Structure Design Of Spiral Bevel Gear Grinding Wheel And Simulation Analysis Of Grinding Process

Spiral bevel gear is the important component of mechanical transmission withthe advantages of low noise, strong bearing capacity, smooth transmission. It is widelyused in automobiles, aircrafts, machine tools, construction machinery, miningmachinery and other mechanical products. Because it is extremely complex in thedesign and manufacturing of spiral bevel gear and it is very difficult to master themanufacturing technique, the engineering approximate method is widely used. Thekey technology of spiral bevel gears grinding has always been monopolized by thecompanies such as Gleason from the United States. Although at present a lot ofuniversities and research institutions in China have done a great deal of research onthe spiral bevel gear grinding methods and process, modification of tooth surface andso on, the research is still based on the Gleason theory and Oerlikon theory, whichexist principle errors.Based on the method of generating line, this thesis studied the generatingprinciple of the spiral bevel gear tooth surface，and designed the structural of obliquespur spiral bevel gear grinding wheel according to grinding process requirements，then analyzed the structural of the grinding wheel by the finite element modalanalysis，harmonic response analysis and stress analysis in ANSYS，after that thesingle grit of grinding simulation was done in DEFORD-3D.Finally，the grindingexperiment of spiral bevel gear was carried out in a numerical control machine tool.Studying on the spiral bevel gear grinding based on the new method of generating linehas very important significance for the spiral bevel gear processing manufacturingindustry in China and changing the current situation that our country spiral bevel gearprocessing technology subjected to the developed countries. The main research of thisthesis is as follows:（1）Based on the method of generating line and grinding process requirements,considering to make the grinding wheel structure simple,easy to manufature andassemble, this thesis designed the structural of oblique spur spiral bevel gearelectroplated CBN grinding wheel，including the choice of substrate material, and determining the cross-section shape and size of the matrix，then designed theassembly planning. Established a solid grinding wheel model in CATIA, and convertthe model to two-dimensional engineering drawings by the software AutoCAD tomanufacture the grinding wheel.（2）Modal analysis aims to analyze the natural frequencies and natural vibrationmodes of a determinate structure, which is the base of the other dynamics analysis.Harmonic response analysis is to predict the continuous dynamic characteristics of adeterminate structure. In this paper, the electroplated CBN grinding wheel matrix’modal analysis, harmonic response analysis and stress analysis have been done.Through the modal analysis obtained the natural frequencies，natural vibration modesand vibration transmission of the grinding wheel matrix at different frequencies. Theresponses of the grinding wheel under the periodic load are obtained through theharmonic response analysis, which determined the amplitude responses of the criticalpositions. Through the stress analysis obtained the stress distribution of the grindingwheel with certain rotating speed.（3）By the large commercial finite element software DEFROM-3D，the thermalcoupling finite element model of the grinding wheel and workpiece was established inthis paper, and the single grit of grinding simulation was done. The grinding force andgrinding heat in the grinding process were calculated, and the grinding force curve,the influences of different grinding parameters on grinding force, as well as thedistribution of stress，strain and temperature were also obtained in this paper.（4）Reasonable grinding process parameters were chose and the grindingexperiment of spiral bevel gear was carried out in the numerical control machine tool.The grinding experiment not only verified the method of generating line, but also laidthe foundation for the application of the principle in the actual gear processing.