Theoretical Research On Transformer Composed Of None-Resonance Structure In Ultrasonic Gear-Horning

Gear honing as a way of high precision machining is directly related to the quality of gear tooth's surfaces and mesh conditions. But further development of conventional honing techniques are restricted by its disadvantages such as low efficiency,easy to plug the honing wheels. It's a good way to solve the disadvantages of the gear honing by adding the ultrasonic to it.Vibration system composed of piezoelectric transducer,horn and tool is a vital portion of ultrasonic honing. The gear to be honed is fixed to the end of the horn by screwing in the ultrasonic honing. The designing of horn's structure instead of vibration system is focused dues to the gear's size which is known. Nowadays most of horns or tools are designed separately which have the same resonant frequency,that is,the whole-resonance. It is difficult to use this method to design ultrasonic transformer if the inherent frequency of the gear is out of the range of the ultrasonic generator's. At this point,appropriate size of horn is desired to be designed. The resonant frequency of the horn and the gear as a whole is in the range of the generator's and is able to vibrate well. A design method of non-resonance structure is required,which made the design method of the transformer from the whole-resonance to the non-resonance.This paper reviews the domestic and international history and development based on the design method of the ultrasonic vibration system,the component of ultrasonic honing is discussed and the mathematical modal is established.The displacement distribution equations of step horn,exponential horn and conical horn are derived by means of longitudinal vibration equation of variable section-area rod. Then the frequency equations of transformers are educed from the equation,plate bending equation,boundary conditions and force-coupling conditions. The frequency equations are solved by Matlab at last.According to the design method,The non--resonance structure's size of the step,exponential and conical transformer are designed separately.Then,the material's selection principal of the horn and the finite element and modal analysis theory are introduced. The three different transformers'modal analyses are carried out.A step transformer is manufactured using 45 steel and a number of experiments followed then. Its resonant frequency is tested by impedance analyzer; then tested with the strike method after the test system is organized; the resonance captured by ultrasonic generator is recorded and the vibration mode is observed at last. Make some summaries after comparing the above resonance frequencies to the designed frequency.In the end, the summaries and prospect are carried out, and the deficiencies and the later development orientation of the paper are indicated.