改善汽车变速器壳体端面波纹度的优化路径分析

为解决某汽车变速器壳体端面在实际加工过程中存在的波纹度问题,通过采用加速度传感器与PCI采集卡在LabVIEW数据采集程序设计平台下进行现场数据采集,实现该变速器壳体端面的振动参数测量;随后借助有限元模态分析以及谐响应分析得出激励响应频谱图,进而指导优化改进装夹定位模式,来改变该汽车变速器壳体端面的加工振动特性,使其固有频率偏离加工激励频率以达到减小加工振动的目的;再次理论测试分析发现该汽车变速器壳体的一阶模态固有频率从212Hz提升到了226 Hz,有效避开了铣削加工的激励频率,同时在加工频率210 Hz处的变形量只有0. 131 mm,相对于原装夹定位模式(1. 13 mm)下降了一个数量级,说明在新定位模式下的加工振动情况有了较大幅度改善;最后通过现场加工诊断测试,结果表明重新装夹后振动信号强度明显减弱,加工表面无显著振纹。可见研究成果可以保证机加工环境下该汽车变速器壳体端面的表面质量与加工性能,为进一步研究该铣削结构系统的振动特性和后期振动故障诊断及动态特性提供依据。

Optimal Path Analysis for Improving the Waviness of the End Surface of the Automobile Transmission Housing

In response to the waviness phenomenon of the end surface of the transmission housing, LabVIEW platform was firstly adopted to complete the parameter measurement in the end surface of the automobile transmission housing with the help of acceleration sensors and PCI acquisition card, secondly, the excitation response analysis in the processing vibration frequency range is implemented by the modal analysis and harmonic response analysis, the vibration distribution of the transmission housing is obtained, in the end, combined with the actual processing conditions, the clamping positioning mode of the transmission housing is optimized to improve the vibration characteristics of the transmission housing in machining process, and to make the natural frequency offset the vibration frequency, so as to reduce the vibration of the machine. The test results show that the machining vibration of the transmission housing is greatly reduced in the new positioning method, and the surface quality and the machining performance of the transmission housing are ensured. Therefore, this study proposes a more practical optimization method for the structural optimization analysis of the parts prone to vibration, through the combination of the experimental test and finite element simulation technology, which provides a basis for further research on vibration characteristics, vibration fault diagnosis and dynamic characteristics of the milling structure system.