System design and experimental research on the tangential ultrasonic vibration-assisted grinding gear

摘要

A tangential ultrasonic vibration-assisted gear grinding (TUVAGG) system was proposed in this paper to enhance the machining accuracy and performance of gears. Firstly, the longitudinal resonant vibration system of the TUVAGG was designed based on the non-resonant theory. The frequency equation and the displacement characteristics for the vibration system were obtained for the particular boundary conditions. Secondly, the vibration system composed of simplified disc and gear was simulated by the finite elements analysis method (FEM) and verified by the resonant measurement test. Finally, the vibration system effectiveness was verified through the ultrasonic vibration-assisted gear grinding test. The normal and tangential grinding forces in TUVAGG were lower by 7.4-28.2 and 8.9-18.9, respectively, than conventional gear grinding (CGG). Besides, the grinding temperature and surface roughness in TUVAGG declined by 7.6-25.7 and 8.6-21.8 respectively compared with CGG, while the former tooth surface residual compressive stress and microhardness exceeded the latter ones by 13.2-29.3 and 8.9-12.7. The non-resonant theory was suitable for the designation of longitudinal vibration system for TUVAGG, and also provided a novel process technology for gear machining.