基于多物理场作用的螺旋锥齿轮数控磨削残余应力研究

摘要

According to the NC grinding mechanism of the spiral bevel gear and the Gleason contact principle,we obtain the mathematical model of grinding physical parameters that influence the grinding residual stress of a spiral bevel gear.We establish the 3D finite element model of the spiral bevel gear;on this basis,we obtain its physical fields such as temperature field and stress field by applying the thermo-elastic-plastic theory and the numerical finite element method.We simulate and analyze the grinding residual stress by doing the coupled computation of the two physical fields.The simulation results show that：（1） the grinding tooth surface of the spiral bevel gear has compressive residual stress;the inside tooth has tensile residual stress;（2） the size of grinding residual stress varies with the varying grinding conditions;the grinding residual stress decreases with decreasing grinding depth and speed of grinding wheel,while increasing with decreasing extended speed;the grinding residual stress is greater in the dry grinding condition than in the wet grinding condition.Finally,the experimental results show that the finite element analysis of grinding residual stresses is effective.%根据螺旋锥齿轮的数控磨削机理和Gleason接触原理,得出了影响磨削残余应力的磨削物理参数数学模型。在建立的单齿3D有限元模型基础上,运用热弹塑性理论和数值有限元方法,得到了螺旋锥齿轮磨削温度与应力等物理场;通过这两个物理场的耦合计算,仿真与分析了磨削残余应力。结果表明：螺旋锥齿轮磨削齿面呈现残余压应力,里层为残余拉应力,其大小随磨削工艺条件的不同,呈现一定的变化规律;磨削残余应力随磨削深度和砂轮速度的减小而下降,而随展成速度的减小而增大,干磨比湿磨条件下可明显增加磨削残余应力。实验验证了有限元分析螺旋锥齿轮磨削残余应力的有效性。