| The technology of Ultrasonic gear honing is a new method of gear finishing, after the introduction of ultrasonic vibration cutting to traditional honing process, it forms ultrasonic combined machining. The gears which are made by this method have high precision, low surface roughness and strong bearing ability, so they can meet the requirements of modern machinery in all aspects. Practice shows that ultrasonic gear honing has high efficiency and it can prolong the life of honing wheel, it can not only solve the problem of inefficiencies, plugged wheel and other defects in traditional honing machining, but also can give full play to the advantages of ultrasonic cutting, it can also provide a new research direction to precise gear machining.The design of vibration system is the key to ultrasonic gear honing technology, it has a direct relationship between the performance of the entire process system. The direction of vibration system design is to find a best way to make the system work in a certain resonance frequency, and to ensure the cutting vibration amplitude, so as to achieve the purpose of combined machining. In this paper, it summarizes the deficiencies of traditional harmonic design theory, through the research and analysis of a variety of vibration theory, it determines to use the non-resonant theory to design the vibration system of ultrasonic gear honing.This paper was supported by the National Natural Science Foundation of China (Grant No.50975191). Based on the access to a lot of literature, it designed two types of ultrasonic horns with the non-resonant theory, and through parametric modeling and finite element analysis, it verified the feasibility and reliability of this method.The main research contents:(1)On the basis of understanding the ultrasonic machining techniques and ultrasonic gear honing process, it summarizes the current traditional design method of vibration system, and makes a non-resonant design improvement.(2)It detailedly summarizes the theoretical basis of non-resonant vibration system design method, derived the vibration equations of one-dimensional slender rod, variable area rod and thin bending disk and solved them.(3)According to the non-resonant design theory, the amplitude transformers of conical-shaped, apertured conical-shaped and catenary-shaped were designed. It established a mathematical model and analyzed the mode and displacement distribution of longitudinal and bending vibration of the amplitude transformers. According to the corresponding boundary conditions, the frequency equations are established, the length of the amplitude transformers is calculated with the help of mathematical software MATLAB. Then it determined the length of transformer and provided data for the following modeling and simulation.(4)The parametric model of amplitude transformers is established by the Pro/E. Through the dedicated channel between Pro/E and ANSYS, the model is imported into ANSYS for modal analysis. By analyzing the results can be seen, it is a good way to reduce design errors if using non-resonant method with the consideration of both horn and the workpiece gear, and the method is feasible and reliable in practical application.(5)Finally, the summing-up and future prospect are done to the whole paper, it analyzed the deficiency of the paper and pointed out the place need to improve and perfect.
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