Study On Influence Of Workpiece On Resonant Frequency In Ultrasonic Assisted Gear-honing System

Ultrasonic assisted gear-honing processing technology is a kind of new gear processing developed through the application of ultrasonic vibration in gear honing. This technology applies ultrasound and gear honing. The real-time dynamic cleaning of gear honing wheels can be strengthened because of the ultrasonic cavitations'phenomenon and cutting fluid, which effectively reduces the honing force and honing wheel jams, and increases efficiency. Accordingly, ultrasonic assisted gear-honing processing technology has a good application prospect. In recent years, the research of this technology was supported by the National Natural Science Fundation of China(Grant No. 5097519), and had also made a lot of achievements. However, there are still some technical problems in dire need for solving.Ultrasonic vibration system, consisted of transducer, horn and machined gear, is the core of ultrasonic gear-honing system. The correctness of transducer selection, horn design and the connection of them, is the key to make ultrasonic vibration system work effectively. In ultrasonic assisted gear-honing processing, the difference of the physical parameters of processed gears certainly will cause the ultrasonic vibration system resonant frequency changes. Accordingly, it is necessary to consider the change caused by installation work piece resulting ultrasonic vibration system resonant frequency, amplitude and other parameters. Consequently, the design of ultrasonic horn is more rational, to guarantee the vibration system in best resonant state.The purpose of this dissertation is to draw this influence regularity, and to provide certain theoretical basis for ultrasonic assisted gear-honing vibration transmission system design. In this paper, the main research contents are listed as follows:(1) Research activities of ultrasonic machining technology, gear processing technology, especially gear-honing technology are summarized. The present status and development trend of ultrasonic gear-honing processing technology are emphatically introduced.(2) By the programming of the longitudinal vibration displacement equation of cone horn, bending vibration equation of disc, and boundary conditions and the force-coupling conditions and the frequency equation of cone transformer in mathematics, the influence law of gear's radius and thickness on vibration system resonant frequency is obtained.(3) Based on the influence of work piece parameters on system resonant frequency, the theory of design on cone horn is researched. Further, the changing trend of length of horn with work piece parameters is obtained, which have great theoretical signification in the reasonable design of horn.(4) Combining the horn designed with the theory and work piece, through modal analysis with ANSYS, the resonant frequency of the horn longitudinal vibration, work piece axial vibration and ultrasonic transformer, is obtained. The results verify the correctness of the derivation results.(5) Analyzing the displacement amplitude curve of the axial vibration of ultrasonic horn and work piece, before and after installation, the position of nodes and lines are compared. The relationships between ultrasonic horn and work piece on displacement amplitude are obtained.(6) In this paper, the influence of work piece on resonant frequency in ultrasonic assisted gear-honing is studied, and some conclusions are obtained. However, it still needs to be improved in the simplification of transformers and so on.