Research On Dynamical Characteristics Of Transformer In Ultrasonic Gear Honing

The world will move it up only when the gears are connected. Gears as one of the most inportant transmission, is not only the foundation industry of equipment manufacturing industry in our country, but also the important basis of the national economic construction fields. Along with the rapid economic development, gears with satisfactory performance are recognized and favoured by industry. Hence, the research and application of gears manufacturing technology appears especially important. The technology of ultrasonic gear honing has been a new craft of precision machining for gear on the basis of traditional honing process, and it is a new exploration of an ultrasonic compound machining for gears. Ultrasonic gear honing machining is useful in the modification of gear, decrease the stemming problems of plugged wheel and the force of honing, hence, the machining efficiency, machining accuracy and the life of honing wheels can be improved, so, it is of important academic significance and application value to study the ultrasonic gear honing machining. To realize the ultrasonic gear honing, one of the key problem solved firstly is to design the ultrasonic vibration system. The problems and shortages in non-resonant structure design theory (NRST) which only can be used to design gear including thin annular plate was focused to be solved in this paper. On the basis of consulting a large number of technical data and documents, a completely new design method for ultrasonic gear honing vibration system was brought forward based on Mindlin’s theory. Just for this reason, the project "Non-resonant structure design theory of Transformer and application of ultrasonic gear shaving honing" which was proposed by our research team was supported by the National Natural Science Foundation of China (No.50975191). As an important sub subject "Dynamical characteristics of transformer in ultrasonic gear honing" was proposed by the Innovation and Entrepreneurial Projects for College Students of Taiyuan (No.110148050). The following researches about dynamical characteristics of transformer in ultrasonic gear honing have been studied:(1) Models of transverse vibration for gear based on Mindlin’s theoryGear was simplified to moderately thick annular plate (MTAP) with the outer diameters of reference circle, according to the structural characteristics of a cylindrical gear with a hole in the center and its ratio of the thickness to radius in the scope of the moderately thick plate theory, i.e., the ratio of the thickness to radius is greater than1/5and less than1/2. The frequency equations for transverse vibration of the moderately thick annular plate were derived with the free boundary conditions based on Mindlin’s theory and solved computationally with the help of MATLAB software. The solutions are in best agreement with those from the finite element method (FEM) and also with the experimental results. The conclusion has certain theoretical significance to guide to design the vibration system of ultrasonic gear honing.(2)Research on dynamical characteristics of transformer in ultrasonic gear honingTo extended the range of application the NRST, the mathematical models of the transformer which were consists of cone, exponential, catenary, step horn and MTAP were built respectively by means of NRST, Mindlin’s theory and force coupling conditions. Then the frequency equations and displacement amplitude equations of corresponding transformer were derived. The design parameters and displacement amplitude of the transformer were solved by using MATLAB software. The results from FEM and dynamical experiment were consistent with the numerical solutions of the frequency equations and displacement amplitude equations. On this basis, in order to verify the compatibility of the proposed transformer design method for the traditional NRST, FEM simulation for the transformer were calculated under various ratio of the thickness to radius. It can be found that dynamical characteristics of transformer are consistent with the theoretical design demands when the ratio of the thickness to radius that covers the range from the CPT to MTAP. The experimental result demonstrates that the method of this paper can extend the transformer design range from gear including thin annular plate to gear including MTAP, and NRST is further improved and perfected.(3)Exploratory research on the new design method for vibration system in ultrasonic gear horningAccording to problem of displacement amplitude on the edge of MTAP is comparatively small in the NRST generally; the whole resonant design theory (WRDT) and NRST ideas were referenced. The traditional tool head was replaced by gear pole which was consists of MTAP and cylindrical pole. The frequency equations and displacement amplitude equations of the gear pole were derived based on force coupling boundary condition. Then the parameter of the cylindrical pole and the displacement amplitude of the MTAP were solved by using MATLAB software, and the dynamical characteristics simulation of the system which was consists of horn and gear pole were got by FEM. It is proved from theoretical solution and FEM that the displacement amplitude on the edge of MTAP is increased than NRST. This part aims to explore a new design ideas for vibration system in ultrasonic gear horning.