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滚针轴承加工工艺设计
Design of rolling bearing processing
轴承是机器中用来支承轴的一种重要零件，其功能是支承轴及轴上的零件，并保持轴的旋转精度；同时减少转动轴与支承之间的摩擦和磨损。
Bearings are used to support shaft of one of the most important parts of the machine, its function is to support shaft and shaft parts, and keep the rotating accuracy of axis and reduce friction and wear between the rotating shaft and bearing.
按轴承工作时的摩擦性质分为滚动轴承和滑动轴承两大类。滚动轴承与滑动轴承相比较，滚动轴承具有摩擦力小、起动快、效率高（η＝0.98～0.99）、润滑与维护方便、易于互换、运转精度高、轴承组合结构较简单等优点，因此在中速、中载和一般工作条件下运转的机器中得到广泛应用。
According to bearing friction at work are divided into two major categories of roller bearings and plain bearings. Compared to rolling bearings and plain bearings, rolling bearings have friction small, quick starting, high efficiency (η =0.98~0.99), lubrication and maintenance is convenient, easy to swap and high operation precision, the advantages of composite bearing structure is relatively simple, general working conditions in its velocity, and is widely used in the following operating machine.
其缺点是抗冲击能力差，高速重载下轴承寿命较低，且出现振动和噪声，径向尺寸比滑动轴承大。
The drawback is the poor impact resistance, low bearing life under high speed and heavy load and vibration and noise, radial size than plain bearings.
滚动轴承是机械行业中常用的标准件之一，由专业厂批量生产，型号齐全，标准化程度高。只要根据工作条件正确选择即可，因此应用广泛。
Roller bearing is one of the commonly used standard parts in machinery industry and by professional plant production, model range, high degree of standardization. As long as the right choice according to work conditions, so widely used. 
滚动轴承结构由内圈、外圈、滚动体、保持架组成。
Bearing structure consists of an inner ring, outer ring, rolling elements and cage composed.
 一般滚动体的形状有：球、圆柱、圆锥、球面、针状等。 
General shape of the rolling elements are: spherical, cylindrical, tapered, spherical, needle etc.
滚动轴承内、外圈及滚动体常采用强度高、耐磨性好的高碳铬轴承钢、渗碳轴承钢，淬火后硬度不低于61～65HRC，滚道及滚动体表面要求磨削抛光。
Inner and outer rings and rolling elements of rolling bearings often use high strength, good wear resistance of high carbon chromium bearing steel, bearing steel carburizing, quenching hardness no less than 61~65HRC, Raceway and the rolling surface requires grinding and polishing.
保持架常选用铜合金、铝合金、低碳钢及工程塑料等减摩性较好的材料。
Cages are often made of copper alloy, aluminum alloy and low carbon good antifriction properties of materials such as steel and plastics.
依轴承工作载荷的大小、方向和性质；转速高低和回转精度的要求；调心性能要求；安装空间大小、装拆方式及经济性等选择合适的类型。 
According to the size, direction and nature of the work load of the bearing; level of speed and rotation accuracy requirements; aligning performance requirements; size, assembling and disassembling and economy of installation space, such as choosing the right types.
转速较高，载荷不大，旋转精度较高宜选点接触的球轴承。 转速较低，载荷较大，宜选用线接触的滚子轴承。 转速高，当径向、轴向载荷都较大时，宜选接触球轴承。 转速不高，当径向、轴向载荷都较大时，宜选用圆锥滚子轴承。 
High speed, load is small, rotating accuracy should be point contact ball bearings. Low speed, larger loads, suitable for line contact of the roller bearings. High speed, when radial and axial loads are large, choose contact ball bearings. Speed is not high, when radial and axial loads are large, suitable for tapered roller bearings.
转速较高，当径向比轴向载荷大很多时，宜选用深沟轴承或角接触球轴承。 转速低，当径向比轴向载荷大很多时，宜选用圆锥滚子轴承。 
High speed, when the radial-axial load is much, suitable for deep groove or angular contact ball bearings. At low speed when the radial-axial load is much, suitable for tapered roller bearings.
转速不高，当轴向比径向载荷大很多时，宜采用推力轴承与圆柱滚子轴承或深沟球轴承的组合。以分别承受轴向、径向载荷。
Speed is not high, when much bigger than the radial load axial, and thrust ball bearings and cylindrical roller bearings should be used or a combination of deep groove ball bearings. To withstand axial and radial loads, respectively.
纯径向载荷，可选用深沟球轴承，圆锥滚子及滚针轴承。 
Pure radial load may make use of deep groove ball bearings, tapered roller and needle roller bearings.
纯轴向载荷，可选用推力轴承，当转速很高而载荷不大时，可采用深沟球轴承或角接触球轴承。 有冲击载荷时宜选用滚子轴承。 
Purely axial loads, the choice of thrust bearing, when high speed and load are unlikely, can be used for deep groove ball bearings or angular contact ball bearings. Impact loads up to date selection of roller bearings.
由于多种原因，导致轴变形大及多支点轴，宜选择调心轴承。 
Due to various reasons, caused by shaft deformation and the pivot axis, self-aligning bearing should be chosen.
轴有足够的刚度，且同一轴上各轴承座孔的同轴度很好时才可选用对偏斜角较为敏感的线接触轴承（圆柱滚子轴承、圆锥滚子轴承、滚针轴承）。 
Axle rigid enough, and the same shaft bearing block hole of the coaxial degree to good use on the more sensitive line offset angle contact bearings (cylindrical roller bearings, tapered roller bearings, needle roller bearings).
要求安装、拆卸方向的场合，宜选用可分离型圆锥滚子、圆柱滚子轴承。
Set-up and disassembly direction, suitable for detachable-type tapered roller bearing, cylindrical roller bearing. 
按经济性选择，通常外形尺寸相当，球比滚子轴承价格低，深沟球轴承最低，公差等级越高价格越高。
According to economy choices usually dimensions, ball than roller bearings, low prices, deep groove ball bearings with lowest rating, the higher the price, the higher the tolerance.
目前我国的深沟密封球轴承与国外先进公司的产品内部结构参数几乎相同，然而我国此类产品的振动与噪声水平却与国外产品相差甚远，主要原因是在制造和工况因素的影响。从轴承行业角度来考虑，工况因素可以对主机提出合理要求来解决，而如何降低由制造因素引起的振动和噪声是轴承行业必须解决的问题。
　　China sealed deep groove ball bearings with inner structural parameters of advanced companies of foreign products are almost the same, but our vibration and noise levels and such products fall far short of foreign products, mainly due to manufacturing and effect of condition factors. From the standpoint in bearing industry, condition factor can solve reasonable demands on the host, and how to reduce vibration and noise caused by production factors is the bearing industry must solve the problem
国内外大量试验表明：保持架、套圈、钢球的加工质量对轴承振动具有不同程度的影响，其中钢球的加工质量对轴承振动影响最明显，其次是套圈的加工质量，最主要影响因素是钢球和套圈的圆度、波纹度、表面粗糙度、表面磕碰伤等。
　　Many experiments show that cage, ring, ball of machining quality of bearing vibration with different degrees of influence of machining quality of bearing steel ball vibration is the most obvious, followed by the ferrule manufacturing quality, the most important factor is the steel ball and ring roundness and waviness, roughness, surface bump hurt.
我国钢球产品最突出的问题是振动值离散大，表面缺陷严重（单点、群点、凹坑等），尽管表面粗糙度、尺寸、形状、误差都不低于圈外水平，但合套后轴承振动值高，甚至产生异音，主要问题是波纹度没有控制（无标准、无合适测试分析仪器），同时说明机床的抗振性差，砂轮、研磨盘、冷却液、工艺参数均存在问题；另一方面要提高管理水平，避免磕碰伤、划伤、烧伤等随时机性质量问题。
　　China steel ball products most highlight of problem is vibration value discrete big, surface defects serious (single points, and group points, and concave pit,), despite surface rough degrees, and size, and shape, and errors are not below circle outside level, but collection sets Hou bearing vibration value high, even produced ISO sound, problems is corrugated degrees no control (no standard, and no suitable test analysis instrument), while description machine of anti-vibration sex poor, wheel, and grinding disc, and cooling liquid, and process parameter are exists problem; on the to improve management level, avoid bump hurt, and designated hurt, and Burn quality issues at any time.
对于套圈，影响轴承振动最为严重的也是沟道波纹度和表面粗糙度。例如，中小型深沟球轴承内外沟道圆度大于2μm时，将对轴承振动产生明显影响，内外沟道波纹度大于0.7μm时，轴承振动值随波纹度增加而增加，沟道严重磕伤可使振动上升4dB以上，甚至出现异音。
　　For ring, bearing vibrations worst Groove waviness and roughness. For example, small and medium sized deep groove ball bearings inner and outer channel roundness when greater than 2 μ m, will have significant effects on bearing vibration, inner and outer Groove waviness when μ m greater than 0.7, increased bearing vibration values increased with waviness, channeling serious knock trauma can raise the vibration 4dB above or even abnormal noise.
无论是钢球还是套圈，波纹度产生于磨削加工，超精研虽然可以改善波纹度并降低粗糙度，但最根本的措施是要降低磨削超精过程中的波纹度，避免随机性磕碰伤，主要有两方面措施：
　　Neither ball nor the ring, waviness generated in grinding, Superfinishing can improve ripple and reduce roughness, but the most fundamental measure is to reduce grinding Superfinishing process, waviness, and avoid random bump hurt, there are two main steps:
一是降低滚动表面磨削超精时的振动，获得良好的表面加工形状精度和表面纹路质量为降低振动，磨超机床必须具有良好的抗振性，床身等重要结构件具有吸振性，超精机床的油石振荡系统具有良好的抗振动性能；提高磨削速度，国外磨削6202外滚道普遍采用6万电主轴，磨削速度60m/s以上，国内一般低得多，主要受主轴及主轴承性能的限制。在高速磨削时，磨削力小，磨削变质层薄，不容易烧伤，又可以提高加工精度和效率，对低噪声球轴承影响很大；主轴动静刚度及其速度特性对低噪声球轴承磨削振动影响很大，刚度越高，磨削速度对磨削力的变化越不敏感，磨削系统振动越小；提高主轴轴承支刚性，采用随机动平衡技术，提高磨削主轴的抗振性。国外磨头振动速度（如Gamfior）约为国内一般主轴的十分之一；提高砂轮油石的切削性能及修整质量至关重要。我国目前砂轮油石主要问题是组织结构均匀性差，严重影响低噪声球轴承磨超加工质量；充分冷却，提高过滤精度；提高精给系统的进给分辨率，降低进给惯性；合理的磨超加工工艺参数和加工流程是不可忽视的因素，磨削留量要小，形位公差从严，中小型球轴承外径不宜用超精研，粗精磨超不宜分开，以保证良好的表面质量。
　　A is reduced scroll surface grinding Super fine Shi of vibration, obtained good of surface processing shape precision and surface lines quality for reduced vibration, mill Super machine must has good of anti-vibration sex, bed body, important structure pieces has sucking vibration sex, Super fine machine of oil stone oscillation system has good of anti-vibration performance; improve grinding speed, abroad grinding 6202 outside rolled road General used 60,000 electric spindle, grinding speed 60M/s above, domestic general low have more, main by spindle and the main bearing performance of limit. In high-speed grinding Shi, grinding force small, grinding metamorphic layer thin, not easy Burns, and can improve processing precision and efficiency, on low noise ball bearing effects is big; spindle movement stiffness and speed characteristics on low noise ball bearing grinding vibration effects is big, stiffness more high, grinding speed on grinding force of changes more not sensitive, grinding system vibration more small; improve spindle bearing support rigid, used with maneuver balance technology, improve grinding spindle of anti-vibration sex. Grinding vibration velocity in foreign countries (such as Gamfior) about the spindle one-tenth; improve the cutting performance of wheel stones and finishing quality is essential. China currently wheel oil stone problems is organization structure uniform sex poor, serious effects low noise ball bearing mill Super processing quality; full cooling, improve filter precision; improve fine to system of into to resolution, reduced into to inertia; reasonable of mill Super processing process parameter and processing process is not ignored of factors, grinding left volume to small, shaped bit tolerances strictly, small and medium ball bearing od should not be with Super acquired, rough fine mill Super should not be separate, to guarantee good of surface quality.
二是提高加工基准面精度，降低磨超加工过程中的误差复映外径与端面是磨超加工过程中的定位基准。外径对沟道超精的误差复映是通过外径对沟磨，沟磨对沟超的误差复映间接传递的。如果工件在传递过程中产生磕碰伤，将直接复映到滚道加工表面上，影响轴承振动。所以必须采取以下措施：提高定位基准表面形状精度；加工过程中传递平稳，无磕碰伤；毛坯留量形位误差不能过大，特别是在留量较小时，过大误差会造成终磨和超精结束时形状精度尚未改善到最终的质量要求，严重影响加工质量的一致性。
　　Second, improve the accuracy of processing Datum, reducing errors in the grinding and Superfinishing processes complex reflects outer diameter and end face grinding and Superfinishing process benchmark. Od error for Raceway Superfinishing complex mapping is through the outer diameter Groove milling, Groove milling on the ditch of Super complex reflects the indirect transfer of error. If the artifacts produced during the transfer process bump hurt, complex reflects directly on the Raceway machined surface, bearing vibrations. So you must take the following measures: to improve positioning surface form accuracy; in the process passed smoothly, no bump hurt, roughcast allowance for form and position errors should not be too large, especially when smaller, too large error will result in final grinding and Superfinishing quality of shape accuracy has not been to the final at the end of the request, seriously affecting machining quality consistency.
从上面分析不难看出：由高性能、高稳定性机床系统组成的自动线方式磨超加工低噪声球轴承最合适，可以避免磕碰伤，降低传递误差，排除人工因素，提高加工效率和质量一致性，降低生产成本，提高企业效益。
　　From the above analysis it is easy to see: high performance, high stability systems of machine tools grinding and Superfinishing automatic line way of processing low-noise ball bearings are the most suitable, you can avoid the bump hurt, reduce transmission errors, excluding artificial factors, increase processing efficiency and quality consistency, reduce production costs, improve business efficiency.
如何降低球轴承噪声呢？应从以下两方面着手努力：
　　How to reduce the noise of ball bearing? efforts from the following aspects:
（一）制造工艺。工艺流程精化，主要指工艺流程尽可能短，工序加工合并，生产无中间库存，有效降低影响低噪声球轴承性能工艺因素；生产洁净化，这是一个系统的技术，包括磨削液、超精液、清洗液、空气、高压空气、生产环境等技术工艺；自动化，从车加工到装配全过程自动化，少人或无人化；规模化，此类轴承特别是静音球轴承，必须形成大规模化，才能具备全球市场竞争能力。
　　(A) the manufacturing process. Process fine of, main refers to process as short, processes processing merged, production no middle inventory, effective reduced effects low noise ball bearing performance process factors; production clean of, this is a system of technology, including grinding liquid, and Super semen, and cleaning liquid, and air, and high-pressure air, and production environment, technology process; automation, from car processing to Assembly full process automation, less people or unmanned of; scale, this class bearing especially mute ball bearing, must formed mass of, to has global market competition capacity.
（二）装备。高速磨削、电主轴精度、刚度、寿命以及各种完善的检测保护性能对磨削加工精度与效率起主要作用；磨床技术，国外内圆磨床一般都具备高速磨削，交流伺服控制，进给分辨率0.25μ，全自动简易操作，自诊断功能等；超精技术，主要以日本大阪精机为代表的无心支承两工位超精和以德国梯伦豪斯为代表的液压定心四工位超精两种方式；在线检测技术，二十世纪八十年代以来，日本轴承工业以主动测量机外反馈控制的自动磨超短线应用最为普遍。我国以此方式构成的磨超自动线应用也比较成熟，目前国内已有100条左右。随着工业先进国家主机技术不断提高，联线越来越简单，逐步减少或不用主动测量和机外检测；无心外圆磨床，圆外（KOYO、MIKROSA等）普遍采用滚动轴承砂轮主轴单元，具有高刚度、高精度、长寿命、装卸方便、使用可*等一系列优点；床身具有阻尼衰减减特性；进给采用高精度微动交流伺服系统，稳定的传动交流变频导轮调整系统，可具备在线随机智能化测量，可实现CBN砂轮磨削等，可实现自动联线，圆度可达0.3μm，尺寸分散可达3μm。
　　(B) equipment. High-speed grinding, and electric spindle precision, and stiffness, and life and various perfect of detection protective can on grinding processing precision and efficiency up main role; grinder technology, abroad within round grinder General are has high-speed grinding, Exchange servo control, into to resolution 0.25 μ, automatic summary operation, since diagnosis function,; Super fine technology, main to Japan Osaka fine machine for representative of Centerless supports two station Super fine and to Germany ladder lunhaosi for representative of hydraulic centering four station Super fine two species way; online detection technology, In the 1980 of the 20th century, the Japan bearing industrial automatic grinding active measuring external feedback control hyper-dash is most common. Consisting of grinding and Superfinishing applications in this way is relatively mature, at present, there are 100 or so. With industrial advanced national hosts technology constantly improve, Alliance line increasingly simple, gradually reduced or without active measurement and machine outside detection; Centerless outside round grinder, round outside (KOYO, and MIKROSA,) General used bearing Wheel spindle unit, has high stiffness, and high precision, and long life, and handling convenient, and using can *, series advantages; bed body has damping attenuation reduction characteristics; into to used high precision micro moving Exchange servo system, stable of drive Exchange frequency wheel adjustment system, Can be measured with a online random intelligence, CBN grinding wheels can be realized, can realize automatic line, rounded up to 0.3 degrees μ m, μ m size deviation of up to 3.
平面磨床，国外双端（如KOYO、Landis Gardner）面磨床主轴都普遍采用高精度、高刚度滚动轴承主轴单元砂轮轴系统，油雾润滑。以Gardner技术为例，该公司研究生产系统装备已有九十多年历史，可磨削轴承、陶瓷、玻璃、橡胶、塑料等材料。主要技术有自动砂轮修整和补偿，砂轮磨头进给以伺服电机丝杠同轴结构，砂轮向内外快速同步进给，进给精度可达到0.25μm，机身放置在两个水平垫块和平衡器上，平衡器具有自平衡支承杆，可自动调整与两个水平垫块成一水平面，使机床得到一个稳固的支承效果，平衡器重点是在维持砂轮轴同心度，增加修整砂轮间隔时间，工件进给有旋转式、往复式、贯穿式和特殊四种形式，可使用超级磨料砂轮，金刚石砂轮和CBN磨削，磨削精度高、稳定性好，极长的砂轮使用寿命和方便的操作调整，可以根据加工要求专门配制磨料、结合剂、结构（圆环、钮状或环节状），从而达到最佳磨削效果，平行差及平面度达1μm。
Surface grinder, double end abroad (like KOYO, Landis Gardner) is a commonly used surface grinding machine spindle of high accuracy, high rigidity spindle Wheel spindle system for rolling bearings, oil mist lubrication. Gardner technology, for example, the company's research and production system equipment has a more than 90-year history, grinding bearings, ceramic, glass, rubber, plastic and other materials. Main technology has automatically wheel dressing and compensation, wheel mill head into gives servo motor screw with axis structure, wheel to both inside and outside fast synchronization into to, into to precision can reached 0.25 μ m, fuselage placed in two level pad block peace weighing Shang, balance device has since balance supports rod, can automatically adjustment and two level pad block into a horizontal, makes machine get a solid of supports effect, balance device focus is in maintained wheel axis concentric degrees, increased dressing wheel interval time, artifacts into to has rotating type, and reciprocating type, and Throughout type and special four species form, can using Super abrasive wheel, diamond wheel and CBN grinding, grinding precision high, and stability good, very long of wheel using life and convenient of operation adjustment, can according to processing requirements specifically preparation abrasive, and combines agent, and structure (ring, and button-like or links-like), thus reached best grinding effect, parallel poor and the plane degrees up 1 μ m.