylindrical rollers, the method specifically includes the following steps:

[0008] The first step is to perform rough turning on the conical or cylindrical roller:

[0009] First, clamp the blank of the conical or cylindrical roller on the chuck of the lathe, and hard-turn the non-base surface, half of the rolling surface and the chamfer of the conical or cylindrical roller blank. When hard-turning the non-base surface of the conical or cylindrical roller blank, the turning allowance is 0.2 - 0.3 mm, and the surface roughness after hard-turning is Ra0.2 - 0.3 μm. When hard-turning half of the rolling surface of the conical or cylindrical roller blank, the turning allowance is 0.3 - 0.45 mm, and a grinding allowance of 0.1 - 0.2 mm is reserved for grinding after hard-turning. The surface roughness after hard-turning is Ra0.4 - 0.6 μm. When hard-turning the chamfer of the conical or cylindrical roller blank, directly turn a white chamfer, and the dimensions meet the design requirements;

[0010] Then, hard-turn the spherical base surface, half of the rolling surface and the chamfer of the conical or cylindrical roller blank. When hard-turning the spherical base surface of the conical or cylindrical roller blank, the turning allowance is 0.2 - 0.3 mm. After hard-turning, the curvature of the spherical base surface should meet the design requirements, and the surface roughness of the spherical base surface is Ra0.1 - 0.2 μm. When hard-turning half of the rolling surface of the conical or cylindrical roller blank, the turning allowance is 0.3 - 0.45 mm, and a grinding allowance of 0.1 - 0.2 mm is reserved for grinding after hard-turning. The surface roughness after hard-turning is Ra0.4 - 0.6 μm. When hard-turning the chamfer of the conical or cylindrical roller blank, directly turn a white chamfer, and the dimensions meet the design requirements;

[0011] Second step: Fine-grind the conical or cylindrical roller:

[0012] Fine-grind the rolling surface of the conical or cylindrical roller after rough turning on an external cylindrical grinder to remove the turning joint marks generated by turning on the hard-turned rolling surface. When fine-grinding the rolling surface, the grinding allowance is 0.1 - 0.12 mm, and a margin of 0.03 - 0.06 mm is reserved for finish grinding. The surface roughness of the rolling surface after fine-grinding is Ra0.3 - 0.5 μm. After fine-grinding, ensure that the angle, roundness and dimensions of the rolling surface meet the requirements of the drawing. After fine-grinding is completed, perform flaw detection on the conical or cylindrical roller;

[0013] Third step: Finish grind and profile the rolling surface of the conical or cylindrical roller:

[0014] Perform finish grinding and profiling on the flaw-detected conical or cylindrical roller on an external cylindrical grinder. The surface roughness after finish grinding the rolling surface is within Ra0.3 μm. The outer diameter dimension, roundness and diameter variation of the rolling surface need to meet the requirements of the drawing. When profiling the rolling surface, the logarithmic curve convexity of the rolling surface needs to be satisfied. The logarithmic curve equation for profiling the convexity of the rolling surface is: Y = A × Ln[1 / (1 - (2X / B)²)] (X ≠ B / 2). After finish grinding the rolling surface and profiling, the convexity value at the corresponding detection position and the entire profiling contour of the rolling surface need to meet the requirements of the logarithmic curve. Then, perform residual magnetic inspection on the conical or cylindrical roller;

[0015] Fourth step: Super-finish the conical or cylindrical roller:

[0016] The conical or cylindrical rollers with qualified residual magnetism detection are superfinished on a superfinishing machine for the rolling surface. The superfinishing of the rolling surface does not change the modified profile, but only changes the surface finish of the rolling surface. After superfinishing, the roughness value is within Ra0.1μm to meet the roughness requirements of the rolling surface.

[0017] For the processing method of the conical or cylindrical rollers, the lathe in the first step is a high-precision CNC lathe, and the model is EU51Ⅱ.

[0018] For the processing method of the conical or cylindrical rollers, in the first step, when hard turning the blank of the conical or cylindrical rollers, a CNC machining program is compiled for control to accurately ensure the requirements of the spherical base surface arc curvature, the runout and height of the spherical base surface, and turning instead of grinding can effectively avoid the disadvantages of grinding burns caused by rough grinding of the rolling surface and both ends.

[0019] For the processing method of the conical or cylindrical rollers, in the second step, the cylindrical grinder is a high-precision roller cylindrical grinder. The processed angle, roundness and dimensions are ensured by the high-precision roller cylindrical grinder. The model of the high-precision roller cylindrical grinder is 3MZ1313A. When detecting the conical or cylindrical rollers for flaw detection, a fluorescent magnetic particle flaw detector is used for flaw detection, and the model of the fluorescent magnetic particle flaw detector is CDW-4000.

[0020] For the processing method of the conical or cylindrical rollers, in the third step, the cylindrical grinder is a high-precision roller cylindrical grinder, and the model is 3MZ1313A. When performing residual magnetism inspection on the conical or cylindrical rollers, a residual magnetometer is used for residual magnetism inspection, and the model of the residual magnetometer is 2057.

[0021] For the processing method of the conical or cylindrical rollers, in the third step, when detecting the conical or cylindrical rollers for flaw detection, since the grinding amount is large during fine grinding of the rolling surface, 100% fluorescent magnetic particle flaw detection is performed after fine grinding of the rolling surface.

[0022] For the processing method of the conical or cylindrical rollers, in the third step, when modifying the logarithmic curve, the logarithmic curve is generated by using the logarithmic equation through CAD software and directly imported into the equipment, and is converted into a modification program through the CAM mode to directly realize the modification, accurately realizing the logarithmic modification profile and convexity requirements of the rolling surface.

[0023] For the processing method of the conical or cylindrical rollers, in the fourth step, the superfinishing machine is a conical roller superfinishing machine, and the model is 3MK62150.

[0024] For the processing method of the conical or cylindrical rollers, in the fourth step, when superfinishing the rolling surface, the entire rolling surface of the roller is superfinished by a superfinishing oilstone, and the roughness requirements of the roller rolling surface are met without changing the modified profile of the rolling surface.

[0025] Adopting the above technical solution, the present invention has the following advantages:

[0026] Through the process route of hard turning - fine grinding the rolling surface - final grinding the rolling surface - superfinishing, the present invention replaces grinding with turning, saving a large amount of manpower and material resources, reducing labor intensity, shortening the processing cycle. By implementing the present invention, both product quality can be ensured and production efficiency can be improved, with good social and economic benefits, etc., and it is suitable for large - scale promotion and application. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is the processing flow chart of conical or cylindrical rollers in the embodiment of the present invention;

[0028] Figure 2 It is the hard turning processing program diagram of the numerical control lathe in the embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0029] The present invention can be more detailedly explained through the following embodiments, and the present invention is not limited to the following embodiments;

[0030] Combined with the attached Figures 1 - 2 A processing method of a conical or cylindrical roller, the method specifically includes the following steps:

[0031] First step, perform rough turning on the conical or cylindrical roller:

[0032] First, clamp the blank of the conical or cylindrical roller on the chuck of the lathe, and hard turn the non - base surface, half of the rolling surface and the chamfer of the blank of the conical or cylindrical roller. When hard turning the non - base surface of the blank of the conical or cylindrical roller, the turning allowance is 0.2 - 0.3 mm, and the surface roughness after hard turning is Ra0.2 - 0.3 μm. When hard turning half of the rolling surface of the blank of the conical or cylindrical roller, the turning allowance is 0.3 - 0.45 mm, and a grinding allowance of 0.1 - 0.2 mm is reserved for grinding after hard turning, and the surface roughness after hard turning is Ra0.4 - 0.6 μm. When hard turning the chamfer of the blank of the conical or cylindrical roller, directly turn a white chamfer, and the size meets the design requirements;

[0033] Then hard turn the spherical base surface, half of the rolling surface and the chamfer of the blank of the conical or cylindrical roller. When hard turning the spherical base surface of the blank of the conical or cylindrical roller, the turning allowance is 0.2 - 0.3 mm, and the curvature of the spherical base surface after hard turning should meet the design requirements, and the surface roughness of the spherical base surface is Ra0.1 - 0.2 μm. When hard turning half of the rolling surface of the blank of the conical or cylindrical roller, the turning allowance is 0.3 - 0.45 mm, and a grinding allowance of 0.1 - 0.2 mm is reserved for grinding after hard turning, and the surface roughness after hard turning is Ra0.4 - 0.6 μm. When hard turning the chamfer of the blank of the conical or cylindrical roller, directly turn a white chamfer, and the size meets the design requirements;

[0034] During implementation, the lathe is a high-precision CNC lathe with the model EU51Ⅱ. When hard turning the blank of tapered or cylindrical rollers, a numerical control processing program is compiled for control. The numerical control processing program control diagram is as shown in the appendix Figure 2 (It should be noted that the hard turning processing program diagram of the CNC lathe shown in the appendix Figure 2 is not the focus of the protection of the present invention. At the same time, this program is also a conventional choice for those skilled in the art. Therefore, the applicant will not elaborate in detail here), accurately ensuring the requirements for the curvature of the spherical base surface arc, the runout and height of the spherical base surface, and effectively avoiding the disadvantages of grinding burns caused by rough grinding the rolling surface and both end faces by turning instead of grinding;

[0035] During specific implementation, the specific requirements for hard turning are shown in the following table:

[0036]

[0037] The second step: Fine grinding the tapered or cylindrical rollers:

[0038] The tapered or cylindrical rollers after rough turning are fine ground on the outer circle grinder for the rolling surface to grind off the turning jointing marks on the rolling surface caused by hard turning. When fine grinding the rolling surface, the grinding amount is 0.1 - 0.12 mm, leaving a margin of 0.03 - 0.06 mm for final grinding. After fine grinding, the surface roughness of the rolling surface is Ra0.3 - 0.5 μm. After fine grinding, ensure that the angle, roundness and dimensions of the rolling surface meet the requirements of the drawing. After fine grinding, perform flaw detection on the tapered or cylindrical rollers;

[0039] During implementation, the outer circle grinder is a high-precision roller outer circle grinder, and the angle, roundness and dimensions after processing are ensured by the high-precision roller outer circle grinder. The model of the high-precision roller outer circle grinder is 3MZ1313A. When performing flaw detection on the tapered or cylindrical rollers, a fluorescent magnetic particle flaw detector is used for flaw detection, and the model of the fluorescent magnetic particle flaw detector is CDW - 4000;

[0040] The third step: Final grinding and profiling of the rolling surface of the tapered or cylindrical rollers:

[0041] After flaw detection, the conical or cylindrical rollers are subjected to final grinding and profiling on an external cylindrical grinder. After final grinding the rolling surface, the surface roughness is within Ra0.3μm. The outer diameter dimension, roundness, and diameter variation of the rolling surface shall meet the requirements of the drawing. When profiling the rolling surface, the logarithmic curve convexity of the rolling surface shall be satisfied. The design of the generatrix convexity of the rolling surface of conical or cylindrical rollers can reduce the edge effect of the rollers, improve the service life and load-bearing capacity of the bearings. Therefore, customers' requirements for the convexity profile of the rolling surface are becoming increasingly strict. Since the logarithmic curve convexity of the rolling surface replaces the original rolling surface shape of the existing conical or cylindrical rollers, the logarithmic curve equation for profiling the rolling surface convexity is: Y = A×Ln[1 / (1 - (2X / B)²)] (X≠B / 2). After final grinding the rolling surface and profiling, the convexity value at the corresponding detection position and the entire profiling contour of the rolling surface shall meet the requirements of the logarithmic curve. Then, the conical or cylindrical rollers are subjected to residual magnetic inspection;

[0042] During implementation, the external cylindrical grinder is a high-precision roller external cylindrical grinder, model 3MZ1313A. When performing residual magnetic inspection on conical or cylindrical rollers, a residual magnetic instrument is used for inspection, and the model of the residual magnetic instrument is 2057;

[0043] Furthermore, when flaw detecting the conical or cylindrical rollers, since the grinding amount is large during fine grinding of the rolling surface, 100% fluorescence magnetic particle flaw detection is performed after fine grinding the rolling surface.

[0044] Furthermore, during profiling, the logarithmic curve is generated by using the logarithmic equation through CAD software and directly imported into the equipment, and is converted into a profiling program through the CAM mode to directly achieve profiling, accurately realizing the logarithmic profiling contour and convexity requirements of the rolling surface;

[0045] Step 4: Superfinishing the conical or cylindrical rollers:

[0046] The conical or cylindrical rollers with qualified residual magnetic detection are superfinished on a superfinishing machine. The superfinishing of the rolling surface does not change the profiling contour, but only changes the surface finish of the rolling surface. After superfinishing, the roughness value is within Ra0.1μm to meet the roughness requirements of the rolling surface.

[0047] During implementation, the superfinishing machine is a conical roller superfinishing machine, model 3MK62150. When superfinishing the rolling surface, the entire rolling surface of the roller is superfinished by a superfinishing oilstone to meet the roughness requirements of the roller rolling surface without changing the profiling contour of the rolling surface.

[0048] When the present invention is specifically implemented, in the first step, during hard turning, the processing process is controlled by numerical control programming of the Fanuc system of a high-precision numerically controlled lathe; after processing, the curvature R of the spherical base surface can be accurately guaranteed to meet the process requirements such as the curvature, runout, chamfer, and height of the spherical base surface; and replacing grinding with turning can effectively avoid grinding burns;

[0049] Furthermore, for the fine grinding of the rolling surface, a high-precision external cylindrical grinding machine is used, which can ensure the angle, roundness and dimensions of the rolling surface after processing.

[0050] Furthermore, when performing final grinding of the rolling surface and profile modification, a numerically controlled high-precision external cylindrical grinding machine is used for processing. The logarithmic curve of the rolling surface profile modification is generated by using a logarithmic equation through CAD software and directly imported into the equipment, and then converted into a profile modification program through the CAM mode to directly achieve profile modification, which can accurately achieve the requirements of the logarithmic profile modification and convexity of the rolling surface.

[0051] Furthermore, when performing superfinishing of the rolling surface, a special superfinishing machine for tapered rollers is used. The entire rolling surface of the roller is superfinished by superfinishing oilstones. Without changing the profile modification of the rolling surface, the surface roughness can reach within 0.1 μm.

[0052] The present invention can fully meet the processing requirements of logarithmically profiled rollers, not only ensuring the processing quality, but also greatly improving the processing efficiency, and has received unanimous praise from applied customers, with good economic and social benefits, etc.

[0053] The present invention has the following advantages:

[0054] 1. By using high-precision numerically controlled hard turning, the requirements for the curvature of the spherical base surface and the runout of the spherical base surface can be ensured, and grinding burns caused by rough grinding can be avoided.

[0055] 2. By using a high-precision external cylindrical grinding machine to convert the logarithmic curve produced by CAD software into a profile modification program through the CAM mode, the logarithmic curve modification of the rolling surface is accurately achieved, ensuring the profile modification and convexity of the rolling surface.

[0056] 3. The new process route is shortened, turning is used instead of grinding, saving a large amount of manpower and material resources, reducing the labor intensity, greatly shortening the processing cycle, and the production efficiency is increased by about 30% compared with the original process.

[0057] The parts not described in detail in the present invention are prior art.

[0058] The embodiments selected herein for disclosing the invention purpose of the present invention are considered to be suitable at present. However, it should be understood that the present invention is intended to include all changes and improvements of all embodiments falling within the scope of this concept and invention.

Claims

1. A processing method for conical or cylindrical rollers, characterized in that: The method specifically includes the following steps: First step: Rough turning of the tapered or cylindrical roller: First, clamp the blank of the tapered or cylindrical roller on the chuck of the lathe, and rough turn the non-base surface, the first half of the rolling surface, and the first chamfer of the blank of the tapered or cylindrical roller. When rough turning the non-base surface of the blank of the tapered or cylindrical roller, the cutting amount is 0.2 - 0.3 mm, and the surface roughness after rough turning is Ra0.2 - 0.3 μm. When rough turning the first half of the rolling surface of the blank of the tapered or cylindrical roller, the cutting amount is 0.3 - 0.45 mm, and a grinding allowance of 0.1 - 0.2 mm is reserved for grinding after rough turning, and the surface roughness after rough turning is Ra0.4 - 0.6 μm. When rough turning the first chamfer of the blank of the tapered or cylindrical roller, directly turn the chamfer, and the size meets the design requirements; Then, rough turn the spherical base surface, the second half of the rolling surface, and the second chamfer of the blank of the tapered or cylindrical roller. When rough turning the spherical base surface of the blank of the tapered or cylindrical roller, the cutting amount is 0.2 - 0.3 mm, and the curvature of the spherical base surface after rough turning should meet the design requirements, and the surface roughness of the spherical base surface is Ra0.1 - 0.2 μm. When rough turning the second half of the rolling surface of the blank of the tapered or cylindrical roller, the cutting amount is 0.3 - 0.45 mm, and a grinding allowance of 0.1 - 0.2 mm is reserved for grinding after rough turning, and the surface roughness after rough turning is Ra0.4 - 0.6 μm. When rough turning the second chamfer of the blank of the tapered or cylindrical roller, directly turn the chamfer, and the size meets the design requirements; Second step: Fine grinding of the tapered or cylindrical roller: Fine grind the rolling surface of the tapered or cylindrical roller after rough turning on an external cylindrical grinder to grind off the turning joint marks generated by turning on the rolling surface during rough turning. When fine grinding the rolling surface, the grinding amount is 0.1 - 0.12 mm, and a margin of 0.03 - 0.06 mm is reserved for final grinding. The surface roughness of the rolling surface after fine grinding is Ra0.3 - 0.5 μm. After fine grinding, ensure that the angle, roundness, and size of the rolling surface meet the requirements of the drawing. After fine grinding is completed, perform flaw detection on the tapered or cylindrical roller; Third step: Final grinding and profile correction of the rolling surface of the tapered or cylindrical roller: Perform final grinding and profile correction on the tapered or cylindrical roller after flaw detection on an external cylindrical grinder. The surface roughness after final grinding of the rolling surface is within Ra0.3 μm, and the outer diameter size, roundness, and diameter variation of the rolling surface need to meet the requirements of the drawing. When correcting the profile of the rolling surface, the convexity of the logarithmic curve of the rolling surface needs to be met. The logarithmic curve equation for the convexity correction of the rolling surface is: Y = A×Ln[1 / (1 - (2X / B)²)] (X≠B / 2). After final grinding of the rolling surface and profile correction, the convexity value at the corresponding detection position and the entire profile correction of the rolling surface need to meet the requirements of the logarithmic curve. Then, perform residual magnetic inspection on the tapered or cylindrical roller; Fourth step: Superfinishing of the tapered or cylindrical roller: Perform superfinishing of the rolling surface of the tapered or cylindrical roller with qualified residual magnetic detection on a superfinishing machine. Superfinishing of the rolling surface does not change the profile correction, but only changes the surface finish of the rolling surface. The roughness value after superfinishing is within Ra0.1 μm to meet the requirements of the rolling surface roughness.

2. The processing method of the conical or cylindrical roller according to claim 1, characterized in that: In the first step, the lathe is a high-precision CNC lathe with the model EU51Ⅱ.

3. The processing method of the conical or cylindrical roller according to claim 1, characterized in that: In the first step, when hard turning the blanks of tapered or cylindrical rollers, a numerical control machining program is compiled for control to accurately ensure the requirements for the curvature of the spherical base surface arc, the runout of the spherical base surface, and the height. Turning instead of grinding effectively avoids the drawback of grinding burns caused by rough grinding the rolling surface and both end faces.

4. The processing method of the conical or cylindrical roller according to claim 1, characterized in that: In the second step, the external cylindrical grinding machine is a high-precision roller external cylindrical grinding machine. The angles, roundness, and dimensions after machining are ensured by the high-precision roller external cylindrical grinding machine. The model of the high-precision roller external cylindrical grinding machine is 3MZ1313A. When detecting the tapered or cylindrical rollers for flaws, a fluorescent magnetic particle flaw detector is used for flaw detection. The model of the fluorescent magnetic particle flaw detector is CDW-4000.

5. The processing method of the conical or cylindrical roller according to claim 1, characterized in that: In the third step, the external cylindrical grinding machine is a high-precision roller external cylindrical grinding machine, with the model of 3MZ1313A. When performing residual magnetic inspection on the tapered or cylindrical rollers, a residual magnetic instrument is used for residual magnetic inspection. The model of the residual magnetic instrument is 2057.

6. The processing method of the conical or cylindrical roller according to claim 1, characterized in that: In the third step, when detecting the tapered or cylindrical rollers for flaws, since the grinding amount is large during fine grinding of the rolling surface, 100% fluorescent magnetic particle flaw detection is carried out after fine grinding the rolling surface.

7. The processing method of the conical or cylindrical roller according to claim 1, characterized in that: In the third step, when performing profiling, the logarithmic curve is generated by using a logarithmic equation through CAD software and directly imported into the equipment. Through the CAM mode, it is converted into a profiling program to directly achieve profiling, accurately realizing the requirements for the logarithmic profiling contour and convexity of the rolling surface.

8. The processing method of the conical or cylindrical roller according to claim 1, characterized in that: In the fourth step, the superfinishing machine is a tapered roller superfinishing machine, with the model of 3MK62150.

9. The processing method of the conical or cylindrical roller according to claim 1, characterized in that: In the fourth step, when superfinishing the rolling surface, the entire rolling surface of the roller is superfinished by a superfinishing oilstone to meet the requirements for the roughness of the roller rolling surface without changing the profiling contour of the rolling surface.

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