Parametric Design Of Surface Microstructure Of Unfolding Wheel Based On Numerical Simulation

The unfolding wheel in the AVIKO series steel ball surface quality automatic tester is the core component of steel ball detection.The steel ball and unfolding wheel are easy to slip during the detection process,which reduces the detection accuracy,and the premature wear and failure of the unfolding wheel increases the detection cost.Researchers from the same research group found that machining the microstructure on the working surface of the unfolding wheel can increase the coefficient of friction while reducing its wear,thereby improving the service life and detection accuracy of the unfolding wheel.The paper optimizes the surface microstructure parameters of the unfolding wheels used when 12 different sizes of steel balls are tested,and obtains the best friction-increasing and abrasion-reducing effect of each group of unfolding wheel surface microstructure parameters matching(shape,area,depth,areal density).The numerical simulations and experiments are conducted to verify the reliability of the optimization results and the accuracy of the numerical simulations,and a library of microstructure surface unfolding wheels is established.Firstly,the parameters of the microstructure are selected and the range of the parameters is determined,and the surface microstructure parameters of each set of unfolding wheels are optimized.Based on Hertz theory,the contact area between 12 sets of steel balls of different sizes and the cone surface of the unfolding wheel is calculated to determine the range of each parameter.The relationship between wear depth,friction coefficient and contact area,load and microstructure parameters is fitted through the previous test and simulation data.Based on the genetic algorithm,MATLAB is used to optimize the microstructure parameters on the surface of 12 groups of unfolding wheels with the aim of maximum friction coefficient and minimum wear.Then,the numerical simulation is performed to verify the reliability of the optimization results,and a test bench is set up for friction and wear tests to verify the accuracy of the simulation.Based on the Archard theory,the calculation formula for the wear depth of the microstructure surface unfolding wheel is derived.The contact and motion between 12 groups of steel balls and the microstructure surface unfolding wheel is simulated by the ABAQUS finite element analysis software.According to the simulation results,12 groups of microstructure surface unfolding wheel wear depths were obtained,and the results are compared with the wear depth formula results to verify the reliability of the optimization results.The corresponding microstructure surface specimens are prepared for friction and wear test to verify the rationality of the simulation.Finally,based on the secondary development of NX UG,the micro-structured surface unfolding wheel is parametrically designed to realize the functions that are available at any time.The part library is designed in NX UG 3D model software.Menu Script and UIStyler are used to design user menus and human-computer interactive pages to implement calls,This part library simplifies the modeling process of the microstructure surface unfolding wheel,reduces the preliminary preparation time of designers and improves design efficiency and design quality.Based on genetic algorithm and MATLAB,this paper optimizes the surface microstructure parameters of 12 sets of unfolding wheels,and validates them by numerical simulation and friction and wear test,and designs the part library of microstructure surface unfolding wheel,which provides theoretical reference for the design,research and practical application of microstructure surface unfolding wheel.