3D Automated Modeling And Simulation Study Of Radial Honer Based On Pro/Engineer

More and more hardened surface gear was be used in the gear drive along with the development of modern machine manufacture, and the research of the high-efficiency, high-accuracy methods have also made certain progress for the hardened surface gear. Honing is the high-efficiency method for the hardened surface gear, and the improvement of honing technology lays great importance on the precise gear manufacture.Due to the principle and movement of the honing is similar to the shaving, moreover the radial shaving has been proved to be a kind of more high-efficiency gear finishing process in the shaving technology, so the axial shaving will gradually be replaced with the radial shaving along with the requirement of gear's quality and capacity enhances unceasingly. Therefore, it is very necessary to process the 3d automated parametric modeling and the simulation study for this new type of honing tools—radial honer, which has similar principle and movement with the radial shaving.According to the principle of spatial-engaging, this paper conduct the study and analysis of new finishing gear tools—radial honer's design theory, and deduced its tooth surface meshing equation and tooth surface coordinates formula through the analysis of gear tooth surface. The analysis result shows that the radial honer and the processed helical gear is no longer dot contact but line contact, and the tooth surface of the radial honer is constituted by contact lines. Morever the end face shape of the radial honer's tooth surface is not involute, and that the tooth surface of the radial honer is not the theoretic involute spiral surface but the special gear surface which conjugated with the processed gear, but the gear surface of the radial honer is highly similar to the involute spiral surface, and could be modified by the involute spiral surface.The tooth surface coordinate, the tooth profile shaping quantity and the tooth alignment shaping quantity of the radial honer was be programmed and calculated automatedly by the software of MATLAB, and the calculation result shows that the radial honer is the form of reverse drum gear in gear length, the opposite direction tilt modified gear on both ends in gear height, and it's end tooth thickness is different in every different end section. The 3d automated parametic modeling and assembly model of radial honer was be processed by the calculated coordinates was be imported in Pro/E which can provide basis for the design, model, shape, contact analysis and process of the radial honer.The assembly model of the radial honer which was be rationally simplified in Pro/E was be imported in ANSYS directly by the comparatively perfect data interface between Pro/E and ANSYS and was be conducted the nonlinear contact analysis. The Mises stress and the contact stress of maximum meshing surface were be compared and analyzed through the radial honer, the spur honer and the helical honer with the same gear number, modulus, torque and solving conditions, which can be found that the Mises stress and the contact stress of maximum meshing surface of the radial honer was smaller relative to the helical honer and the spur honer, so the error of gear tooth shape concave can be reduced, and drum gear was be easily processed by the radial honer which was be proved again.