A thin-wall bearing ring grinding method

Abstract

The application discloses a thin-wall bearing ring grinding method, and relates to the technical field of part machining. A control system calculates data collected by a sensor, compares a calculation structure with a preset model, controls output of a grinding parameter adjustment scheme according to a comparison result, and adjusts a grinding parameter in real time according to the grinding parameter adjustment scheme. After a single ring grinding process is completed, the control system stores and counts each grinding parameter. As the number of machined workpieces increases, the control system can record an adjustment range of all machining parameters, calculate a machining parameter change curve, form a specific quantitative machining parameter model, and be applied to machining of workpieces in the same batch to correct preset grinding parameters online. The thin-wall bearing ring grinding method provided by the application greatly shortens the research and development cycle of optimal process parameters of different products, has high quantification of process parameters, avoids subjective interference, and has high reliability.

Description

Technical Field

[0001] This invention relates to the field of parts processing technology, and in particular to a method for grinding thin-walled bearing rings. Background Technology

[0002] The bearing industry has developed rapidly in recent years, and at the same time, various industries have increasingly higher requirements for bearing precision. Compared with ordinary bearings, thin-walled bearings are lighter, smaller, and more precise, possessing unparalleled advantages. Because the rings of thin-walled bearings have very thin walls and narrow widths, they are very prone to deformation during processing, making it extremely difficult to achieve high manufacturing precision. This significantly increases the production difficulty and limits the rapid development of the industry; currently, most high-end bearings in China rely on imports.

[0003] Currently, thin-walled bearing manufacturers, taking flexible bearings as an example, generally still use the machining process of normal-wall-thickness bearing rings. The only difference is that the placement of the rings is more meticulous and careful during the heat treatment process before machining, the raceways are formed by two or more grinding passes, and an additional tempering process is added between the rough and fine grinding steps. These measures improve the bearing's precision to some extent, but significantly reduce the manufacturing efficiency of thin-walled rings, thereby increasing the manufacturing cost of thin-walled bearings. The fundamental contradiction in thin-walled bearing ring machining technology lies in the fact that during the grinding and ultra-precision machining of the rings, they are inevitably subjected to magnetic attraction, clamping force, and supporting force from the fixture, as well as pressure and cutting force from the grinding wheel. Under these forces, normal-wall-thickness rings will not deform or deform very little, while thin-walled rings, especially flexible bearing rings, will undergo significant deformation. The degree of deformation also differs after changes in force and the removal of external force. Reducing the feed rate and grinding wheel speed would further affect production efficiency.

[0004] The appropriate process parameters for different products are obtained through a process of "trial production-testing-re-trial production," resulting in a low product qualification rate, long R&D cycles, and highly empirical parameters. It is difficult to obtain optimal process parameters that balance processing quality and production energy consumption, leading to high production costs and hindering mass production. In the processing of bearing rings, grinding accounts for a significant portion of the work, requiring a large amount of labor for repetitive tasks. Furthermore, thin-walled bearing rings require high precision, and the materials used are often high-carbon chromium alloys with high density; therefore, collisions or drops with hard, sharp objects must be strictly avoided during loading and unloading.

[0005] The difficulty in achieving high machining accuracy for thin-walled bearing rings, coupled with the increasing precision requirements of the market for thin-walled bearings, presents a significant contradiction, severely restricting further improvements in the operational accuracy and limiting speed of lightweight mainframes. Therefore, developing processes to significantly improve the machining accuracy and efficiency of thin-walled bearing rings, especially flexible bearing rings, is both urgent and necessary. Summary of the Invention

[0006] The purpose of this invention is to provide a method for grinding thin-walled bearing rings to solve the problems existing in the prior art. This method significantly shortens the development cycle of optimal process parameters for different products, has a high degree of quantification of various process parameters, avoids subjective interference, and has high reliability.

[0007] To achieve the above objectives, the present invention provides the following solution:

[0008] This invention provides a method for grinding thin-walled bearing rings, comprising the following steps:

[0009] Step 1: Configure a waterproof sensor that can dynamically monitor the diameter, roundness, and distance between the bearing ring and the bearing ring in real time, and connect the sensor to the grinding machine control system.

[0010] Step 2: Start the grinding machine, select the preset grinding parameters according to the preset model, and control the motion mechanism to grind the ring.

[0011] Step 3: The control system performs calculations based on the data collected by the sensors, compares the calculated structure with the preset model, and outputs a grinding parameter adjustment scheme based on the comparison results. The action mechanism adjusts the grinding parameters in real time according to the grinding parameter adjustment scheme.

[0012] Step 4: After completing the grinding process of a single ring, the control system stores and statistically analyzes the grinding parameters and compares them with the preset model processing parameters. As the number of workpieces processed increases, the control system can record the adjustment range of all processing parameters, calculate the processing parameter change curve, and automatically prompt and eliminate outliers to form a specific quantitative processing parameter model, which can be applied to the processing of the same batch of workpieces to correct the preset grinding parameters online.

[0013] Preferably, in step two, when the actuating mechanism grinds the ring, grinding fluid is sprayed onto the grinding cross-section.

[0014] Preferably, in step three, the grinding parameter adjustment scheme is as follows: when the deformation of the ring is small, the grinding speed is increased; when the deformation of the ring is large, the feed rate and grinding wheel speed are reduced.

[0015] Preferably, the grinding machine is provided with a feeding trough, which is inclined inwards towards the inside of the grinding machine.

[0016] Preferably, the inclination angle of the feeding trough is 10-15°.

[0017] The present invention achieves the following technical effects compared to the prior art:

[0018] The thin-walled bearing ring grinding method provided by this invention uses sensors to monitor the deformation during the ring machining process online, calculates process parameters and compensation conditions in real time, and automatically and synchronously corrects the grinding process. Simultaneously, it achieves intelligent, automated, and dynamic control of the grinding process, forming a machining process model based on statistical laws. This significantly shortens the development cycle for optimal process parameters for different products, and the high degree of quantification of various process parameters avoids subjective interference, resulting in high reliability. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 A flowchart of the thin-walled bearing ring grinding method provided by the present invention; Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] The purpose of this invention is to provide a method for grinding thin-walled bearing rings to solve the problems existing in the prior art. It significantly shortens the research and development cycle of the optimal process parameters for different products, and the process parameters are highly quantified, avoiding subjective interference and ensuring high reliability.

[0023] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0024] This invention provides a method for grinding thin-walled bearing rings, the process of which is as follows: Figure 1 As shown, it includes the following steps:

[0025] Step 1: Configure a waterproof sensor that can dynamically monitor the diameter, roundness, and distance between the bearing ring and the bearing ring in real time, and connect the sensor to the grinding machine control system.

[0026] Step 2: Start the grinding machine, select the preset grinding parameters according to the preset model, and control the motion mechanism to grind the ring.

[0027] Step 3: The control system performs calculations based on the data collected by the sensors, compares the calculated structure with the preset model, and outputs a grinding parameter adjustment scheme based on the comparison results. The motion mechanism adjusts the grinding parameters in real time according to the grinding parameter adjustment scheme.

[0028] Step Four: After completing the grinding process of a single ring, the control system stores and statistically analyzes the grinding parameters and compares them with the preset model processing parameters. As the number of workpieces processed increases, the control system records the adjustment range of all processing parameters, calculates the processing parameter change curves, and automatically prompts and eliminates outliers, forming a specific quantitative processing parameter model. This model can be applied to the processing of workpieces in the same batch, allowing for online correction of the preset grinding parameters. Since the model parameters are all specific quantitative values, they can be directly adopted, avoiding excessive reliance on work experience when adjusting parameter sizes during processing. Simultaneously, during the use of process parameters, differences between different batches of blanks, such as deviations caused by heat treatment, cutting, and other front-end processes, can be dynamically corrected through the actual processing. This expands the error tolerance of the process scheme to a certain extent, reduces the actual workload, and significantly shortens the development cycle of optimal process parameters.

[0029] In step two, when the actuating mechanism grinds the ring, grinding fluid is sprayed onto the grinding surface. The grinding fluid is used to stabilize grinding conditions and reduce the heat generated during the grinding process. After being filtered by the lower filtration system, the grinding fluid is recycled to reduce impurity content, improve heat dissipation, maintain high raw material utilization, and reduce production costs and environmental impact.

[0030] In step three, the grinding parameter adjustment scheme is as follows: when the deformation of the ring is small, the grinding speed is increased to improve production efficiency; when the deformation of the ring is large, the feed rate and grinding wheel speed are reduced to ensure machining accuracy. By changing the magnitude of the cutting stress during the machining process, the influence of deformation is reduced.

[0031] The thin-walled bearing ring grinding method provided by this invention uses sensors to monitor the deformation during the ring machining process online, calculates process parameters and compensation conditions in real time, and automatically and synchronously corrects the grinding process. When the ring deformation is small, the grinding speed is increased to improve production efficiency; when the ring deformation is large, the feed rate and grinding wheel speed are reduced to ensure machining accuracy. This invention uses intelligent automatic control of the grinding process to perform statistical analysis on the grinding process, dynamically adjust various process parameters, and form a machining process model based on statistical laws, significantly shortening the R&D cycle for optimal process parameters for different products. The research of this invention has resulted in innovative key technologies for thin-walled bearing ring grinding with high stability and high precision, breaking the technological blockade in the field of high-end grinding abroad and promoting the progress of high-precision grinding technology and thin-walled bearing manufacturing in China.

[0032] This invention primarily targets the high-precision grinding of the outer diameter of thin-walled bearing rings. It employs a vertical grinding machine structure, with loading and unloading positioned vertically, enabling automatic loading and unloading via gravity. Basic function buttons, sensor data collection, and computational results are all integrated onto a single control panel, providing a clear view of the current processing status. Mechanical buttons for key components such as the stop, feed arm, and chuck allow for manual grinding control. The entire grinding process takes place within a sealed processing chamber. Sensors and other electronic components are waterproof, the chamber door features a safety interlock, and a transparent observation window facilitates monitoring of the grinding process. The data display screen and manual operation buttons are integrated onto the same control panel for convenient operation and observation. Manual operation is also included to handle special situations.

[0033] In the machining of bearing rings, grinding accounts for a significant portion of the workload, requiring substantial labor for repetitive tasks. Furthermore, due to the high precision requirements of thin-walled bearing rings and the use of high-carbon chromium alloys with high density, collisions or drops with hard, sharp objects must be strictly avoided during loading and unloading. By installing a loading trough at the top of the grinding machine, multiple workpieces of varying diameters can be simultaneously placed and arranged sequentially. The trough is inclined inwards towards the grinding machine at a 10-15° angle to the ground, allowing the bearing rings to roll forward under gravity. The loading mechanism is equipped with a shield, and the feed arm picks up one bearing ring at a time for processing. After processing, the bearing ring enters the discharge port, where the loading mechanism picks up a new workpiece for processing. A grinding fluid recovery tank is located at the bottom of the discharge port. The entire machining process, from loading to unloading, is automatically controlled by the equipment. By using automation and other technologies, highly repetitive manual labor is replaced, significantly reducing worker workload and effectively avoiding the risks of collisions and drops caused by human operation, thereby improving product quality stability and yield.

[0034] After the grinding ring enters the electromagnetic clamping device and is fixed, it rotates at a certain initial speed. Simultaneously, sensors dynamically monitor grinding parameters such as the roundness of the ring. The monitored values ​​are transmitted through a data acquisition system to the microprocessor of the control system for analysis and calculation. Based on the real-time processing results of the grinding data, the microprocessor issues commands to synchronously adjust the grinding action, which is then executed by the grinding wheel, feed arm, and other moving mechanisms. Sensors dynamically monitor the execution of these commands and provide feedback to the microprocessor for data synchronization, thus achieving dynamic adjustment of the entire grinding process. Under the control of the control system, the grinding wheel maintains a certain pressure and performs grinding operations on the rotating ring at a preset rotational and feed speed. Grinding fluid is sprayed onto the grinding surface through 2-6 hoses to maintain heat dissipation and stability during grinding. Multiple grinding fluid spray nozzles are pre-installed, allowing adjustment of the spray position according to the workpiece diameter. The grinding process takes place in a sealed chamber equipped with safety features, vibration reduction devices, and emergency stop mechanisms. The grinding fluid is filtered and recycled to ensure personnel safety and minimize environmental impact. After completing the grinding of a single ring, the microprocessor stores the grinding parameters and compares them with preset model parameters. As the proportion of workpieces processed increases and the process parameters exhibit statistical regularities, the microprocessor corrects the preset parameters online. Outliers in individual processing parameters are removed and an alarm is triggered. After each stage of processing is completed, a quantitative, statistically based processing model is formed, avoiding subjective influences on the processing and shortening the development cycle for optimal process parameters.

[0035] The sensor provided by this invention is preferably a certain model imported from Japan, with a measurement accuracy of 0.1 micrometers or higher. It is installed below the ring machining position to avoid signal interference caused by grinding fluid splashes, and can directly measure parameters such as the distance from the ring to the sensor and the ring diameter. During grinding, the ring is clamped by an electromagnetic clamping mechanism and rotates around its center, while the sensor continuously monitors the ring diameter. The changes in the measured diameter and the linear velocity of the ring's rotation reflect the magnitude of the ring's deformation. The monitoring signal is transmitted to the information processing system via a data transmission system. Parameters such as data acquisition rate and transmission rate allow for the selection of modular machining models based on actual requirements such as machining accuracy, better adapting to the grinding of workpieces of various specifications. The entire monitoring process is continuous during grinding. The microprocessor has high-speed computing capabilities, the transmission mechanism's feedback response time is at the millisecond level, and the rotating mechanism uses frequency conversion technology to change the rotation speed in real time according to instructions. The feed mechanism uses precise positioning and is equipped with limit blocks. The entire transmission mechanism is directly controlled by the control system, which has a fast response speed and high action precision. It also has a calibration function to avoid deviation caused by factors such as vibration during processing, ensuring the stability and reliability of equipment life, processing accuracy, and other parameters. Adjustable parameters such as grinding wheel speed and feed rate have been precisely calibrated, and real-time values ​​are displayed intuitively on the LCD screen, which can realize synchronous and precise adjustment of grinding action and greatly improve processing accuracy.

[0036] The main technical indicators of the thin-walled bearing ring grinding method provided by the present invention are shown in Table 1.

[0037] Table 1 Main Technical Specifications of the Product

[0038]

[0039]

[0040] The research on the thin-walled bearing ring grinding method provided by this invention breaks the technological blockade in the field of high-precision grinding of outer rings in China, fills the domestic technological gap, and the product indicators are superior to the requirements of national and industry standards. The technology and performance comparison of similar products are shown in Table 2.

[0041] Table 2 Comparison of Technical and Performance Advantages with Similar Products

[0042] Comparison Projects ordinary grinding machine This project's technology Operability Manual or semi-automatic Manual and fully automatic Machining accuracy Roundness > 0.5μm Roundness ≤ 0.2μm Processing efficiency Fixed, high scrap rate High, low scrap rate Processing speed Manual speed adjustment Intelligent dynamic speed regulation Grinding wheel dressing method Manual or hydraulic Manual or programmed automatic Automation level Low, requires manual operation High efficiency, fully automated grinding process.

[0043] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A thin-walled bearing race grinding method characterized by: Includes the following steps: Step 1: Configure a waterproof sensor that can dynamically monitor the diameter, roundness, and distance between the bearing ring and the bearing ring in real time, and connect the sensor to the grinding machine control system. Step 2: Start the grinding machine, select the preset grinding parameters according to the preset model, and control the motion mechanism to grind the ring. Step 3: The control system performs calculations based on the data collected by the sensors, compares the calculated structure with the preset model, and outputs a grinding parameter adjustment scheme based on the comparison results. The action mechanism adjusts the grinding parameters in real time according to the grinding parameter adjustment scheme. Step 4: After completing the grinding process of a single ring, the control system stores and statistically analyzes the grinding parameters and compares them with the preset model processing parameters. As the number of workpieces processed increases, the control system can record the adjustment range of all processing parameters, calculate the processing parameter change curve, and automatically prompt and eliminate outliers to form a specific quantitative processing parameter model, which can be directly applied to the processing of the same batch of workpieces to correct the preset grinding parameters online.

2. The method for grinding thin-walled bearing rings according to claim 1, characterized in that: In step two, when the actuating mechanism grinds the ring, grinding fluid is sprayed onto the grinding surface.

3. The method for grinding thin-walled bearing rings according to claim 1, characterized in that: In step three, the grinding parameter adjustment scheme is as follows: when the deformation of the ring is small, increase the grinding speed; when the deformation of the ring is large, decrease the feed rate and the grinding wheel speed.

4. The method for grinding thin-walled bearing rings according to claim 1, characterized in that: The grinding machine is provided with a feeding trough, which is inclined inwards towards the inside of the grinding machine.

5. The method for grinding thin-walled bearing rings according to claim 4, characterized in that: The inclination angle of the feeding trough is 10-15°.

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