WO2018040391A1 - 一种滚道带凸度的交叉滚子轴承及其制作方法 - Google Patents

一种滚道带凸度的交叉滚子轴承及其制作方法 Download PDF

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Publication number
WO2018040391A1
WO2018040391A1 PCT/CN2016/111107 CN2016111107W WO2018040391A1 WO 2018040391 A1 WO2018040391 A1 WO 2018040391A1 CN 2016111107 W CN2016111107 W CN 2016111107W WO 2018040391 A1 WO2018040391 A1 WO 2018040391A1
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Prior art keywords
raceway
ferrule
convex
shaped
roller bearing
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PCT/CN2016/111107
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English (en)
French (fr)
Inventor
赵联春
赵思澄
陈淑英
Original Assignee
上海斐赛轴承科技有限公司
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Priority claimed from CN201621016804.1U external-priority patent/CN206246534U/zh
Priority claimed from CN201610777488.8A external-priority patent/CN106195015B/zh
Application filed by 上海斐赛轴承科技有限公司 filed Critical 上海斐赛轴承科技有限公司
Publication of WO2018040391A1 publication Critical patent/WO2018040391A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
    • F16C33/30—Parts of ball or roller bearings
    • F16C33/58—Raceways; Race rings

Definitions

  • the invention relates to the technical field of rolling bearings, in particular to a cross roller bearing with a convexity of a raceway and a manufacturing method thereof.
  • the applicant has described the structure of the raceway of the ordinary structural bearing and the hard-car processing method of the raceway in the rolling bearing of the precision rigid-car forming of the 2014100202253 ferrule and the processing method thereof, and solved the raceway existing in the rolling-path grinding process.
  • manufacturing has engineering practical significance.
  • the prior art does not involve the improvement of the structure and manufacturing method of the cross roller bearing, and the need for the development of the cross roller bearing technology cannot be satisfied. This application is further improved and extends to the field of crossed roller bearings and their processing methods.
  • the cross-roller bearing is structurally different from the general structural rolling bearing in 2014100202253: the ferrule raceway is of the "V" type, because it can simultaneously bear axial, radial and angular combined loads, in the axial direction and diameter. Both the direction and the angular direction have very high rigidity and are used in more and more wide applications, especially in the mainframes and systems with high running stiffness and precision requirements, such as precision machine tool turntable, industrial robot waist, ankle, precision instrumentation. Spindles, etc., have significant advantages over other types of bearings.
  • the geometry of the working surface of the crossed roller bearing ferrule, ie the raceway, is different from that of other types of bearings, and the ferrule raceway is of the "V" shape.
  • the plain lines of the V-shaped raceway are straight lines without any convexity.
  • the advantage of the straight line of the ferrule raceway is that the shape is simple and the production is relatively easy, but there are some outstanding technical and quality problems.
  • the shape of the raceway of the crossed roller bearing and the contact state with the roller are very special, the shape of the raceway is V-shaped, when the working surface of one of the rollers (the cylindrical roller is a cylindrical surface, the tapered roller is When the conical surface is in contact with one of the raceways of one of the ferrules, the non-working surface of the roller, that is, the end surface is just in contact with the other side raceway of the ferrule; and the roller adjacent to the roller, The opposite is true. Therefore, any one of the V-shaped raceways is in contact with the outer circumferential surface of one row of rollers, and is also in contact with the end faces of the other row of vertically aligned rollers.
  • either side of the V-shaped raceway is both the raceway of one row of rollers and the rib of the other row of rollers. Since the machining accuracy of the roller end face is far less than the outer circular surface and the V-shaped raceway surface, and because the hardness of the roller is higher than the hardness of the raceway, the contact area between the roller end face and the raceway is larger, relatively The harder and rougher roller end faces the greater risk of scratching and scratching the raceway surface. When the scratched raceway is in contact with the working surface of another row of rollers, under the effect of relatively high contact stress, the flexibility and stability of the bearing operation are firstly affected, and at the same time, scratching is also an early fatigue failure. The root cause affects the reliability and longevity of bearing operation.
  • Cross-roller bearings are often used in applications where the speed is not high but the load type is complex, the load value is large, and the accuracy of the various directions is extremely high, such as precision machine tool turntables, industrial robot waist and ankles, etc.
  • the bearing is required to have high radial stiffness, axial stiffness, angular stiffness or moment stiffness.
  • the cross roller bearing often uses a small clearance or even a negative clearance, and the clearance is small.
  • there are many internal rollers of the cross roller bearing that is, the number of roller-to-roller contact pairs is large (NN rollers have 4N contact pairs), thus increasing the starting and running friction torque and increasing the torque.
  • the current raceway has a convex roller bearing with a convexity and a linear contact with the roller.
  • the V-shaped raceway of the crossed roller bearing without crown will cause the edge effect of the pressure singular distribution at the ends of the contact area at the ends of the contact area when the roller is in contact with the raceway, and This leads to the phenomenon of pressure concentration in the middle of the raceway. Since the bearing failure occurs at the contact point where the stress in the contact zone is the greatest, the bearing capacity of the bearing is seriously degraded, and the risk of local early fatigue failure in the contact zone is high, and the roller is made. The anti-skew ability is very poor, the external eccentric load, the bearing will have the risk of rotation and even stuck.
  • one of the ferrules adopts an overall split structure, that is, the ferrule is fastened by two ferrules with one side raceway by a connecting screw, since the two half ferrules need to be separately before heat treatment Production processing, not only processing accuracy is poor, processing efficiency is also low.
  • the current technical cross-roller bearing ring raceway is formed by the cutting and grinding method, which is limited by the precision of the grinding wheel and the poor heat dissipation condition of the grinding wheel.
  • the processed ferrule raceway not only has the size and shape accuracy. Not high enough, and there is grinding and deterioration of the layer and even burns, making the shape and performance of the raceway worse, affecting the running accuracy, life and reliability of the bearing.
  • the raceway is not a straight line with the crown V. Type raceway, cutting into grinding method is powerless
  • the raceway has a convex cross roller bearing that can improve and avoid the roller end face to the raceway surface. Scratch, reduce the temperature rise of the bearing, improve the anti-skew ability of the crossed roller bearing, avoid the edge effect of the singular distribution of stress when the two ends of the raceway are in contact with the roller, thereby significantly improving the running performance and life of the bearing.
  • a partial split ferrule structure is provided, so that the crossed roller bearing can meet the needs of loading the roller and the roller spacer, and has higher processing precision than the current ferrule integral split structure.
  • Another object of the present invention is to provide a method for manufacturing a cross roller bearing with a convexity of a raceway, comprising a method for processing a V-shaped raceway with a crown in a roller bearing ring, and a method for processing a crossed roller bearing Improved quality, longevity and productivity.
  • the present invention is a raceway crowned cross roller bearing comprising a crossed cylindrical roller bearing and a crossed tapered roller bearing, wherein the crossed roller bearing comprises an annular inner V-shaped raceway.
  • Outer ring, inner ring with annular outer V-shaped raceway, embedded V-shaped raceway of outer ring and V-shaped raceway of inner ring and cross row The row of rollers or the roller spacer, the lubricant, the seal and the connecting screw, the V-shaped raceway with at least one ferrule is a V-shaped raceway with a convexity.
  • the convex V-shaped raceway in the application of the invention not only improves the contact state of the roller working surface (roller outer circular surface) with the raceway, but also improves the non-working surface of the roller (roller end surface) and the raceway.
  • the contact state reduces or avoids the abrasion of the roller end face on the raceway surface, improves the anti-skew ability of the bearing, reduces the friction torque and the operating temperature rise of the bearing, and avoids the singularity of the roller-raceway contact end.
  • the edge effect of the distribution significantly improves the running accuracy and operational reliability of the bearing and prolongs the service life of the bearing.
  • the convex shape of the above-mentioned convex V-shaped raceway includes a straight line type, a full convex arc type, an intersection of an arc and a straight line, an arc and a straight line tangent type, an arc and a circular tangent type, Multi-segment arc repair or logarithmic curve convex; the convexity of the convex V-shaped raceway is less than 500 microns.
  • the V-shaped raceway with convexity means that the geometrical lines of the two sides of the V-shaped raceway are no longer a straight line, but the effective contact width between the roller and the raceway (the convex part, that is, the raceway and the block are not included)
  • the middle protrusion of the chamfer between the sides and the chamfer between the raceway and the bottom overtravel groove is reduced to both sides, taking the logarithmic convex type as an example, that is, the shape of the busbar of the raceway support surface is from the middle It is composed of a symmetrical logarithmic curve on both sides.
  • the logarithmic curve busbar is convex in the middle and decreases to both sides.
  • the two ends of the logarithmic curve busbar are smoothly connected with the two chamfered arcs.
  • the type and size of the external load are very different.
  • the convex design and the convex metric cannot be used to move the cylindrical roller bearing. It must be calculated by computer based on the design input of the crossed roller bearing. The specific differences between the two bearings are listed below.
  • the ferrule with a convex V-shaped raceway is a bearing outer ring.
  • the friction damage of the outer ring raceway is heavier than the inner ring.
  • a cross-roller bearing structure in which the inner ring or the outer ring is partially split, and a ferrule having a raceway notch, which is matched with the notch and includes a side portion of the V-shaped raceway
  • the raceway block of the raceway is blocked at the notch, and the raceway block is fastened along the axial direction of the ferrule by a connecting screw and a notched ferrule to form a ferrule with a V-shaped raceway.
  • Partially split cross-roller bearings with block ferrules, with respect to the ferrule integral split cross-roller bearing, have significant technical and quality advantages as shown in the table below.
  • the present invention also provides a method of making a crossed roller bearing, including final processing of a V-shaped raceway with a crown (the “final processing” refers to the final machining step of the article, followed by Assembly), which is characterized by the following methods:
  • Method 1 the V-shaped raceway of the ferrule is cut into the grinding by the grinding wheel corrected by the diamond roller, or
  • Method 2) Pre-milling two precision hard cars with reference surfaces, this method can improve the processing efficiency.
  • Method 2) includes:
  • the precision hard car of the outer ring V-shaped raceway the steps include: pre-preparing the reference end face and the outer round face of the outer ring, adsorbing the reference end face by the pole piece fixed on the electromagnetic chuck, and using the pole piece on the pole piece
  • the guiding surface guides the outer circular surface for rapid centering, and precision hard-car forming of the unground to be finished surface including at least the outer ring V-shaped raceway; or
  • the precision hard car of the inner ring V-shaped raceway the steps include: grinding the reference end face and the inner round face of the inner ring in advance, adsorbing the reference end face by the pole piece fixed on the electromagnetic chuck, and using the pole piece
  • the guiding surface guides the inner circular surface for rapid centering, and forms a precision hard-wearing surface for the unground to be finished surface including at least the inner ring V-shaped raceway; or
  • Method 3) Pre-grinding a precision hard car with one reference surface, this method can minimize the position error between the processed surfaces.
  • Method 3) includes:
  • Electromagnetic adsorption precision hard car the steps include: pre-grinding the ferrule reference end face, and the pole piece directly adsorbed or fixed on the electromagnetic chuck through the electromagnetic chuck adsorbs the reference end face while setting the center, and the outer ring includes at least V Forming raceway and outer circular surface, including the V-shaped raceway and the inner circular surface, including the V-shaped raceway and the inner circular surface, the precision grinding of the surface to be finished;
  • the steps include: the ferrule of the vertical hard car with an outer diameter of 300 mm or more, which is pre-formed to the ferrule reference end face, and then the ferrule reference end face is placed horizontally downward, the ferrule center Axis, After the three axes of the rotary axis of the machine tool turret and the central axis of the ferrule support are combined, the ferrule is directly fixed on the machine tool turret, or the ferrule is fixed on the turntable by the support, and then the outer ring includes at least the V-shaped raceway and the outer circle.
  • the inner and inner rings include at least a V-shaped raceway and an inner circular surface, and the unground to be finished surface is precision hard-car formed.
  • the V-shaped raceway with convexity is precision-hardened by numerical control method: when the raceway convex type is composed of a straight line and an arc only, the ISO code is adopted. Instruction programming; when the raceway line includes a non-circular quadratic curve, such as a logarithmic curve, the user macro program function is used for programming.
  • the tool materials used for precision hard car forming include CBN, PCBN, diamond, diamond-like, ceramic and hard alloy.
  • the tip angle is not more than 45 degrees.
  • the surface roughness Ra of the precision hard car is less than or equal to 1.6 microns.
  • the precision hard-car forming surface has a shape and positional accuracy of at least P5, and the precision hard-vehicle V-shaped raceway has a convexity of less than 500 microns.
  • a method for manufacturing a crossed roller bearing with a block ferrule characterized in that the method comprises the following steps: (1) manufacturing an integral ferrule blank with a V-shaped raceway, designing and processing the blank There is a screw hole for the block block block fixing, and the screw hole passes through the bottom of the V-shaped raceway from the end face of the ferrule in the axial direction of the ferrule; (2) quenching and tempering heat treatment of the integral ferrule blank; (3) adopting Slowly cut the wire, take the U-shaped track, cut out the fixed screw hole, the width is not less than the diameter of the roller and the width of the spacer, the height is equal to the distance from the end to the bottom of the V-shaped raceway, and the thickness of the slit on both sides is equal.
  • the raceway block is blocked, and a U-shaped raceway notch which matches the raceway block is generated at the same time; (4) the raceway block is fastened with the notched bearing ring by the connecting screw, and the paired heat treatment is performed. Precision hard-car processing; (5) When the bearing is assembled, loosen the connecting screw, remove the raceway block, fill all the rollers and spacers from the gap of the ferrule; (6) put in the raceway block, And the connecting screw is fastened with the ferrule to complete the sleeve of the bearing ring and the rolling element.
  • the invention relates to a cross roller bearing with a convexity of a raceway and a manufacturing method thereof, comprising a cross cylindrical roller bearing with convexity and a cross tapered roller bearing with convexity, wherein the raceway of the ferrule is provided with Convex, crowned raceway CNC grinding or CNC precision hard forming.
  • the raceway crown involves two parameters, convex and convex.
  • the raceway convex shape is divided into multiple types as described above, the roller-to-track contact stress is distributed as uniform as possible along the raceway width.
  • the convex shape of the arc tangent to the arc shown in Fig. 8E and the logarithmic curve convex shape of the variable curvature shown in Fig. 8G are preferred.
  • the convex measure is based on the specific bearing parameters and operation. Conditions (such as lubrication conditions, speed, load type and load size, etc.) are obtained by computer numerical calculation.
  • the convex shape of the arc tangent to the arc has the advantage that the transition between the arc and the arc is smooth due to the tangency, but the arc still belongs to the fixed curvature curve, because the curvature of different geometric positions (points) is the same,
  • the contact stress of each position (point) is different;
  • the logarithmic curve is a quadratic curve of variable curvature, and the curvature changes correspondingly with the change of the geometric position (point), so that the contact stress of each position (point) is the same, that is, Equal stress, so that the material can be used for the strength of the points on the working surface of the raceway and the rolling element, and because the logarithmic curve is continuous and smooth, therefore, whether to avoid the scratch of the raceway or avoid the singular distribution of stress
  • the logarithmic curve is the most ideal convex shape of the cross roller bearing raceway.
  • the current cross-roller bearing ferrule integral split structure is innovated into a partial split structure, which not only simplifies the process flow, reduces the processing cost, improves the machining accuracy, but also improves the assembly precision of the bearing. The risk of micro-dislocation of the two halves of the ring during the operation of the bearing is avoided.
  • V-shaped raceways with crowns can be cut-in grinding if the convex metric is not large and the convex shape is not complicated.
  • the outer ring is the end face and the outer round face
  • the inner ring is the end face and the inner round face, which can be mechanically clamped, but when mechanically clamped, the outer ring must be The outer ring surface and the end surface are positioned.
  • the inner ring must be positioned with the inner circular surface and the end surface. Therefore, when the outer ring is in the hard car raceway, the outer ring surface of the outer ring cannot be hard-wheeled, and the inner ring cannot be used when processing the raceway.
  • the inner circular surface of the inner ring is hard-wheeled, but the mutual positional accuracy between the outer circular surface and the raceway surface of the outer ring, the inner circular surface of the inner ring and the raceway surface is essential, and the accuracy is directly and significantly affected.
  • the running performance of the bearing Furthermore, clamping the outer circular surface of the outer ring or expanding the inner circular surface of the inner ring by the multi-clip clamp causes radial deformation of the ferrule (for example, the outer ring outer three-lobed step chuck causes the outer ring to have a triangular edge
  • the deformation of the ferrule affects the machining accuracy of the ferrule. For a cross-roller bearing ferrule with a narrow width and a relatively thin wall, this negative effect is more significant. Therefore, in order to obtain high shape and positional accuracy, the present invention provides a ferrule.
  • One or two surfaces in the middle are used as reference surfaces to ensure the implementation of the process by precision hard forming process and designing corresponding processing fixtures and auxiliary
  • any end face can be used as the positioning reference surface of the post-process; when the difference between the two end faces is large, a single-end grinder is used, after grinding one end face and then grinding the other end face, one end face is agreed as the positioning reference for the post process surface.
  • the end face (even if the two end faces are the same, can be distinguished) is only a reference plane, so in the above "pre-grind two datum planes", the two datum planes do not refer to the two end faces of the ferrule, and It refers to the end face plus another (not the ferrule end face, the outer ring is the outer circle surface; the inner ring is the inner circle surface) reference surface, and the pre-grinding reference surface refers to grinding the surface to the final size.
  • the surface to be finished which is not pre-ground to the reference surface, can be coarsely ground before the finishing of the finished car.
  • the precision hard car In order to improve the machining accuracy, the precision hard car needs to use numerical control equipment.
  • the accuracy of the ISO command programming is sufficient, but when the convex shape is a non-circular quadratic curve, such as a logarithmic curve,
  • the ISO command and multi-segment arc approach programming can not meet the high precision requirements, and other high-precision programming methods are required.
  • the solution of the invention has the following advantages: (1) The raceway crown improves the friction between the roller and the raceway, reduces heat generation, and improves the quality and life of the bearing. (2) The raceway camber is designed according to the type and size of the actual bearing load when the bearing is working, which fundamentally improves the running reliability and actual work of the bearing. Service life under conditions; (3) The convexity value is calculated according to the working conditions, and then processed, which is very flexible and accurate; (4) The contact between the outer and outer faces of the roller and the V-shaped raceway is improved at the same time.
  • the product of the present application can improve the performance and life of the crossed roller bearing, and the manufacturing method thereof can improve the quality and production efficiency of the crossed roller bearing.
  • Figure 1 is a schematic cross-sectional view of a cylindrical roller bearing with a crown.
  • Figure 2A is a right side view of the bearing outer ring of Figure 1.
  • FIG. 2B is a schematic cross-sectional view of the outer ring of the bearing shown in FIG. 1.
  • FIG. 3 is a schematic cross-sectional view of the inner ring of the bearing shown in FIG. 1.
  • Fig. 4 is a schematic cross-sectional view showing a partially split crowned tapered roller bearing of the inner ring.
  • Figure 5 is a schematic cross-sectional view of the outer ring of the bearing shown in Figure 4.
  • 6A is a schematic cross-sectional view of the inner ring of the bearing shown in FIG. 4.
  • Figure 6B is a left side view of the inner ring of the bearing shown in Figure 4.
  • Fig. 6C is a schematic view showing the U-shaped path processed by wire cutting in the production of the inner ring raceway block block shown in Fig. 4.
  • Fig. 7A is a partially enlarged schematic cross-sectional view of a straight raceway without a crown in a cross roller bearing ring.
  • Fig. 7B is a cross-roller bearing ring (removing the inner ring of the cross-tapered roller bearing), and the straight-rolled section without the convexity is partially enlarged.
  • Fig. 7C is a partial enlarged view of a straight raceway without a crown in the inner ring of the crossed tapered roller bearing.
  • Fig. 8A is a partially enlarged schematic view showing the straight line convex type raceway.
  • Fig. 8B is a partially enlarged schematic view showing the full convex arc-shaped raceway.
  • Fig. 8C is a partially enlarged schematic cross-sectional view showing a circular arc and a straight line intersecting convex raceway.
  • FIG. 8D is a partially enlarged schematic view showing a circular arc and a straight line tangent convex type raceway.
  • Fig. 8E is a partially enlarged schematic cross-sectional view of a circular arc and a circular arc tangential convex raceway.
  • FIG. 8F is a partially enlarged schematic cross-sectional view of a multi-section arc intersecting convex type raceway.
  • Fig. 8G is a partially enlarged schematic view showing a logarithmic curved convex raceway.
  • Figure 9 is a schematic diagram of a precision hard car in which the electromagnetic chuck directly adsorbs the outer end surface of the outer ring.
  • Fig. 10 is a schematic view of the precision hard car of the electromagnetic chuck sucking the inner end surface of the inner ring through the pole piece.
  • Figure 11 is a schematic view of the multi-surface of the inner ring of the vertical precision hard machining.
  • Fig. 12 is a schematic view showing the relationship between the pole piece and the outer ring with the outer circumferential guiding surface of the outer ring.
  • Figure 13 is a schematic view of a pole shoe with an inner circumferential guiding surface of the inner ring.
  • Figure 14 is a schematic view showing the relationship between the pole piece and the inner ring of Figure 13;
  • FIG. 1 is a cross-sectional view of the outer ring with a convex cross cylindrical roller bearing, including an outer ring having a two-half structure, the semi-outer ring 111 and the other half outer ring 112 being fastened by a connecting screw 113, and the inner ring 12 being a raceway belt.
  • the inner ring of the crown-cross cylindrical roller bearing, 13 is a cylindrical roller, and the two rows of cylindrical rollers are alternately placed at 90 degrees one by one, and are placed in a convex V-shaped groove between the inner ring 12 and the outer ring 11 from the figure.
  • the center roller rotation center line distinguishes one row of rollers from another row of rollers, and the two rows of rollers are identical in size and precision.
  • FIG. 2A is a right side view of the outer ring 12 of the cylindrical roller bearing with a crown which is integrally divided as shown in FIG. 1, and it can be seen that three connecting screws are used to connect the two outer rings 111, 112. Solid connected as a whole.
  • FIG. 2B is a cross-sectional view of the outer ring of the bearing shown in FIG. 1, it can be seen that the V-shaped raceway is adjacent to the side end of the reference end face, and the angle between the reference end face is 45 degrees, between the raceways on both sides. The angle is 90 degrees.
  • the raceway has a convexity and is no longer a straight line within the effective width range, the line is connected between the start point and the end point of the convexity curve, and the two side raceways each obtain a straight line, and the roll is close to the side of the reference end face.
  • the angle between the connection and the reference end face is also 45 degrees, and the angle between the two lines is also 90 degrees.
  • the two angles related to the convexity track are designed, processed and measured.
  • the raceway is the obtuse angle with the rib and the raceway and the overrun groove on the inside of the ferrule body.
  • Figure 3 is a schematic cross-sectional view of the inner ring of the bearing of Figure 1.
  • Figure 4 is a cross-sectional view of a tapered tapered roller bearing
  • 21 is a raceway with a convex tapered roller bearing outer ring
  • 22 is a raceway with a convex tapered roller bearing inner ring
  • 23 is a tapered roller
  • the row of tapered rollers are alternately placed at an angle of 90 degrees.
  • the outer ring 21 and the inner ring 22 of the crossed tapered roller bearing shown in Fig. 4 are partially divided structures of the inner ring.
  • Fig. 5 is a schematic cross-sectional view showing the outer ring of the cross-tapered roller bearing with the convexity of the raceway of Fig. 4, the outer ring being an integral outer ring.
  • 6A is a schematic cross-sectional view showing the inner ring of the partial-concave convex-cone tapered roller bearing of the inner ring of FIG. 4.
  • 6B is a side view of the inner ring of the inner ring partially divided with the convex cross-tapered roller bearing shown in FIG. 4.
  • Fig. 6C is a view taken along line A of Fig. 6B.
  • Fig. 7A is a partially enlarged schematic cross-sectional view of a straight roller bearing without a crown of a cross roller bearing ring. Zoom in on any raceway section for a clear view and place the raceway line in a horizontal position. From Fig. 7A to Fig. 7C, Figs. 8A to 8G do the same.
  • the raceway line AB is a straight line
  • AC is the rib portion
  • BD is the overtravel groove
  • the intersection of the raceway and the rib is A
  • the intersection of the same and the overrun is B
  • the raceway is not convex. degree.
  • Fig. 7B is a partial enlarged geometrical relationship diagram of a straight raceway without a crown of a crossed roller bearing ring (excluding the inner ring of a crossed tapered roller bearing).
  • the raceway line AB is a straight line
  • AC is the rib part
  • BD is the overtravel groove part
  • the angle between AB and AC on the outer side of the bearing body is both 45 degrees.
  • Fig. 7C is a partially enlarged geometrical relationship diagram of the straight raceway without the convexity of the inner ring of the crossed tapered roller bearing.
  • the tracker line AB is a straight line
  • AC is a part of the rib
  • BD is a part of the overtravel groove.
  • the angle between AB and AC on the outside of the bearing body is 45 degrees minus the cone angle of the tapered roller (2 ⁇ ) of the bearing, and the angle between AB and BD on the outside of the bearing body is 45 degrees plus the tapered roller of the bearing. Cone angle (2 ⁇ ).
  • Fig. 8A is a partially enlarged schematic view showing the straight line convex type raceway.
  • the line AB between the two points A and B symmetrically distributed in the raceway is a straight line
  • the radius of the convex arc is R
  • the radius of the chamfered arc is r
  • the intersection with the straight section of the raceway is A
  • the intersection with the chamfered arc is C
  • the intersection of the chamfered arc and the raceway rib is E
  • EG is the rib portion
  • the intersection point is B
  • the intersection with the chamfered arc is D
  • the intersection of the chamfered arc and the overtravel groove is F
  • FH is the overtravel groove.
  • the distance from the highest point of the raceway to the point C or D is the raceway metric Td.
  • Fig. 8B is a partially enlarged schematic view showing the full convex arc-shaped raceway.
  • the radius of the convex arc is Rc
  • the intersection of the convex arc and the rib is A
  • the intersection of the same overrun is B
  • AC is Part of the rib
  • BD is the part of the overtravel groove.
  • the distance from the highest point of the raceway to point A or point B is the raceway metric Td.
  • FIG. 8C is a partially enlarged schematic cross-sectional view of a circular arc and a straight line intersecting convex raceway.
  • the convex arc radius is Rc
  • the convex arc and the rib are connected by a straight line AC, and between the overtravel groove.
  • the straight line segment BD Connected by the straight line segment BD, the convex arc intersects with AC and BD, EC is the rib portion, and DF is the overtravel groove.
  • the distance from the highest point of the raceway to point A or point B is the raceway metric Td.
  • FIG. 8D is a partially enlarged schematic view showing a circular arc and a straight tangential convex raceway.
  • the convex arc radius is Rc
  • the convex arc and the rib are connected by a straight line AC
  • the overtravel groove The line is connected by a straight line segment BD
  • the convex arc is tangent to AC and BD
  • EC is the rib portion
  • DF is the overtravel groove.
  • the distance from the highest point of the raceway to point A or point B is the raceway metric Td.
  • Fig. 8E is a partially enlarged schematic cross-sectional view of a circular arc and a circular arc tangential convex raceway.
  • the convex arc radius is Rc
  • the convex arc and the rib are connected by an arc segment AC having a radius R.
  • the overtravel groove is connected by a circular arc segment BD of radius R
  • the convexity arc is tangent to the AC arc and the BD arc
  • EC is the rib portion
  • DF is the overtravel groove.
  • the distance from the highest point of the raceway to point A or point B is the raceway metric Td.
  • Fig. 8F is a partially enlarged schematic view showing the intersection of a plurality of arcs intersecting each other (5 sections).
  • the radius of the five arcs is Rc1, Rc2, Rc3, Rc4, Rc5, and the five arcs are composed.
  • Curve AB the chamfered arc between the convex arc and the rib is AC, the radius is r, the chamfered arc between the convex arc and the overtravel groove is BD, the radius is r, and the EC is the rib Locally, DF is the part of the overtravel slot.
  • the distance from the highest point of the raceway to point A or point B is the raceway metric Td.
  • Fig. 8G is a partially enlarged schematic view showing a convex curve of a logarithmic curve.
  • the AB segment is a logarithmic curve
  • the highest point of the logarithmic curve is on the vertical line of the effective width of the raceway, and slowly decreases to the sides
  • logarithm The chamfer arc between the curve and the rib is AC, the radius is r, the chamfer arc between the same and the overtravel groove is BD, the radius is r, EC is the rib portion, and DF is the overtravel groove.
  • the distance from the highest point of the raceway to point A or point B is the raceway metric Td.
  • Figure 9 is a plan view of the outer ring directly mounted on the electromagnetic jig.
  • Figure 10 is a perspective view of the inner ring mounted on the electromagnetic chuck through the pole piece.
  • Figure 11 is a vertical machining diagram.
  • Figure 12 is a plan view of the outer ring mounted on the electromagnetic chuck pole piece (with the outer circumferential guiding surface).
  • Figure 13 is an electromagnetic jig diagram of the inner lead guide shoe with inner ring.
  • Figure 14 is a plan view of the inner ring mounted on the pole piece shown in Figure 13.
  • Embodiment 1 as shown in FIG. 1 is a schematic diagram of a crossed roller bearing, which is an overall cross-section of a cylindrical roller bearing with a convexity, including an outer ring 11 having an annular inner V-shaped raceway, and an annular outer V-shaped roller.
  • the inner ring 12 of the track, the cylindrical roller 13 embedded between the outer ring V-shaped raceway and the inner ring V-shaped raceway, and the outer ring 11 is designed as a two-half structure, including two half rings 111 and 112, two The half ferrule is fastened to the overall outer ring by a number of connecting screws 113. It can be seen from FIG. 2B and FIG.
  • the angle between the inner ring and the outer ring V-shaped raceway near the respective reference end face side and the respective reference end faces is 45 degrees, and the angle between the two side raceways At 90 degrees, the V-shaped raceway is sandwiched between the ferrule rib and the overtravel groove at the bottom of the raceway.
  • a generally or lightly loaded cross-roller bearing can be provided with a projection as shown in Figure 8A or 8E on the V-shaped raceway of the outer ring shown in Figures 2B and 5 (because the raceway geometry of the outer ring is the inner cone)
  • the surface has a large friction contact surface when in contact with the end surface of the roller, which is more susceptible to damage than the inner ring raceway, so as to reduce the abrasion of the roller end surface on the raceway surface, reduce the bearing temperature rise, and improve the running precision of the bearing. Life and fatigue life.
  • the inner ring and the outer ring raceway are respectively provided with the convexity as shown in Fig. 8E, and the convexity is composed of three segments of circular arc tangent, the intermediate arc radius For Rc, the center of the arc is located on the mid-perpendicular line of the width of the raceway. The radius of the arc on both sides is R.
  • the arc with radius Rc and the two arcs with radius R are tangent to A and B respectively.
  • the arc with radius R near the rib is tangent to the rib at point C.
  • the arc with radius R near the overtravel groove is tangent to the overtravel groove at point D, EC is the rib portion, and DF is the overrun. Part of the groove.
  • the distance from the highest point of the raceway to point A or point B is the raceway crown metric Td ranging from 0.1 microns to 500 microns.
  • the parameters Rc, R and Td are known in terms of bearing installation and service conditions (such as operating speed, load type and size, etc.). After the bearing is determined by design parameters (material parameters, geometric parameters, etc.) other than the crown, the value is calculated by the computer. The calculation is given.
  • the convexity is composed of three segments of circular arc tangent
  • the convex shape intersecting the straight line and the straight line and the arc intersecting the straight line has the advantages of smooth transition and smoothness.
  • the arc is a quadratic curve of constant curvature.
  • the radius of curvature at different points of the entire raceway has only two values.
  • the middle of the raceway is Rc
  • the ends of the raceway are R
  • the radius of curvature at different points is equal.
  • Example 2 Partially split inner ring with crown and cross tapered roller bearing - logarithmic curve convex
  • the inner ring partial section with convexity cross-tapered roller bearing is shown in Fig. 4, including the outer ring 21, the inner ring 22, the tapered roller embedded between the outer ring V-shaped raceway and the inner ring V-shaped raceway. Sub 23, a row of tapered rolls The cone top of the sub-cone and the conical top of the other row of tapered rollers respectively fall at two points on both sides of the bearing on the center line of the bearing rotation.
  • the outer ring 21 is of unitary construction as shown in Fig. 5.
  • the inner ring 22 is shown in Figs. 4, 6A, 6B and 6C, and a sufficient number of tapered rollers 23 are filled into the bearing, and the inner ring 22 is designed to be rolled.
  • the partial split structure of the block block, the inner ring 22 is formed by a notched inner ring 221, a block plug 222 and a connecting screw 223 for fixing the block plug 222 to the notched inner ring 221 in the radial direction of the inner ring.
  • the notch is opened from the inner ring rib to the inner circular surface; in the axial direction of the inner ring, the notch is opened from the end surface to the middle of the V-shaped raceway; in the circumferential direction of the inner ring, the notch width is larger than the roller diameter of the bearing and the installed spacer
  • the width of the bearing (the bearing does not have a spacer block, that is, the full complement of the cross roller bearing), in order to ensure that the roller and the spacer can smoothly fill the inner ring V-shaped raceway and outer ring from the notch when the bearing is assembled.
  • the block 222 is matched with the size of the notch on the notched inner ring 221.
  • the connecting screw 223 is used to block and fasten the block 222 to the notched inner ring 221 to form a complete inner portion.
  • Circle 22 It can be seen from Fig. 5 that the angle of the raceway on the side of the outer ring V-shaped raceway near the reference end face is 45 degrees from the reference end face, and the angle between the raceways on both sides is 90 degrees, as can be seen in Fig. 6A.
  • the angle between the raceway on the side close to the reference end face and the reference end face is 45 degrees plus the taper angle 2 ⁇ of the tapered roller mounted on the bearing, and the angle between the raceways on both sides is 90 degrees plus 4 ⁇ , V
  • the type raceway is sandwiched between the ferrule rib and the overrun groove at the bottom of the raceway.
  • Both the inner ring and the outer ring raceway have the convexity shown in Fig. 8G, and the convex shape is a logarithmic curve.
  • the highest point of the logarithmic curve AB is on the middle line of the track width, and gradually decreases from this point to the sides, EC
  • the straight line is the rib part, which is connected with the logarithm curve AB by the arc chamfer of radius r
  • the FD line is the part of the overtravel groove, which is connected with the log curve AB by the arc chamfer of radius r
  • the distance Td from the highest point of the number curve to point A or point B is a logarithmic curve or a convex measure of the raceway, ranging from 0.1 micrometers to 500 micrometers.
  • the coefficient term, constant term, and convexity value Td in the logarithmic curve equation are known in terms of bearing installation and service conditions (such as running speed, load type and size, etc.), and bearing parameters other than convexity (material parameters, geometric parameters) After being determined, the numerical calculation is given by the computer.
  • the logarithmic curve is a quadratic curve of variable curvature, that is, the curvature of each point on the logarithmic convex race varies with position, so that the contact stress of each point is equal or substantially equal when in contact with the working surface of the roller.
  • the logarithmic curve convex raceway is viewed from the point of avoiding the raceway scratch, reducing the temperature rise or avoiding the singular distribution of the contact stress. It is the most ideal convex raceway.
  • the precision machining of the logarithmic curve convex raceway requires a numerically controlled machine tool and is programmed by a user macro program. User macro programming, you can use variables, and assign values to variables, can be operated between constants, can jump when the program is running, greatly improving the flexibility of programming and the processing accuracy of non-circular quadratic curves.
  • Embodiment 3 Partially split inner ring with convexity cross tapered roller bearing structure, processing and assembly
  • FIG. 4 shows the assembly drawing of the inner ring partial-section convex-cone tapered roller bearing.
  • Figure 5 is the The cross-sectional view of the outer ring 21 shows that the outer ring 21 has a unitary structure, FIG. 6A is a cross-sectional view of the inner ring 22 therein, FIG. 6B is a left side view of the inner ring 22 therein, and FIG. 6C is an A-direction view of FIG. 6B, which can be seen.
  • the inner ring 22 is a partial split structure, which is composed of a notched inner ring 221, a race block block 222 and a connecting screw 223, wherein the connecting screw The nail 223 secures the block 222 to the notched inner ring 221, and the block and the notch coincide.
  • the manufacturing method of the partial split structure inner ring 22 is as follows: (1) manufacturing a whole inner ring blank with a V-shaped raceway, and designing and processing a screw hole for the raceway block block on the blank, the screw hole is along the axial direction of the ring From the side end of the ferrule through the bottom of the V-shaped raceway and extending forward a distance, the total width of the ferrule is B; (2) quenching and tempering heat treatment of the whole inner ring blank; (3) using slow wire cutting , take the U-shaped track (as shown in Figure 6C), cut out including the fixed screw hole, the width W is not less than the diameter of the roller and the width of the spacer, the height H is equal to the distance from the end to the bottom of the V-shaped raceway, two The raceway block 222 having the same side slit thickness T and the U-shaped raceway notch which coincides with the raceway block plugging; (4) the raceway block 222 and the notched bearing inner ring 221 are tightly connected by the connecting screw 2
  • Embodiment 4 Cutting-in grinding forming processing method with convex outer ring
  • the cutting-in grinding method of the outer ring 11 with the convex V-shaped raceway is the same as the current cutting-in grinding method without the convex V-shaped raceway, including before the grinding raceway.
  • the opposite concavity is used for grinding.
  • the grinding wheel is trimmed with the same diamond roller as the raceway crown. For this purpose, the diamond roller is customized.
  • the outer ring is composed of two halves, the two halves of the outer ring are paired for grinding in the state where the connecting screws are fastened.
  • the inner ring of the cylindrical roller bearing with convexity is shown in Figure 3.
  • the cutting-in grinding method of the inner ring with the convex V-shaped raceway is the same as the current cutting-in grinding method without the convex V-shaped raceway, including Before grinding the raceway, first grind the inner end surface of the inner ring and the inner circle surface of the inner ring, then use the electromagnetic centerless clamp to absorb the inner end surface of the inner ring and support the inner ring raceway surface to grind the inner ring raceway (the branch raceway grinding)
  • the raceway method the difference is that the working face of the grinding wheel should be ground with the concavity opposite to the curvature of the raceway.
  • the same diamond with the crown of the raceway should be used. The wheel is used to trim the grinding wheel, and the diamond wheel is customized for this purpose.
  • the raceway block is paired with the inner ring with the corresponding notch to be paired for precision hard machining.
  • Example 5 (using the 3A method in the manufacturing method) electromagnetically adsorbing a precision hard car ferrule
  • the multi-surface composite precision hard car is formed, and the ferrule with the V-shaped raceway is formed by sequential precision hard-car forming in one clamping position.
  • the ferrule Before the precision hard car forming process, the ferrule has only one fine grinding end face as the reference surface.
  • the inner ring is formed by a hard bicycle.
  • the electromagnetic chuck has a plurality of T-shaped grooves.
  • the pole pieces are concentrically fixed on the electromagnetic chuck by connecting screws, and the reference plane of the workpiece is concentrically sucked by the end faces of the pole pieces.
  • the outer diameter of the end of the pole piece is smaller than the outer diameter of the reference surface of the ferrule, and the inner diameter of the end of the pole piece is larger than the sleeve.
  • precise hard machining of the rib, the V-shaped raceway, the other end surface and the inner circular surface is completed in sequence. Due to the convexity of the inner ring raceway, a CNC precision hard car is required.
  • the raceway convexity and convexity value are known, that is, the raceway line equation is known, when the raceway line is only by straight line and circle.
  • the arc When the arc is composed, it is programmed by the ISO code instruction; when the raceway line includes a non-circular quadratic curve, such as a logarithmic curve, the user macro program function is used for programming.
  • the precision hard car adopts CBN or PCBN inserts, and the surface roughness value Ra after processing is less than or equal to 1.6 micrometers, and the shape and positional accuracy of the surface are at least P5.
  • the convex gauge of the precision hard car raceway can range from 0 to 500 microns.
  • Example 6 (using the 3A method in the manufacturing method), as shown in FIG. 9, is a precision hard car forming process of the outer ring, and the steps are similar to the inner ring hard car processing of the fifth embodiment, except that without the pole piece, in the precision
  • the outer circle or the rib of the hard car is used, if the tool does not interfere with the electromagnetic chuck, the chamfer size between the two surfaces and the reference end face should not be too small.
  • Embodiment 7 (using the 3B method in the manufacturing method) vertical precision hard car; the inner ring type precision hard car forming processing method with the convexity cross roller bearing inner ring - multi-surface composite precision hard car
  • the machine tool turret has a number of T-shaped grooves, and the ferrule support supports the ferrule (illustrated as the inner ring).
  • the ferrule support is fixed on the turntable by the support fixing bolts, and the ferrule support With screw holes, after the ferrule is placed on the ferrule support, the urging screw passes through the mounting hole or the process hole on the ferrule (the cross-roller bearing often has several mounting screw holes on the outer ring and the inner ring) Or through holes, if not, can also process 3 or more process holes. Fix the ferrule on the ferrule support and rotate it concentrically with the turret.
  • the end portion of the ferrule holder that is in contact with the reference end face of the ferrule has an outer diameter slightly smaller than the outer diameter of the reference end face side of the ferrule, and the inner diameter is slightly larger than the inner diameter of the reference end face side to avoid interference between the cutter and the support during machining.
  • an inner ring clamping and fixing method can complete the inner ring including the V-shaped raceway and the inner circular surface in one clamping position.
  • Composite precision hard-car forming of functional surfaces According to the above processing method, in one clamping position, precise hard machining of the rib, the V-shaped raceway and the inner circular surface is completed in sequence.
  • a CNC precision hard car is required.
  • the raceway convexity and convexity value are known, that is, the raceway line equation is known, when the raceway line is only by straight line and circle.
  • the arc is composed, it is programmed by the ISO code instruction; when the raceway line includes a non-circular quadratic curve, such as a logarithmic curve, the user macro program function is used for programming.
  • the precision hard car adopts CBN or PCBN inserts, and the surface roughness value Ra after processing is less than or equal to 1.6 micrometers, and the shape and positional accuracy of the surface are at least P5.
  • the convex gauge of the precision hard car raceway can range from 0 to 500 microns.
  • the raceway block When the inner ring is partially divided, the raceway block is paired with the inner ring with the corresponding notch to be paired for precision hard machining.
  • Outer ring processing is similar to inner ring, outer ring is clamped Once fixed, the V-shaped raceway and outer surface of the outer ring and other parts to be machined can be machined with precision.
  • Embodiment 8 as shown in FIG. 12, a hard car of the V-shaped raceway of the outer ring (using the 2A method in the manufacturing method), is formed by the two-grinding reference outer ring V-shaped raceway precision hard car, adopting a guide surface The design of the pole piece in the overall pole piece and the quick and precise clamping method of the outer ring.
  • the outer ring has two grounding reference faces, that is, an outer ring end face and an outer circular face
  • an electromagnetic jig is used, and the outer round end face is still used as a reference surface, and the pole piece is used, and the pole piece adsorbs the reference end face of the outer ring.
  • the outer circular guiding surface is designed on the entrance opening of the pole piece, which can quickly and accurately concentrically position the electromagnetic ring with the outer ring, which not only greatly saves the processing auxiliary time, but also improves the hard forming surface and other non-hard forming surfaces. The mutual positional accuracy between them.
  • the integral pole piece is fixed on the electromagnetic chuck by a fixing screw, and the integral pole piece has a stepped hole, and a small gap or a transition fit is formed between the size of the step hole diameter and the outer circumferential surface of the outer ring, and the hole is formed when the outer ring is placed
  • the step surface in the step hole absorbs the reference end face of the outer ring.
  • the ferrule is machined on the pole piece and machined to complete the crowned raceway and raceway ribs with at least a hard car. Due to the convexity of the raceway, a CNC precision hard car is required.
  • the raceway convexity and convexity value are known, that is, the raceway line equation is known, when the raceway element line is composed only of straight lines and arcs.
  • the raceway line includes a non-circular quadratic curve, such as a logarithmic curve, the user macro program function is used for programming.
  • the precision hard car adopts CBN or PCBN inserts, the blade tip angle is not more than 45 degrees, the surface roughness value Ra after processing is less than or equal to 1.6 microns, and the surface shape and positional accuracy are at least P5.
  • the convex gauge of the precision hard car raceway can range from 0 to 500 microns.
  • the outer ring is composed of two outer rings, the two outer rings are paired for precision hard machining under the condition that the connecting screws are fastened.
  • the overall pole piece is fixed and unadjustable due to its radial dimension. Therefore, a ferrule of a size specification generally corresponds to a pole piece, and the concentric adjustment of the pole piece and the electromagnetic chuck and the ferrule is relatively quick, and is suitable for mass production.
  • the overall pole piece can also be replaced with a multi-petal pole piece.
  • Embodiment 9 the precision hard car of the inner ring V-shaped raceway (the inner ring is processed by the 2B method in the manufacturing method), as shown in Fig. 14, the two grinding into the reference surface inner ring V-shaped raceway precision hard car forming adopts the belt guide Design of multi-lobed pole shoe and fast and precise clamping method of inner ring
  • FIG. 13 is a schematic diagram of the clamp pole shoe, and the pole shoe is adsorbed by the inner ring.
  • the reference surface, the inner circular guiding surface on the pole piece, can quickly and accurately position the inner ring, which not only greatly saves the auxiliary time during processing, but also improves the hard forming surface and other non-hard forming surfaces. The mutual positional accuracy between them.
  • Figure 13 is a schematic view of a multi-lobed pole shoe (shown as 6 petals). The pole shoe is fixed on the electromagnetic chuck by a fixing screw.
  • the outer part of the pole piece is stepped, and the outer circumference of the head cylinder
  • the diameter forms a small gap or a transition fit with the inner ring reference surface, that is, the inner circular surface.
  • the inner ring When the inner ring is placed, since the diameter of the head cylinder surface is slightly smaller than the diameter of the inner circular surface, it serves as a guiding surface to guide the inside.
  • the bottom of the step absorbs the inner ring reference surface.
  • the other parts except the inner ring reference plane can be sequentially completed, including at least the V-shaped raceway and the inner ring. Precision hard machining of the outer surface.
  • a CNC precision hard car is required.
  • the raceway convexity and convexity value are known, that is, the raceway line equation is known, when the raceway line is only by straight line and circle.
  • the arc is composed, it is programmed by the ISO code instruction; when the raceway line includes a non-circular quadratic curve, such as a logarithmic curve, the user macro program function is used for programming.
  • the precision hard car adopts CBN or PCBN inserts, and the surface roughness value Ra after processing is less than or equal to 1.6 micrometers, and the shape and positional accuracy of the surface are at least P5.
  • the convex gauge of the precision hard car raceway can range from 0 to 500 microns.
  • the crossed roller bearing described above includes a crossed cylindrical roller bearing and a crossed tapered roller bearing when not specified; the ferrule includes an inner ring and an outer ring when not specified; the overall split and the partial Splitting requires only one ferrule, either the inner ring or the outer ring.
  • the example processing method for example, the outer ring processing of the inner ring has the same reference significance.
  • the outer ring has the same reference significance for the inner ring processing.

Abstract

一种滚道带凸度的交叉滚子轴承及其制作方法，交叉滚子轴承的V型滚道带有凸度，带凸度的V型滚道切入磨削成形或精密硬车成形，或将带凸度的V型滚道与套圈其它重要的精加工表面在一次装卡定位中顺序精密硬车成形。按所述设计、加工的带凸度的交叉滚子轴承相比滚道不带凸度且磨削成形的交叉滚子轴承，大幅度减小乃至完全避免了滚子、滚道接触副的边缘效应，改善了滚子外圆面和端面与滚道的接触状态，降低了轴承运转摩擦功耗和温升，提高了轴承的抗歪斜能力，从而提高了轴承的运转精度、承载能力、运行可靠度和服役寿命，具有非常重要的工程实际意义。

Description

一种滚道带凸度的交叉滚子轴承及其制作方法 技术领域
本发明涉及滚动轴承技术领域，特别涉及一种滚道带凸度的交叉滚子轴承及其制作方法。
背景技术
申请人曾在2014100202253套圈精密硬車成型的滚动轴承及其加工方法中述及普通结构轴承的滚道的结构及滚道的硬車加工方法，解决了滚道磨削成型加工中存在的滚道截面形状设计受限、磨削变质甚至烧伤等问题，使套圈各表面能够面向工况进行设计，而且能够以非常高的形位精度成型，对高密封、高可靠性等高性能滚动轴承的设计和制造具有工程实际意义。但现有技术未涉及交叉滚子轴承结构和制作方法的改进发展，尚不能满足交叉滚子轴承技术发展的需要。本申请是进一步将其改进，并扩大到交叉滚子轴承及其加工方法领域。
交叉滚子轴承从结构上看，与2014100202253中的一般结构滚动轴承不同的是：套圈滚道呈“V”型，因能同时承受轴向、径向和角向联合载荷，在轴向、径向和角向都具有非常高的刚度而获得越来越广泛的应用，尤其是在运转刚度和精度要求比较高的主机及系统，比如精密机床转台、工业机器人的腰部、胯部、精密仪器仪表主轴等，相比其它类型的轴承，具有显著优势。
交叉滚子轴承套圈工作表面即滚道的几何形状不同于其它类型的轴承，套圈滚道呈“V”型。现有技术中，V型滚道的素线均为直线，不带任何凸度。套圈滚道的素线为直线的优点是形状简单，制作较容易，但也因此存在一些比较突出的技术和质量问题。由于交叉滚子轴承的滚道形状和与滚子的接触状态都十分特别，其滚道形状呈V型，当其中一个滚子的工作表面(对圆柱滚子为圆柱面，对圆锥滚子为圆锥面)与一个套圈的其中一侧滚道接触时，该滚子的非工作表面即端面刚好与该套圈的另一侧滚道相接触；而与该滚子相邻的滚子，情况恰恰相反。因此V型滚道中的任一侧滚道与一排滚子的外圆面相接触的同时，也与另外一排垂直交叉排列的滚子的端面相接触。换句话说，V型滚道的任一侧滚道，既为一排滚子的滚道又为另外一排滚子的挡边。由于滚子端面的加工精度远不及外圆表面，也不及V型滚道表面，又由于滚子的硬度高于滚道的硬度，因此，滚子端面与滚道的接触面积越大，相对较硬且粗糙的滚子端面对滚道面擦伤和划伤的风险就越大。当被擦划伤的滚道同另一排滚子的工作表面接触时，在比较高的接触应力作用下，首先影响轴承运转的灵活性、平稳性，同时，擦划伤也成为早期疲劳失效的根源，影响轴承运行的可靠度和寿命。
交叉滚子轴承往往使用在速度不高但载荷类型复杂、载荷值较大、各向精度要求极高的场合，如精密机床转台、工业机器人腰部和胯部等，高的各向运行精 度反过来要求轴承要具备很高径向刚度、轴向刚度、角向刚度或力矩刚度，为了提高轴承的刚度，交叉滚子轴承往往采用很小的游隙乃至负游隙，游隙很小加上交叉滚子轴承内部滚子很多，即滚子-滚道接触副个数很多(N个滚子就有4N个接触副)，因此带来启动和运转摩擦力矩的增大，力矩增大反过来引起轴承温度升高，温度升高必然导致轴承及主机的精度下降，这是一个客观存在的结构性矛盾，现行滚道不带凸度、同滚子直线接触的交叉滚子轴承，在运行精度和服役寿命方面存在上述不足。
在较重的负荷时，交叉滚子轴承V型滚道不带凸度会导致滚子与滚道接触时在接触区域的两端即滚道的端部出现压力奇异分布的边缘效应，以及会导致在滚道的中部出现压力集中的现象，由于轴承失效发生在接触区应力最大的接触部位，因此，轴承的承载能力下降严重，发生接触区局部早期疲劳失效的风险很大，而且使得滚子的抗歪斜能力很差，外部稍有偏心载荷，轴承就会存在旋转不灵乃至卡滞的风险。
现行交叉滚子轴承结构中，其中一个套圈采用整体剖分结构，即该套圈由两个各带一侧滚道的套圈通过连接螺钉紧固，由于两半套圈在热处理之前需要分别制作加工，不仅加工精度较差，加工效率也较低。
从制作工艺上看，现行技术交叉滚子轴承套圈滚道采用切入磨削方式成型，受砂轮精度不高和磨削散热条件很差的限制，加工后的套圈滚道不仅尺寸和形状精度不够高，而且存在磨削变质层乃至磨削烧伤，使得滚道的形状和性能变差，影响到轴承的运转精度、寿命和可靠度，另外，对滚道素线不是直线的带凸度V型滚道，切入磨削加工方法无能为力
发明内容
本发明的目的在于提供一种滚道带凸度的交叉滚子轴承，以克服现行技术的上述不足，滚道带凸度交叉滚子轴承，能够改善、避免滚子端面对滚道面的擦划伤，降低轴承运转温升，提高交叉滚子轴承的抗歪斜能力，避免滚道两端同滚子接触时应力奇异分布的边缘效应，进而显著提高轴承的运转性能和寿命。同时，提供一种局部剖分式套圈结构，使得交叉滚子轴承既能满足装填滚子和滚子隔离块的需要，又比现行的套圈整体剖分式结构具有更高的加工精度、装配精度和更低的加工成本。本发明的另一目的在于提供一种滚道带凸度的交叉滚子轴承的制作方法，包括滚子轴承套圈中的带凸度的V型滚道的加工方法，使交叉滚子轴承的质量、寿命和生产率提高。
本发明的技术方案如下：
1、本发明是一种滚道带凸度的交叉滚子轴承，包括交叉圆柱滚子轴承和交叉圆锥滚子轴承，其特征是，所述交叉滚子轴承包括具有环形内V形滚道的外圈、具有环形外V形滚道的内圈、嵌入外圈V型滚道和内圈V型滚道之间并交叉排 列的滚子或还包括滚子隔离块、润滑剂、密封件和连接螺钉，至少有一个套圈的V型滚道为带凸度V型滚道。
本发明申请中的带凸度V型滚道，不仅改善了滚子工作表面(滚子外圆面)同滚道的接触状态，而且改善了滚子非工作表面(滚子端面)同滚道的接触状态，减轻或避免滚子端面对滚道面的擦伤，提高了轴承的抗歪斜能力，降低了轴承的摩擦力矩和运转温升，避免了滚子-滚道接触端部应力奇异分布的边缘效应，从而显著提高了轴承的运转精度和运行可靠度，延长了轴承的服役寿命。
2、上述的带凸度V型滚道的凸型包括直素线型、全凸圆弧型、圆弧与直线相交型、圆弧与直线相切型、圆弧与圆弧相切型、多段圆弧修型或对数曲线凸型；所述的带凸度V型滚道的凸度量小于500微米。
带凸度V型滚道，指V型滚道的两侧滚道几何素线不再是一条直线，而是在滚子与滚道有效接触宽度(凸型部分，即不包括滚道与挡边之间的倒角和滚道与底部越程槽之间的倒角)的中部凸起，向两侧减小，以对数凸型为例，就是滚道支撑面的母线形状为由中部向两侧均为一条对称的对数曲线组成，对数曲线母线中部凸起，向两侧减小，对数曲线母线的两端与两倒角圆弧光滑连接。
交叉滚子轴承同圆柱滚子轴承在滚道宽度同滚子长度比值、滚道母线同挡边和越程槽(或称油沟)的夹角、滚子本身的长径比、运转速度、所受外部载荷类型、大小等方面差别迥异，其凸型设计和凸度量不能照搬圆柱滚子轴承，必须根据交叉滚子轴承的全部设计输入，通过计算机进行数值计算获得。两种轴承之间存在的具体区别如下表。
Figure PCTCN2016111107-appb-000001
Figure PCTCN2016111107-appb-000002
交叉滚子轴承滚道不带凸度时，滚子端面会擦伤滚道，原因在于，滚子端面会接触到滚道，而且滚子端面比滚道硬而粗糙；轴承运转温升高，原因在于，轴承内滚子-滚道摩擦副个数成倍增多，而且滚子端面会接触擦伤滚道；轴承抗歪斜能力低，原因在于，轴承内部游隙很小而且常常为负值，轴承内部摩擦副个数很多，而且每个摩擦副的接触状态都为线状，在倾覆力矩的作用下或当内圈与外圈出现不同心时，接触副两个物体相互之间的自调整、适应能力很差，极易导致轴承卡滞。当交叉滚子轴承滚道带凸度后，这些问题就会得到实质性的改善或彻底解决。
3、所述的一个带凸度V型滚道的套圈为轴承外圈。外圈滚道的摩擦损坏重于内圈。
4、还提供一种所述的内圈或外圈为局部剖分式的交叉滚子轴承结构，包括带有滚道缺口的套圈，由与缺口吻合的、包含V型滚道一侧部分滚道的滚道块堵补在缺口处，滚道块堵通过连接螺钉与带缺口的套圈沿套圈轴向紧固在一起，形成带V型滚道的套圈。
带块堵的套圈局部剖分式交叉滚子轴承，相对于套圈整体剖分式交叉滚子轴承，具有如下表所示的显著技术和质量优势。
Figure PCTCN2016111107-appb-000003
Figure PCTCN2016111107-appb-000004
5、本发明还提供一种交叉滚子轴承的制作方法，包括带凸度V型滚道套圈的最后加工(所述的“最后加工”指对该制品的最后机械加工步骤，之后即进行装配)，其特征是包括以下方法：
方法1)、套圈V型滚道用经金刚滚轮修正过的砂轮切入磨削成形，或
方法2)、预磨2个基准面的精密硬车，此方法能使加工效率提高。方法2)包括：
2A)、外圈V型滚道的精密硬车，步骤包括：预先对外圈的基准端面和外圆面磨削成形，通过固定在电磁吸盘上的极靴吸附基准端面，并借助极靴上的引导面引导外圆面以快速定中心，对至少包括外圈V型滚道在内的未磨削待精加工表面精密硬车成形；或
2B)、内圈V型滚道的精密硬车，步骤包括：预先对内圈的基准端面和内圆面磨削成形，通过固定在电磁吸盘上的极靴吸附基准端面，并借助极靴上的引导面引导内圆面以快速定中心，对至少包括内圈V型滚道在内的未磨削待精加工表面精密硬车成形；或
方法3)、预磨1个基准面的精密硬车，此方法能使各被加工面之间位置误差最小。方法3)包括：
3A)电磁吸附精密硬车，步骤包括：预先对套圈基准端面磨削成形，通过电磁吸盘直接吸附或固定在电磁吸盘上的极靴吸附该基准端面的同时调定中心，对外圈至少包括V型滚道和外圆面在内、内圈至少包括V型滚道和内圆面在内的未磨削待精加工表面精密硬车成形；
3B)立式精密硬车；步骤包括：立式硬车外径在300毫米以上的套圈，预先对套圈基准端面磨削成形，然后将套圈基准端面朝下水平放置，套圈中心轴线、 机床转台回转轴线和套圈支座中心轴线三线合一后，将套圈直接固定在机床转台上，或通过支座将套圈固定在转台上，然后对外圈至少包括V型滚道和外圆面在内、内圈至少包括V型滚道和内圆面在内的未磨削待精加工表面精密硬车成形。
6、上述的方法2)、3)中，是用数控方法将带凸度V型滚道进行精密硬车成形：当滚道凸型即素线仅由直线和圆弧组成时，采用ISO代码指令编程；当滚道素线包括非圆二次曲线，比如对数曲线时，采用用户宏程序功能编程。
7、精密硬车成形所用的刀具材料包括CBN、PCBN、金刚石、类金刚石、陶瓷和硬质合金，刀尖角不大于45度，精密硬车成形后的表面粗糙度值Ra小于等于1.6微米，精密硬车成形表面的形状和位置精度至少达P5级，精密硬车V型滚道的凸度量为小于500微米。
8、还提供一种带块堵的套圈的交叉滚子轴承的制作方法，其特征是，包括如下步骤：(1)制作带V型滚道的整体套圈车坯，车坯上设计加工有滚道块堵固定用螺孔，螺孔沿套圈轴向从套圈一侧端面通过V型滚道底部；(2)对整体套圈车坯进行淬火、回火热处理；(3)采用慢走丝线切割，走U形轨迹，割出包括固定螺孔在内、宽度不小于轴承所装滚子直径和隔离块宽度、高度等于端面到V型滚道底部距离、两侧切口厚度相等的滚道块堵，同时产生与滚道块堵相吻合的U型滚道缺口；(4)用连接螺钉将滚道块堵与带缺口的轴承套圈紧固，配对进行热处理后的磨削和精密硬车加工；(5)轴承合套装配时，松开连接螺钉，拿掉滚道块堵，从套圈缺口处填入全部滚子和隔离块；(6)放入滚道块堵，并用连接螺钉与套圈紧固，完成轴承套圈与滚动体的合套。
本发明是滚道带凸度的交叉滚子轴承及其制作方法，包括带凸度的交叉圆柱滚子轴承和带凸度的交叉圆锥滚子轴承，其特点是，套圈的滚道带有凸度，带凸度的滚道数控磨削成形或数控精密硬车成形。
滚道凸度涉及凸型和凸度量两个参数，尽管如前所述，滚道凸型分为多种，但从滚子-滚道接触应力沿滚道宽度分布尽可能均匀、更好地避免边缘效应的角度考虑，会优先选用图8E所示圆弧与圆弧相切的凸型和图8G所示变曲率的对数曲线凸型，凸度量则要根据具体的轴承参数和运行工况条件(比如润滑条件、转速、载荷类型和载荷大小等)，通过计算机进行数值计算获得。圆弧与圆弧相切的凸型，优点是在圆弧与圆弧的连接处因相切而平滑过渡，但圆弧仍然属于定曲率曲线，由于不同几何位置(点)的曲率一样，反使得各位置(点)的接触应力不同；对数曲线是变曲率二次曲线，随着几何位置(点)的变化，曲率相应变化，这样就能使得各位置(点)的接触应力相同，即等应力，这样方能对滚道和滚动体工作表面上各点的材料等强度利用，又由于对数曲线处处连续、光滑，因此，无论是从避免滚道擦伤的角度还是避免应力奇异分布(各点应力严重不等)的角度，对数曲线都是交叉滚子轴承滚道最理想的凸型。
在交叉滚子轴承的V型滚道带上凸度后，为进一步提高轴承的加工精度、装 配精度和工作精度，将现行交叉滚子轴承套圈整体剖分式结构创新为局部剖分结构，不仅简化了工艺流程，降低了加工成本，提高了加工精度，而且还提高了轴承的装配精度，避免了轴承运转过程中两半套圈微观错位的风险。
带凸度的V型滚道，如果凸度量不大、凸型也不复杂，可以采用切入磨削成形加工方法，但切入磨削工艺存在两个原理性技术局限：(1)对凸量较大或/和凸型复杂的V型滚道，磨削非常困难甚至是无能为力；(2)难以在一次装卡定位中将套圈的多个功能表面顺序加工出来，以保障各功能表面的相互位置精度；(3)存在磨削变质层乃至磨削烧伤等重要质量问题。采用精密硬车成形，如果有两个磨成基准面，对外圈是端面和外圆面，对内圈是端面和内圆面，可以采用机械装夹方式，但机械装夹时，外圈必需以外圆面和端面定位，内圈必需以内圆面和端面定位，因此，外圈在硬车滚道时就无法对外圈的外圆面进行硬车，内圈在加工滚道时，就无法对内圈的内圆面进行硬车，但外圈的外圆面和滚道面、内圈的内圆面和滚道面之间的相互位置精度至关重要，这个精度的高低直接、显著影响轴承的运行性能。再之，采用多瓣夹具夹紧外圈的外圆面或胀紧内圈的内圆面会使套圈发生径向变形(例如外圈外圆三瓣式阶梯夹头会使外圈发生三棱式变形)，影响到套圈的加工精度，对宽度比较窄、壁比较薄的交叉滚子轴承套圈，这个负面影响更加显著，因此，为了获得高的形状和位置精度，本发明提供套圈中的一个或二个表面作为基准面，以精密硬车成形工艺、并设计相应的加工夹具及辅具，保证工艺的实施。
对套圈端面，不管两端面是否对称相同，一般都会将两个端面全部磨削出来，当两端面对称相同或基本对称相同时，采用双端面磨床将两个端面同时磨出，两个端面不做区别，任一端面都可以作为后工序的定位基准面；当两端面差异较大时，采用单端面磨床，磨完一个端面后再磨另一个端面，约定其中一个端面作为后工序的定位基准面。端面(即便是两个端面相同，可以不做区分)只算为一个基准面，因此上文“预磨两个基准面”中，两个基准面不会是指套圈的两个端面，而是指端面加上另外一个(不是套圈端面，对外圈是外圆表面；对内圈是内圆表面)基准面，预磨基准面指将所磨表面磨至最终尺寸。另外，对不是预磨成基准面的待精车加工表面，为了减少硬车加工余量、提高精密硬车效率，在精车成形加工前，也可以对这些表面进行粗磨。
为提高加工精度，精密硬车需要采用数控设备，对一次曲线和圆弧二次曲线，采用ISO指令编程精度足以满足要求，但当凸型为非圆二次曲线，比如对数曲线时，采用ISO指令、多段圆弧逼近的编程方式满足不了高精度要求，需要采用其它高精度编程方式。
本发明方案具有以下优势，(1)滚道凸度改善滚子与滚道之间的摩擦，减少发热，提高轴承的质量、寿命。(2)滚道凸度根据轴承工作时实际承受载荷类型和大小进行面向工况的针对性设计，从根本上提高了轴承的运行可靠度和实际工 况条件下的服役寿命；(3)凸度值根据工况条件进行计算，然后进行加工，非常灵活，准确；(4)同时改善了滚子外圆面和两端面同V型滚道的接触状态，显著降低了轴承启动和运转摩擦力矩以及轴承温升，同样避免了滚子端面对滚道的擦伤、温升，所有这些，对保障轴承的运行精度、运转平稳性、精度寿命和避免轴承早期失效具有十分重要的意义；(5)彻底消除了滚子-滚道接触时存在的应力边缘效应，提高了轴承的承载能力和抗歪斜能力，大大延长了轴承的疲劳寿命。
综上所述，本申请产品能提高交叉滚子轴承的性能、寿命，其制作方法能提高交叉滚子轴承的质量、生产效率。
附图说明
图1为带凸度交叉圆柱滚子轴承剖切示意图。
图2A为图1所示轴承外圈右视图。
图2B为图1所示轴承外圈剖切示意图。
图3为图1所示轴承内圈剖切示意图。
图4为内圈局部剖分带凸度交叉圆锥滚子轴承剖切示意图。
图5为图4所示轴承外圈剖切示意图。
图6A为图4所示轴承内圈剖切示意图。
图6B为图4所示轴承内圈左视图。
图6C为图4所示为内圈滚道块堵制作中，用线切割加工U型轨迹示意图。
图7A交叉滚子轴承套圈中，不带凸度的直滚道剖切局部放大示意图。
图7B为交叉滚子轴承套圈(除去交叉圆锥滚子轴承内圈)，不带凸度的直滚道剖切局部放大几何关系图。
图7C为交叉圆锥滚子轴承内圈中，不带凸度的直滚道剖切局部放大图。
图8A为直素线凸型滚道剖切局部放大示意图。
图8B为全凸圆弧形滚道剖切局部放大示意图。
图8C为圆弧与直线相交凸型滚道剖切局部放大示意图。
图8D为圆弧与直线相切凸型滚道剖切局部放大示意图。
图8E为圆弧与圆弧相切凸型滚道剖切局部放大示意图。
图8F为多段圆弧相交凸型滚道剖切局部放大示意图。
图8G为对数曲线凸型滚道剖切局部放大示意图。
图9为电磁吸盘直接吸附外圈基准端面，精密硬车示意图。
图10为电磁吸盘通过极靴吸附内圈基准端面，精密硬车示意图。
图11为立式精密硬车加工内圈多表面示意图。
图12为带外圈外圆引导面的极靴与外圈定位关系示意图。
图13为带内圈内圆引导面的极靴示意图。
图14为图13中极靴与内圈定位关系示意图。
具体实施方式
以下结合附图，详细说明本发明。
图1为外圈整体剖分带凸度交叉圆柱滚子轴承剖视图，包括外圈为两半结构，半外圈111和另一半外圈112通过连接螺钉113紧固，内圈12为滚道带凸度交叉圆柱滚子轴承内圈，13为圆柱滚子，两排圆柱滚子呈90度逐个交替交叉放置在内圈12和外圈11之间的带凸形的V形槽中，从图中滚子回转中心线区分一排滚子和另外一排滚子，两排滚子的尺寸和精度完全相同。
图2A为图1所示外圈为整体剖分的、带凸度交叉圆柱滚子轴承外圈12的右侧视图，图中可以看出采用了三颗连接螺钉将两半外圈111、112固连为一个整体。
图2B为图1所示轴承外圈的剖切示意图，可以看出，V型滚道靠近基准端面的一侧滚道，同基准端面之间的夹角为45度，两侧滚道之间的夹角为90度。当滚道带有凸度、在有效宽度范围内不再为一条直线时，在凸度曲线的起点和终点之间连线，两侧滚道各得到一条直线，对靠近基准端面一侧的滚道，该连线同基准端面之间的夹角同样为45度，两条连线之间的夹角同样为90度，此处所述带凸度滚道相关两个角度设计、加工、度量的原则同样适用于带凸度交叉圆柱滚子轴承的内圈、带凸度交叉圆锥滚子轴承的外圈和内圈，后面就不再一一重述。滚道同挡边、滚道同越程槽在套圈实体内侧均构成钝角。
图3为图1中轴承内圈剖切示意图。
图4为带凸度交叉圆锥滚子轴承剖视图，21为滚道带凸度交叉圆锥滚子轴承外圈，22为滚道带凸度交叉圆锥滚子轴承内圈，23为圆锥滚子，两排圆锥滚子呈90度逐个交替交叉放置，图4所示交叉圆锥滚子轴承外圈21和内圈22是内圈局部剖分结构。
图5为图4中滚道带凸度的交叉圆锥滚子轴承的外圈剖切示意图，该外圈为整体外圈。
图6A为图4内圈局部剖分带凸度交叉圆锥滚子轴承的内圈剖切示意图。
图6B为图4所示内圈局部剖分带凸度交叉圆锥滚子轴承内圈侧视图。
图6C为图6B的A向视图。
图7A为交叉滚子轴承套圈不带凸度的直滚道剖切局部放大示意图。为清晰看图将任一滚道截面放大，并把滚道素线置于水平位置。从图7A到图7C，图8A到图8G都是这样做的。图7A中，滚道素线AB为一条直线，AC为挡边局部，BD为越程槽局部，滚道同挡边的交点为A，同越程槽的交点为B，滚道不带凸度。
图7B为交叉滚子轴承套圈(除去交叉圆锥滚子轴承内圈)不带凸度的直滚道剖切局部放大几何关系图。图中滚道素线AB为一条直线，AC为挡边局部，BD为越程槽局部，AB与AC在轴承实体外侧的夹角、AB与BD在轴承实体外侧的夹角均为45度。
图7C为交叉圆锥滚子轴承内圈不带凸度的直滚道剖切局部放大几何关系图。图中滚道素线AB为一条直线，AC为挡边局部，BD为越程槽局部。AB与AC在轴承实体外侧的夹角为45度减去轴承所装圆锥滚子的圆锥角(2β)、AB与BD在轴承实体外侧的夹角为45度加上轴承所装圆锥滚子的圆锥角(2β)。
图8A为直素线凸型滚道剖切局部放大示意图。图中，对称分布在滚道中垂线两侧A、B两点之间的连线AB为直线，凸度圆弧的半径为R，倒角圆弧的半径为r，左侧凸度圆弧与滚道直线段的交点为A、与倒角圆弧的交点为C，倒角圆弧与滚道挡边的交点为E，EG为挡边局部；右侧凸度圆弧与直线滚道的交点为B、与倒角圆弧的交点为D，倒角圆弧与越程槽的交点为F，FH为越程槽局部。从滚道最高点度量到C点或D点的距离为滚道凸度量Td。
图8B为全凸圆弧形滚道剖切局部放大示意图，图中，凸度圆弧半径为Rc，凸度圆弧同挡边的交点为A，同越程槽的交点为B，AC为挡边局部，BD为越程槽局部。从滚道最高点度量到A点或B点的距离为滚道凸度量Td。
图8C为圆弧与直线相交凸型滚道剖切局部放大示意图，图中，凸度圆弧半径为Rc，凸度圆弧与挡边之间由直线段AC相连，与越程槽之间由直线段BD相连，凸度圆弧与AC、BD均相交，EC为挡边局部，DF为越程槽局部。从滚道最高点度量到A点或B点的距离为滚道凸度量Td。
图8D为圆弧与直线相切凸型滚道剖切局部放大示意图，图中，凸度圆弧半径为Rc，凸度圆弧与挡边之间由直线段AC相连，与越程槽之间由直线段BD相连，凸度圆弧与AC、BD均相切，EC为挡边局部，DF为越程槽局部。从滚道最高点度量到A点或B点的距离为滚道凸度量Td。
图8E为圆弧与圆弧相切凸型滚道剖切局部放大示意图，图中，凸度圆弧半径为Rc，凸度圆弧与挡边之间由半径为R的圆弧段AC相连，与越程槽之间由半径为R的圆弧段BD相连，凸度圆弧与AC圆弧、BD圆弧均相切，EC为挡边局部，DF为越程槽局部。从滚道最高点度量到A点或B点的距离为滚道凸度量Td。
图8F多段圆弧相交(图示出了5段)凸型滚道剖切局部放大示意图，图中，五段圆弧的半径分别为Rc1、Rc2、Rc3、Rc4、Rc5，五段圆弧组成曲线AB，凸度圆弧与挡边之间的倒角圆弧为AC，半径为r，凸度圆弧与越程槽之间的倒角圆弧为BD，半径为r，EC为挡边局部，DF为越程槽局部。从滚道最高点度量到A点或B点的距离为滚道凸度量Td。
图8G对数曲线凸型滚道剖切局部放大示意图，图中，AB段为对数曲线，对数曲线的最高点在滚道有效宽度的中垂线上，向两侧缓慢降低，对数曲线同挡边之间的倒角圆弧为AC，半径为r，同越程槽之间的倒角圆弧为BD，半径为r，EC为挡边局部，DF为越程槽局部。从滚道最高点度量到A点或B点的距离为滚道凸度量Td。
图9为直接装在电磁夹具上的外圈加工图。
图10为通过极靴装在电磁夹具上的内圈加工图。
图11为立车加工图。
图12为装在电磁夹具极靴(带外圆引导面)上的外圈加工图。
图13为带内圈内圆引导面极靴的电磁夹具图。
图14为装在图13所示极靴上的内圈加工图。
实施例1、如图1所示为交叉滚子轴承示意图，为外圈整体剖分带凸度交叉圆柱滚子轴承，包括具有环形内V形滚道的外圈11、具有环形外V形滚道的内圈12、嵌入外圈V型滚道和内圈V型滚道之间并交叉排列的圆柱滚子13，外圈11设计为两半结构，包括两半套圈111和112，两半套圈通过若干连接螺钉113连接紧固为整体外圈。从图2B和图3可以看出，内圈和外圈V型滚道靠近各自基准端面一侧的滚道和各自基准端面之间的夹角为45度，两侧滚道之间的夹角为90度，V型滚道夹在套圈挡边和滚道底部的越程槽之间。
一般或较轻负荷的交叉滚子轴承，可在图2B和图5所示外圈的V型滚道上设置如图8A或8E所示的凸起(因外圈的滚道几何形状为内圆锥表面，与滚子端面接触时摩擦接触面较大，较之内圈滚道更易于受损)，以减少滚子端面对滚道面的擦伤、降低轴承温升、提高轴承的运转精度寿命和疲劳寿命。
重载工况下的交叉滚子轴承，为了避免滚子对滚道面的擦伤、降低轴承温升、提高轴承的抗歪斜能力、避免重载工况下应力奇异分布(即接触端部的应力集中)现象，从而提高轴承的运转性能和运行可靠度，在内圈和外圈滚道均带如图8E所示的凸度，凸度由三段圆弧相切组成，中间圆弧半径为Rc，圆弧中心位于滚道宽度的中垂线上，两侧圆弧半径均为R，半径为Rc的圆弧与半径为R的两个圆弧分别相切于A、B两点，靠近挡边的半径为R的圆弧与挡边相切于C点，靠近越程槽的半径为R的圆弧与越程槽相切于D点，EC为挡边局部，DF为越程槽局部。从滚道最高点度量到A点或B点的距离为滚道凸度量Td，范围在0.1微米至500微米。参量Rc、R和Td在轴承安装和服役条件(比如运行速度、载荷类型和大小等)已知，轴承除了凸度以外的设计参数(材料参数、几何参数等)得以确定后，由计算机进行数值计算给出。
由于凸度由三段圆弧相切组成，因此，相比直线与直线相交、圆弧与直线相交的凸型具有过渡平顺、光滑的优势。但圆弧为定曲率二次曲线，在整个滚道的不同位置点处的曲率半径只有两个值，滚道中部为Rc，滚道两端部为R，不同位置点处的曲率半径相等，反过来会导致各点的接触应力不等，但会比无凸度滚道的应力奇异分布现象(载荷越重这种现象越显著)有显著改善，由于三段圆弧相切凸型编程、加工简单，因此，该凸型仍然有非常好的实际应用价值。
实施例2、内圈局部剖分带凸度交叉圆锥滚子轴承-对数曲线凸型
内圈局部剖分带凸度交叉圆锥滚子轴承如图4所示，包括外圈21、内圈22、嵌入外圈V型滚道和内圈V型滚道之间并交叉排列的圆锥滚子23，一排圆锥滚 子的锥顶和另一排圆锥滚子的锥顶分别落在轴承回转中心线上轴承两侧的两点。外圈21如图5所示，为整体结构，内圈22如图4、图6A、6B和6C所示，为往轴承内填入足够数量的圆锥滚子23，内圈22设计为带滚道块堵的局部剖分结构，内圈22由带缺口的内圈221、块堵222和将块堵222固连到带缺口内圈221之上的连接螺钉223，在内圈径向方向，缺口从内圈挡边到内圆表面开通；在内圈轴向方向，缺口从端面开到V型滚道中部；在内圈圆周方向，缺口宽度大于轴承所装滚子直径和所装隔离块的宽度(图示轴承不带隔离块，即为满装交叉滚子轴承)，以保证轴承合套装配时，滚子和隔离块能从缺口处顺利填入内圈V型滚道和外圈V型滚道之间，块堵222同带缺口内圈221上的缺口尺寸吻合，因此，采用连接螺钉223，刚好将块堵222封堵固连在带缺口内圈221上，形成完整的内圈22。从图5可以看出，外圈V型滚道靠近基准端面一侧的滚道同基准端面夹角为45度，两侧滚道之间的夹角为90度，图6A可以看出，内圈靠近基准端面一侧的滚道同基准端面之间的夹角为45度加上轴承所装圆锥滚子的圆锥角2β，两侧滚道之间的夹角为90度加上4β，V型滚道夹在套圈挡边和滚道底部的越程槽之间。内圈和外圈滚道均带图8G所示的凸度，凸型为对数曲线，对数曲线AB的最高点在滚道宽度的中分线上，从此点向两侧逐渐降低，EC直线为挡边局部，其与对数曲线AB由半径为r的圆弧倒角连接，FD直线为越程槽局部，其与对数曲线AB同样由半径为r的圆弧倒角连接，对数曲线的最高点到A点或B点之间的距离Td为对数曲线或滚道的凸度量，范围在0.1微米至500微米。对数曲线方程中的系数项、常数项、凸度值Td在轴承安装和服役条件(比如运行速度、载荷类型和大小等)已知，轴承除了凸度以外的设计参数(材料参数、几何参数等)得以确定后，由计算机进行数值计算给出。
对数曲线为变曲率二次曲线，即对数凸型滚道上各点的曲率随着位置的变化而变化，因此使得，在与滚子工作表面接触时，各点的接触应力相等或基本相等，同时又因为对数曲线各点处处光滑连续，因此可以说，对数曲线凸型滚道无论从避免滚道擦伤、减小温升还是从避免接触应力奇异分布现象的角度来看，都是最为理想的凸型滚道。当然，对数曲线凸型滚道的精密加工，需要采用数控机床，采用用户宏程序编程。用户宏程序编程，可以使用变量，并给变量赋值，常量之间可以运算，程序运行时可以跳转，大大提高了编程的灵活性和非圆二次曲线的加工精度。
实施例3、内圈局部剖分带凸度交叉圆锥滚子轴承结构、加工及装配
局部剖分交叉滚子轴承，只需局部剖分其中一个套圈，内圈或外圈，图4给出内圈局部剖分带凸度交叉圆锥滚子轴承的装配图，图5是其中的外圈21的剖视图，可以看出外圈21为整体结构，图6A是其中的内圈22剖视图，图6B是其中的内圈22左侧视图，图6C是图6B中的A向视图，可以看出内圈22为局部剖分结构，由带缺口的内圈221、滚道块堵222和连接螺钉223组成，其中连接螺 钉223将块堵222固定在带缺口的内圈221上，块堵和缺口相吻合。局部剖分结构内圈22的制造方法如下：(1)制作带V型滚道的整体内圈车坯，车坯上设计加工有滚道块堵固定用螺孔，螺孔沿套圈轴向从套圈一侧端面通过V型滚道底部并向前延伸一段距离，套圈总宽为B；(2)对整体内圈车坯进行淬火、回火热处理；(3)采用慢走丝线切割，走U形轨迹(如图6C所示)，割出包括固定螺孔在内、宽度W不小于轴承所装滚子直径和隔离块宽度、高度H等于端面到V型滚道底部距离、两侧切口厚度T相等的滚道块堵222，同时产生与滚道块堵相吻合的U型滚道缺口；(4)用连接螺钉223将滚道块堵222与带缺口的轴承内圈221紧固，配对进行热处理后的磨削和精密硬车加工；(5)轴承合套装配时，松开连接螺钉223，拿掉滚道块堵222，从带缺口的轴承内圈221处将全部滚子23和隔离块填入外圈21的V型滚道和内圈22的V型滚道之间；(6)放回滚道块堵222，并用连接螺钉223与带缺口内圈221紧固，完成轴承套圈与滚动体的合套。在轴承整个加工和装配过程中，块堵从哪个套圈上割下来的，在加工和装配过程中始终跟着这个套圈配对，进行加工和装配，不宜混淆。
实施例4带凸度外圈的切入磨削成形加工方法
如图2A和图2B所示，外圈11带凸度V型滚道的切入磨削方法与现行不带凸度V型滚道的切入磨削工艺方法原理相同，包括在磨削滚道前，先磨削外圈两个端面和外圆表面，然后采用电磁无心夹具吸附外圈基准端面，支撑外圆面磨削滚道，所不同的是，砂轮工作面要带与滚道凸度恰恰相反的凹度进行磨削，为保证砂轮工作表面的形状，就要采用带与滚道凸度一样的金刚滚轮对砂轮进行修整，为此要定制金刚滚轮。当外圈由两半组成时，两半外圈要在连接螺钉紧固状态下配对进行磨削加工。
带凸度圆柱滚子轴承内圈如图3所示，内圈带凸度V型滚道的切入磨削方法同现行不带凸度V型滚道的切入磨削工艺方法原理相同，包括在磨削滚道前，先磨削内圈两个端面和内圈内圆表面，然后采用电磁无心夹具，吸附内圈基准端面，支撑内圈滚道面磨削内圈滚道(支滚道磨滚道工艺方法)，所不同的是，砂轮工作面要带与滚道凸度恰恰相反的凹度进行磨削，为保证砂轮工作表面的形状，就要采用带与滚道凸度一样的金刚滚轮对砂轮进行修整，为此要定制金刚滚轮。
当内圈为局部剖分结构时，滚道块堵要在与带对应缺口的内圈用连接螺钉紧固状态下配对进行精密硬车加工。
实施例5(采用制作方法中的3A方法)电磁吸附精密硬车套圈
多表面复合精密硬车成形，将带V型滚道的套圈在一次装夹定位中顺序精密硬车成形。在精密硬车成形加工前，套圈只有一个精磨端面作为基准面。如图10所示为内圈的硬车成形，电磁吸盘上带有若干T型槽，用连接螺钉将极靴同心固定在电磁吸盘上，工件基准面被极靴端面同心吸牢。为保证刀具在加工时与极靴不会发生干涉，极靴端部的外径小于套圈基准面的外径，极靴端部的内径大于套 圈基准面的内径。在一次装夹定位中，依次完成对挡边、V型滚道、另一端面和内圆表面的精密硬车加工。由于内圈滚道带有凸度，需采用数控精密硬车，在滚道凸型和凸度值已知即滚道素线方程已知的情况下，当滚道素线仅由直线和圆弧组成时，采用ISO代码指令编程；当滚道素线包括非圆二次曲线，比如对数曲线时，采用用户宏程序功能编程。精密硬车采用CBN或PCBN刀片，加工后的表面粗糙度值Ra小于等于1.6微米，表面的形状和位置精度至少达到P5级。精密硬车滚道的凸度量可以从0至500微米。当内圈为局部剖分结构时，滚道块堵要在与带对应缺口的内圈用连接螺钉紧固状态下配对进行精密硬车加工。
实施例6、(采用制作方法中的3A方法)如图9所示为外圈的精密硬车成形加工，步骤与实施例5的内圈硬车加工类似，只不过不带极靴，在精密硬车外圆或挡边时，若使刀具不与电磁吸盘发生干涉，这两个表面与基准端面之间的倒角尺寸不能太小。
实施例7、(采用制作方法中的3B方法)立式精密硬车；带凸度交叉滚子轴承内圈立式精密硬车成形加工方法-多表面复合精密硬车
如图11，当套圈外径超过300毫米，尤其是超过350毫米时，工件尺寸已经超出绝大部分卧式车床的加工范围，则采用立式精密硬车成形工艺方法，立式车床给工件安装提供了一个水平转台(转台绕竖直的中心轴线旋转)，如欲在一次装夹定位中加工多个重要功能表面，就不能直接将套圈放置或固定在转台上。如图11所示，机床转台上带有若干T型槽，采用套圈支座支撑套圈(图示为内圈)，套圈支座通过支座固定螺栓固定在转台上，套圈支座带有螺孔，套圈在放置在套圈支座上后，施力螺钉通过套圈上的安装孔或工艺孔(交叉滚子轴承外圈和内圈上往往已经有若干个安装用螺孔或通孔，如果没有的话，也可以加工3个或更多的工艺孔)将套圈固定在套圈支座上，与转台一起同心旋转。
套圈支座与套圈基准端面相接触的端部，其外径略小于套圈基准端面侧的外径，内径略大于基准端面侧的内径，以免加工时刀具与支座发生干涉。如图11，内圈只有一个磨成基准面时，采用这样的内圈装夹固定方法，能在一次装夹定位中，完成对内圈包括V型滚道和内圆表面在内的多个功能表面的复合精密硬车成形。按上述的加工方法编程，在一次装夹定位中，依次完成对挡边、V型滚道和内圆表面的精密硬车加工。
由于内圈滚道带有凸度，需采用数控精密硬车，在滚道凸型和凸度值已知即滚道素线方程已知的情况下，当滚道素线仅由直线和圆弧组成时，采用ISO代码指令编程；当滚道素线包括非圆二次曲线，比如对数曲线时，采用用户宏程序功能编程。精密硬车采用CBN或PCBN刀片，加工后的表面粗糙度值Ra小于等于1.6微米，表面的形状和位置精度至少达到P5级。精密硬车滚道的凸度量可以从0至500微米。当内圈为局部剖分结构时，滚道块堵要在与带对应缺口的内圈用连接螺钉紧固状态下配对进行精密硬车加工。外圈加工与内圈类似，外圈装夹固 定后，即可精密硬车加工该外圈的V型滚道和外圆表面以及其它需要加工部位。
实施例8、如图12，外圈V型滚道的硬车(采用制作方法中的2A方法)，为两个磨成基准面外圈V型滚道精密硬车成形，采用带引导面的整体极靴时极靴的设计及外圈快速精准装夹方法。
当外圈有两个磨成基准面，即一个外圈端面和外圆面时，采用电磁夹具，仍然以外圆端面为基准面，使用极靴，极靴吸附的是外圈的基准端面，在极靴的进入口上设计外圆引导面，可以对外圈起到快速、准确的与电磁吸盘的同心定位作用，不仅大幅度节省加工辅助时间，而且提高了硬车成形表面与其它非硬车成形表面之间的相互位置精度。整体极靴通过固定螺钉固定在电磁吸盘上，整体极靴上带有台阶孔，台阶孔口径尺寸与外圈的外圆表面之间形成小间隙或过渡配合，在安放外圈时，该孔起到引导作用，以利于外圈在极靴上的快速、精确同心定位，台阶孔内台阶面吸牢外圈基准端面。套圈在极靴上定位后进行加工，完成至少用硬车加工带有凸度的滚道和滚道挡边。由于滚道带有凸度，需采用数控精密硬车，在滚道凸型和凸度值已知即滚道素线方程已知的情况下，当滚道素线仅由直线和圆弧组成时，采用ISO代码指令编程；当滚道素线包括非圆二次曲线，比如对数曲线时，采用用户宏程序功能编程。精密硬车采用CBN或PCBN刀片，刀尖角不大于45度，加工后的表面粗糙度值Ra小于等于1.6微米，表面的形状和位置精度至少达到P5级。精密硬车滚道的凸度量可以从0至500微米。当外圈由两半外圈组成时，两半外圈要在连接螺钉紧固状态下配对进行精密硬车加工。
整体极靴由于其径向方向的定位尺寸固定不可调整，因此，一般是一个尺寸规格的套圈对应一个极靴，极靴与电磁吸盘和套圈的同心调整比较快捷，适于批量生产。
整体极靴也可以用多瓣式极靴来替代。
实施例9、内圈V型滚道的精密硬车(采用制作方法中的2B方法加工内圈)，如图14，两个磨成基准面内圈V型滚道精密硬车成形采用带引导面的多瓣极靴时的设计及内圈快速精准装夹方法
当内圈有两个磨成基准面，即一个内圈端面和内圆面，采用电磁夹具，仍然以内圈端面为基准面，如图13为夹具极靴示意图，极靴吸附的是内圈的基准面，在极靴上设计内圆引导面，能对内圈起到快速、准确的定位作用，不仅大幅度节省加工时的辅助时间，而且提高了硬车成形表面与其它非硬车成形表面之间的相互位置精度。如图13所示为多瓣极靴(图示为6瓣)的示意图，极靴瓣通过固定螺钉固定在电磁吸盘上，极靴头部外圆部分呈台阶状，头部柱面的外圆直径与内圈基准面即内圆面形成小间隙或过渡配合，在安放内圈时，由于头部柱面直径较之内圆面直径略小，作为引导面，起到引导作用，以利于内圈在极靴上的快速、精确同心定位，台阶底部吸附内圈基准面。在内圈同心被极靴吸牢后，在一次装夹定位中，能依次完成除内圈基准面外的其它部位，至少包括对V型滚道和内圈 外表面的精密硬车加工。
由于内圈滚道带有凸度，需采用数控精密硬车，在滚道凸型和凸度值已知即滚道素线方程已知的情况下，当滚道素线仅由直线和圆弧组成时，采用ISO代码指令编程；当滚道素线包括非圆二次曲线，比如对数曲线时，采用用户宏程序功能编程。精密硬车采用CBN或PCBN刀片，加工后的表面粗糙度值Ra小于等于1.6微米，表面的形状和位置精度至少达到P5级。精密硬车滚道的凸度量可以从0至500微米。
以上所述交叉滚子轴承，没有特指时，均包括交叉圆柱滚子轴承和交叉圆锥滚子轴承；所述套圈，没有特指时，均包括内圈和外圈；整体剖分和局部剖分都只需剖分一个套圈，可以是内圈，也可以是外圈。举例的加工方法，举例内圈的对外圈加工具有同样的借鉴意义，举例外圈的，对内圈加工具有同样的借鉴意义。
以上公开的仅为本申请的几个具体实施例，但本申请并非局限于此，任何本领域的技术人员能思之的变化，都应落在本申请的保护范围内。

Claims (8)

  1. 一种滚道带凸度的交叉滚子轴承，包括交叉圆柱滚子轴承和交叉圆锥滚子轴承，其特征是，所述交叉滚子轴承包括具有环形内V形滚道的外圈、具有环形外V形滚道的内圈、嵌入外圈V型滚道和内圈V型滚道之间并交叉排列的滚子或还包括滚子隔离块、润滑剂、密封件和连接螺钉，至少有一个套圈的V型滚道为带凸度V型滚道。
  2. 如权利要求1所述的交叉滚子轴承，其特征是，所述的带凸度V型滚道的凸型包括直素线型、全凸圆弧型、圆弧与直线相交型、圆弧与直线相切型、圆弧与圆弧相切型、多段圆弧修型或对数曲线凸型；所述的带凸度V型滚道的凸度量小于500微米。
  3. 如权利要求2所述的交叉滚子轴承，其特征是，所述的一个带凸度V型滚道的套圈为外圈。
  4. 如权利要求2所述的交叉滚子轴承，其特征是，所述的内圈或外圈为局部剖分式结构，包括带有滚道缺口的套圈，由与缺口吻合的、包含V型滚道一侧部分滚道的滚道块堵补在缺口处，滚道块堵通过连接螺钉与带缺口的套圈沿套圈轴向紧固在一起，形成带V型滚道的套圈。
  5. 根据权利要求1-4中任一所述的交叉滚子轴承的制作方法，包括带凸度V型滚道套圈的最后加工过程，其特征是包括以下方法：
    方法1)、套圈V型滚道用经金刚滚轮修正过的砂轮切入磨削成形，或
    方法2)、预磨2个基准面的精密硬车，包括：
    2A)、外圈V型滚道的精密硬车，步骤包括：预先对外圈的基准端面和外圆面磨削成形，通过固定在电磁吸盘上的极靴吸附基准端面，并借助极靴上的引导面引导外圆面以快速定中心，对至少包括外圈V型滚道在内的待精加工表面精密硬车成形；或
    2B)、内圈V型滚道的精密硬车，步骤包括：预先对内圈的基准端面和内圆面磨削成形，通过固定在电磁吸盘上的极靴吸附基准端面，并借助极靴上的引导面引导内圆面以快速定中心，对至少包括内圈V型滚道在内的待精加工表面精密硬车成形；或
    方法3)、预磨1个基准面的精密硬车，包括：
    3A)电磁吸附精密硬车，步骤包括：预先对套圈基准端面磨削成形，通过电磁吸盘直接吸附或由固定在电磁吸盘上的极靴吸附该基准端面的同时调定中心，对外圈至少包括V型滚道和外圆面在内、内圈至少包括V型滚道和内圆面在内的待精加工表面精密硬车成形；
    3B)立式精密硬车；步骤包括：立式硬车外径在300毫米以上的套圈，预先对套圈基准端面磨削成形，然后将套圈基准端面朝下水平放置，套圈中心轴线、机床转台回转轴线和套圈支座中心轴线三线合一后，将套圈直接固定在机床转台上，或通过支座将套圈固定在转台上，然后对外 圈至少包括V型滚道和外圆面在内、内圈至少包括V型滚道和内圆面在内的待精加工表面精密硬车成形。
  6. 如权利要求5所述的交叉滚子轴承的制作方法，其特征是，所述的方法2)、3)中，是用数控方法将带凸度V型滚道进行精密硬车成形：当滚道凸型即素线仅由直线和圆弧组成时，采用ISO代码指令编程；当滚道素线包括非圆二次曲线，比如对数曲线时，采用用户宏程序功能编程。
  7. 如权利要求6所述的交叉滚子轴承的制作方法，其特征是，精密硬车成形所用的刀具材料包括CBN、PCBN、金刚石、类金刚石、陶瓷和硬质合金，刀尖角不大于45度，精密硬车成形后的表面粗糙度值Ra小于等于1.6微米，精密硬车成形表面的形状和位置精度至少达P5级，精密硬车V型滚道的凸度量为小于500微米。
  8. 如权利要求4所述交叉滚子轴承的制作方法，其特征是，包括如下步骤：(1)制作带V型滚道的整体套圈车坯，车坯上设计加工有滚道块堵固定用螺孔，螺孔沿套圈轴向从套圈一侧端面通过V型滚道底部；(2)对整体套圈车坯进行淬火、回火热处理；(3)采用慢走丝线切割，走U形轨迹，割出包括固定螺孔在内、宽度不小于轴承所装滚子直径和隔离块宽度、高度等于端面到V型滚道底部距离、两侧切口厚度相等的滚道块堵，同时产生与滚道块堵相吻合的U型滚道缺口；(4)用连接螺钉将滚道块堵与带缺口的轴承套圈紧固，配对进行热处理后的磨削和精密硬车加工；(5)轴承合套装配时，松开连接螺钉，拿掉滚道块堵，从套圈缺口处填入全部滚子和隔离块；(6)放入滚道块堵，并用连接螺钉与套圈紧固，完成轴承套圈与滚动体的合套。
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