Research On Rapid Design Method Of Vibration System In Ultrasonic Gear Honing

Gear and gear products are the crucial parts in foundation structures of mechanical industry as they are widely used in primary transmission parts of most packaged machine equipments. With the development of gears orienting toward high speed, standardization, miniaturization, it is required that the higher material and manufacturing technology. And the manufacturing technology of hardened-tooth-flank gear increasingly shows its importance. Recently, the traditional method of gear finishing can not fulfill the demands of gear products with high precision, it is imperative to introduce non-traditional machining methods combined machining technology into gear manufacturing fields. The ultrasonic machining introduced into the hardened-tooth-flank gear machining can not only open widely application field of ultrasonic theory, but also can change the current situation that the application of non-traditional machining in gear industry drops behind obviously in other industry. Ultrasonic vibration system is the key of the ultrasonic processing system in ultrasonic machining, which has a direct relationship between the performance of the entire process system. Therefore, to realize the ultrasonic gear honing, the key problem is to design the ultrasonic vibration system. Transformer is an important part of ultrasonic vibration system. According to the deficiencies of the whole resonant theory, it determines to use the transformer with non-resonant unit to the design vibration system in ultrasonic gear honing. This dissertation was supported by National Natural Science Fundation of China(Grant No.50975191).In order to reduce the labor intensity of designer and improve the design efficiency of vibration system in ultrasonic gear honing, this dissertation explains how to use Visual Basic6.0, MATLAB R2011a and SolidWorks2011programming tools and means of combining them to rapid design of vibration system in ultrasonic gear honing. The following contents were mainly researched in this dissertation:(1) The software which calculates the parameters of ultrasonic horn is developed by means of combining VB and MATLAB. The rapid design of ultrasonic horn, based on the platform of SolidWorks, is achieved by utilizing VB to call the API function of SolidWorks which can generate a three-dimensional model of horn automatically in SolidWorks by parameter-driven. It is compared and analyzed the finite element modal analysis results and hammer method modal experimental results, to verify the accuracy of the design method.(2) For the gear, with less than100millimeter diameter of reference circle and more than0.3of thickness to diameter ratio, can be simplified as a cylinder with the diameter of its reference circle and thickness. The transformer in longitudinal vibration is designed by the design theory of the composite horn. For the gear, with more than100millimeter diameter of reference circle and less than0.3of thickness to diameter ratio, can be simplified as a thick circular or thick annular plate with the diameter of its reference circle on the basis of its central hole. The transformer in longitudinal and transversal vibration is designed by non-resonant design theory and Mindlin theory.(3) The theoretical analysis model of transformers and vibration frequency equation are respectively established. Then the parameters of transformer, which can ensure the right vibration frequency and modal, is achieved by programming and solving the vibration frequency equation through MATLAB. The software which calculates the parameters of amplitude is developed by means of combining VB and MATLAB. The rapid design of transformer, based on the platform of SolidWorks, is achieved by utilizing VB to call the API function of SolidWorks which can generate a three-dimensional model of horn automatically in SolidWorks by parameter-driven. It is compared and analyzed the finite element analysis results and experimental results, to verify the accuracy of the design method.(4) The research on the rapid design of vibration system in ultrasonic gear honing includes:system architecture and function modules, the design methods of system and the establishment of user interface, the design examples of vibration system in ultrasonic gear honing based on SolidWorks platform.