Research On Key Technologies Of Cold Rolling For Flexspline Of Harmonic Reducer

The research on the key technology of the cold rolling process for flexspline is to solve the insufficient manufacturing capacity of key parts of harmonic reducer.Compared with the traditional flexspline manufacturing process,such as hobbing,slotting etc.,the precision plastic forming process has its unique advantages.Based on the engineering project,researched the key technology of the cold rolling process for flexspline by the combined method of simulation and experiment.Emphatically researched and analyzed the influence of the forming parameters on flexspline cold rolling process,the cold rolling forming equipment,the residual stress distribution and the fatigue life of cold rolling flexspline,which provide new method and theoretical basis for the flexspline manufacturing.The main research work are listed as:Based on the analysis of flexspline cold rolling process,established and researched the flexspline cold rolling process model,including double-circular tooth profile design,formalization design of machining allowances,mold design and modified design of flexspline blank diameter.Then introduced the typical defects of flexspline cold rolling process,analyzed the causes and put forward the improvement measures.Analyzed the strengthening mechanism of cold rolling process on flexspline based on the residual stress.Established the finite element model of flexspline cold rolling forming process.Then researched and analyzed the influence of different processing parameters on forming load and strain distribution uniformity,to obtain the determined load of optimized forming parameters with DEFORM-3D,which provides a theoretical basis for the follow-up design of flexspline cold rolling equipment.Researched the function module division and put forward the overall structure layout scheme of flexspline cold rolling equipment.Then design and checked the key components of roller system,including rolling spindle and drive device.Emphatically researched the design of radial feeding device,the selection of reciprocal teeth screw and screw servo motor was completed through the calculation method.Researched and analyzed the influence of different processing parameters on the residual stress distribution of cold rolling flexspline.Then put forward the prediction model of residual stress of cold rolling flexspline based on the fitting regression strategy,and analyzed the prediction process with an example of the the maximum value design of radial and circumferential residual stress of the tooth root.The physical flexspline was made by the above equipment and the residual stress distribution of cold rolling flexspline was measured by X ray diffraction method.Verified the prediction model by the comparison between measured value and predicted value.Established and analyzed the fatigue life calculation model of cold rolling flexspline.Then the dynamic stress distribution simulations of flexspline were separately completed in ANSYS/Workbench under the load and unload condition.Researched and analyzed the fatigue life,considering the influence of residual stress distribution,of the stress focus of flexspline tooth root with nCode Design-Life.Researched and analyzed the influence of different cold rolling processing parameters on the fatigue life of the stress focus of flexspline tooth root.