花键磨削热力耦合状态数值模拟方法研究

Research on Numerical Simulation Method of Thermal Coupling State of Spline Grinding

摘要: 花键联接因具有大接触面积、高承载能力、低应力集中等优势，已广泛应用于汽车、航空航天以及重型装备等行业，成为传递力和扭矩的重要功能部件。磨削加工工艺虽然能够有效提升花键的表面性能，但加工过程复杂，影响因素较多，采用传统解析法的应力应变分析仅能够对一些简单的问题做出估计，无法应用于复杂零部件的加工。本文基于有限元方法对工件的变形规律进行研究，介绍了有限元分析的原理，并利用DEFORM-3D平台对花键齿形成形过程热力耦合状态进行了数值模拟，结果表明，成形的最大应力发生在齿槽处，且轴向力、切向力、径向力均随着变形温度的升高和应变速率的下降而明显下降。该研究有助于深入理解花键磨削过程中的应力应变演化特征，为复杂齿形结构的磨削烧伤抑制提供理论支持。

Abstract: Spline coupling has been widely used in automotive, aerospace and heavy equipment industries as an important functional component for transmitting force and torque due to its advantages of large contact area, high load carrying capacity and low stress concentration. Although the grinding process can effectively improve the surface performance of the spline, the processing is complex, with many influencing factors, and the stress-strain analysis using the traditional analytical method can only estimate some simple problems, which can not be applied to the processing of complex parts. This paper is based on the finite element method to study the deformation law of the workpiece, introduces the principle of finite element analysis, and uses the DEFORM-3D platform to numerically simulate the thermal coupling state of the spline tooth forming process, and the results show that the maximum stress of the forming occurs in the tooth groove, and the axial, tangential, and radial forces all decrease significantly with the rise of the deformation temperature and the decrease of the strain rate. This study helps to deeply understand the stress-strain evolution characteristics in the spline grinding process, and provides theoretical support for the grinding burn inhibition of complex tooth structures.