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摘要: 新能源汽车的NVH要求齿轮精加工工艺的变革。磨料流加工是齿轮等复杂型面表面抛光的有效手段之一,夹具设计是磨料流加工工艺至关重要的环节。针对磨料流夹具设计优化过程中,物理模型选用对仿真结果准确性与计算成本相互矛盾的难题,分别选用不同粘度介质,应用不同粘度模型以及流动模型开展仿真试验,对体现加工均匀性的流体压力分布、速度矢量、壁面剪切以及流线分布云图予以分析,探究狭缝模型中磨料流稳态仿真结果。发现不同物理模型的仿真结果分布趋势具有较强的相似性,能够实现仿真结果中加工区域流线的一致,证明用简单的物理模型替代复杂物理模型进行夹具优化仿真的可行性。应用仿真结果,采用最简单的牛顿流体——水为介质,借助加工区域流线分布,开展齿轮轴磨料流夹具设计优化,实现了磨料流加工后齿轮鬼阶的去除。Abstract: The NVH problem of electric vehicles requires a revolution in gear precision machining technology. Abrasive flow machining is one of the effective methods for polishing complex surfaces such as gears, and fixture design is a crucial part of the abrasive flow machining process. In the process of optimizing the design of abrasive flow fixtures, the selection of physical models contradicts the accuracy of simulation results and the computational expense of simulation. Different viscosity media were selected, and simulation experiments were conducted using different viscosity models and flow models. The fluid pressure distribution, velocity vector, wall shear, and streamline distribution cloud maps reflecting machining uniformity were analyzed to explore the steady-state simulation results of abrasive flow in the slit model. It was found that the distribution trend of simulation results from different physical models has strong similarity, which can achieve consistency in the processing area streamline in the simulation results, proving the feasibility of replacing complex physical models with simple physical models for fixture optimization simulation. By applying simulation results and using the simplest Newtonian fluid - water as the medium, and utilizing the streamline distribution in the machining area, the design optimization of the gear shaft abrasive flow fixture was carried out, achieving the removal of gear “ghost frequencies” after abrasive flow machining.
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Key words:
- fluid simulation /
- CFD /
- turbulence model /
- rheological properties /
- fixture optimization
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