Research On Mechanism And Related Experiment In Ultrasonic Gear Honing

Gear is the key components in the machinery industry. It is playing a decisive role in all fields of national economy. Therefore, the gear fabrication technology is the major research direction in machinery science. The gear honing process is one of the finishing methods, and it has the advantages of high efficiency, low cost, good tooth surface quality and surface texture. However, it also has many defects such as the force imposing on the abrasive, the clogging among the abrasive and so on. But the defects motioned above could have been overcome with ultrasonic gear honing process. The essence in honing gear could be cleared through analyzing the mechanism of ultrasonic honing. The theoretical proof could be presented in the thesis.Therefore, the gear workpiece tooth profile equation and vector equation had been deduced with establishing auxiliary coordinate system and transforming coordinate. The tooth to the sliding velocity and normal profile sliding velocity had been analyzed, under the condition of engaging between the tool with helical tooth and the workpiece with spur tooth. An explanation had been displayed to the tooth profile scratches.The instantaneous contact arc of workpiece length and abrasive maximum depth are deduced and their effect on honing effects are analyzed.Increasing the honing honing speed and reducing the feed of honing can improve the machining quality and increase the service life of the gear honing wheel.Decreasing the cutting depth and increasing honing speed, honing velocity component is smaller.Contact normal force is independent to power, but its size is more than two times the cutting velocity component.It is related to the component of workpiece deflection, honing wheel cutting residue of rigidity and machining accuracy.Especially when the honing wheel surface is passivation and clogging, the force will become larger. The axial force is Proportional to the amount of feed proportion,and is quite smaller compared with the previous two components.As for single particle, the force is large,but each grain is with random angle of inclination.So each component offsets each other, the total will be smaller.The basic principle of ultrasonic honing and the grain on the tooth surface scratches have been researched.Pulse honing force model of ultrasonic honing is established through the analysis model, the reason of the small average cutting resistance, the better machining accuracy and surface roughness have been found by studying the effects of process parameters on ultrasonic honing.The chip formation of the ordinary honing grinding and honing the grinding mechanism are researched.The tooth surface of honing abrasives is curvilinear motion, extrusion, friction direction of the contact point will change.Cutting can easily fluid into the grinding zone, and the processing zones for lubrication to reduce the honing force and the abrasion of gear honing wheel, which can increase the honing of grinding speed, improve material removal rates.Vibration of ultrasonic honing is exacerbated the impact abrasive on chip and makes it early fall off, which can increase the grinding depth and improve material removal rates.The grinding curve vibration particle corresponds to extend the unit time grinding away which is the equivalent of grinding speed,so the material removal rate is improved.The frequency equation of cone type and combination type transformer is established, and the length of unknown amplitude transformer is calculated by Matlab.Then a three-dimensional model of the two kinds of transformer are built in Solidworks2011and Pro/E5.0, and their resonant frequencies are found by ANSYS.The result shows that the resonant frequency of the horn decreases with the gear aperture ratio increasing. When the aperture ratio reached0.2and above, the vibration frequency of transformer decreases or vibration frequency does not exist.At the same time,the relative deviation is also gradually reduced.The longitudinal bending resonant honing and ordinary honing experiment are done in Y4650gear honing machine.The six span length of normal line gear teeth, tooth surface roughness of the above two cases are achieved and Tooth surface microscopic and macroscopic photograph two kinds of machining process are compared.The results show that:the processing effect of ultrasonic gear honing is better than that of the ordinary honing process.Finally, the above all are a summarized and outlooked, the shortcomings and future directions in the work are discussed.