花键齿形加工过程成形误差分析方法研究

Research on the Forming Error Analysis Methods for Spline Tooth Profile Machining Processes

摘要: 花键联接由于具有接触面积大、承载能力高等优点，在航空航天、汽车工业、重型机械等领域得到了广泛的应用，其加工质量直接影响传动系统的稳定性和可靠性。滚轧成形加工工艺虽然能够有效提升花键的表面性能，但在理论上仍然缺乏系统性的研究。本文针对渐开线花键轴的滚轧成形过程，分析了其运动规律及齿形误差的形成机理，并提出了解决齿形加工误差的三种办法：改变模具齿距p、保持定传动比传动、改变进给方式。通过对比三种方法的适用性与实际可行性，选择在轴向进给方式下加工的方法来消除齿形加工误差。结合体积不变准则和实际加工参数，确定最小坯料直径为50.13 mm，为滚轧成形精度控制提供了理论依据与工艺参考。

Abstract: Due to their large contact area and high load-bearing capacity, spline connections are widely used in aerospace, automotive, and heavy machinery industries. The machining quality of splines directly affects the stability and reliability of transmission systems. Although the rolling forming process has proven effective in enhancing the surface performance of splines, systematic theoretical investigations on this process remain limited. This study focuses on the rolling forming process of involute spline shafts, analyzing the kinematic characteristics and identifying the underlying causes of tooth profile errors. Three approaches are proposed to mitigate these errors: modifying the die pitch p, maintaining a constant transmission ratio, and altering the feed method. Through comparative analysis of the feasibility and applicability of these strategies, axial feeding is selected as the most effective method for minimizing tooth profile errors. Based on the principle of volume constancy and actual process parameters, the minimum required billet diameter is determined to be 50.13 mm. The findings provide a theoretical foundation and practical guidance for improving the precision of spline rolling forming.