基于精度进化原理的球面滚子圆柱螺旋直线沟槽循环研磨精度创成机理及形、性调控机制

球面滚子是风电等重要装备领域调心滚子轴承的核心元件。针对高精度调心滚子轴承制造瓶颈“球面滚子径向尺寸一致性差”，提出一种基于精度进化原理的球面滚子圆柱螺旋/直线沟槽循环研磨新方法。通过径向尺寸比较实现材料选择性去除，结合外循环，实现球面滚子批量加工高径向尺寸一致性。以滚动面与研具螺旋槽工作面“十字交叉”接触线为发生线，通过自旋主运动和螺旋进给运动实现球面滚子滚动表面的超精密研磨；分析研具沟槽工作面磨损与球面滚子径向尺寸和轴截面廓形演化规律，提出基于精度进化的球面滚子控形工艺策略；通过滚子与研具沟槽工作面之间的滚压强化及材料去除耦合机制，实现球面滚子高表面完整性加工。在解决“基于运动创成及精度进化的球面滚子几何精度创成机理”等关键科学问题的基础上，形成球面滚子批量加工高精度、高表面完整性精密加工新原理与技术体系。项目研究对突破国家高端装备轴承制造技术瓶颈具有重要的理论意义和工程应用价值。

Spherical roller is the key part of self-aligning roller bearing which is widely applied in wind power fields. In order to solve the bottleneck in manufacturing of high performance self-aligning roller bearing, that is, the poor consistent performance of the radial and axial profile dimensions, this project proposed a novel cylinder helix-straight grooves lapping approach based on accuracy evolution principle. Material of spherical roller can be selectively removed though the comparison of radial and axial profiles, meanwhile, by combining the circulation process in the lapping system, high consistent performance for radial and axial profile dimensions of spherical roller can be achieved. In the project, ultra-precision machining of the profile of spherical surface can be achieved by the self-rotation and helix feed movement of the crossed type contact lines. The geometry control strategies will be proposed according to the accuracy evolution theory, based on the analysis of the evolution laws of the wear of the machining surfaces of the lapping grooves and the radial and axial profile dimensions. High surface integrity of spherical roller can be achieved by combined mechanisms of material removal and surface rolling by the relative movement of spherical roller and lapping grooves. The critical science problems such as the formation mechanism of geometrical accuracy of spherical roller based on the movement formation and accuracy evolution will be studied in this project. The novel principle and technology system for batch precision-machining of spherical rollers with high geometrical accuracy and high surface integrity will be developed. The project has a great theoretical and engineering application meaning for solving the bottleneck of bearing manufacturing technology for high performance mechanical equipment.