Abstract
The surface machining precision of parts is closely related to the contact performance between the mating surfaces of the assembly, and it will create a waste of resources to ensure the system performance by excessively improving the machining accuracy of parts. In order to ensure the high performance of the system on the basis of low cost and low manufacturing precision, this study proposes a method to achieve the goal by adjusting the surface topography parameters in the design phase. First, the surface topography information of the measured parts was characterized by different parameters to realize the parametric expression of the surface topography; second, the mechanical properties of the mating surface with different surface topographies were obtained by numerical analysis and experimental methods; third, the functional relationship models between different surface topography parameters and the contact performance of the mating surface were obtained by using the fitting algorithm; finally, taking the contact stiffness of the mating surface as the objective and the surface machining accuracy as the constraint condition, the surface topography parameters are optimized. The results show that the average variance σ of the surface topography of the two different specimens after optimization increases by 0.98% and 2.71%, respectively, compared with that before optimization, which indicates the relative reduction in the difficulty and cost of surface processing. This study can provide an effective way to improve the optimization design of surface topography parameters and the performance of the whole machine.
Highlights
The surface topography information of the measured parts was characterized by different parameters to realize the parametric expression of the surface topography; second, the mechanical properties of the mating surface with different surface topographies were obtained by numerical analysis and experimental methods; third, the functional relationship models between different surface topography parameters and the contact performance of the mating surface were obtained by using the fitting algorithm; taking the contact stiffness of the mating surface as the objective and the surface machining accuracy as the constraint condition, the surface topography parameters are optimized
The results show that the average variance σ of the surface topography of the two different specimens after optimization increases by 0.98% and 2.71%, respectively, compared with that before optimization, which indicates the relative reduction in the difficulty and cost of surface processing
The nonGaussian theory simulation method is used to simulate the part surface based on the measured surface topography characteristics, which provides an effective model basis for analyzing the contact performance between the mating surfaces
Summary
The mating surface makes many structures in the mechanical system no longer continuous, which increases the complexity of mechanical properties, such as stiffness and damping of the mechanical system. Due to the comprehensive influence of processing methods, cutting parameters, vibration, tool temperature, and other factors, there are micro-convex bodies with different geometric shapes on the machined surface of the parts, so the coordination of different parts is mainly the mutual contact between some microconvex bodies resulting in the nonlinear and complex characteristics of the stiffness and other properties of the mechanical system. the surface topography of the parts is the key factor affecting the contact performance of the mating surface and the mating quality of the whole machine. The research on the relationship between the surface topography of parts and the contact performance of the mating surface is mainly based on the numerical analysis method, which simplifies and assumes the contact model to a certain extent in the analysis process, resulting in a certain deviation between the analysis results and the real situation. In order to achieve high assembly performance of mechanical systems based on low manufacturing accuracy of parts, this research is mainly realized by pre-controlling the surface topography requirements of parts. In order to ensure the contact stiffness of the mating surface, the surface topography characteristic parameters were optimized, so as to achieve the purpose of high assembly performance of mechanical systems based on low manufacturing accuracy of parts. This paper provides a new way to improve the contact performance of mechanical systems from the perspective of a surface topography design
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