Research On The Basic Theory And Technology Of CNC Internal Gearing Power Honing Process

The level of gear finishing technology has great influence on the manufacture precision of gear which is the industrial basic part.At present,CNC gear grinding and CNC internal gearing power honing is the two more advanced gear finishing processes,CNC gear grinding process has been very mature in China,However,owning to the CNC internal gearing power honing process is very complex and the key technology is monopolized by foreign countries,which greatly restrict the development and application of CNC internal gearing power honing process,CNC system and its machine tools in China,thus,the researches of the key technology of CNC internal gearing power honing process are very important.According to research,the internal gearing power honing CNC system is mostly from foreign,such as SIEMENS of Germany,FANUC of Japan and so on,these advanced CNC system has great limitations to the machine user,the worker can't change their needed parameters to improve the process quality,and the process is very single in these CNC system,the machine user even need to invite expensive foreign technical support,which causes the waste of resources and time.In order to make a further study on the CNC internal gearing power honing process,improve the gear honing quality and break the monopoly of foreign honing process and CNC system technology,this paper started from the internal gearing power honing process principle,developed the internal gearing power honing machine CNC system based on the embedded hardware platform,and did a further research in the formation mechanism of honing texture on work-piece gear tooth surface,the microscopic quality of gear tooth surface roughness and the macroscopic quality of total gear profile error,the main researches can be obtained as follows:1.Study on the internal gearing power honing process technology.According to the analysis of the principle of internal gearing power honing process and the motion principle of the machine,the machining mathematical model of the internal gearing power honing has been derived,and based on the analysis of the internal gearing power honing,gear tooth addendum circle dressing and gear profile dressing,the calculation of the key path points of these three processes has been carried out.2.Development of the internal gearing power honing CNC system.Based on the embedded CNC system hardware platform,through using object oriented programming methods,this paper has finished design of the core function module of CNC system,such as the overall design and every function module design of the CNC system HMI,honing process parametric automatic programming design and so on,after that,the internal gearing power honing CNC system software based on Wince system has been developed,and the realization experiment of each function module has been carried out on the independent developed CNC system platform.3.Study on the formation mechanism of tooth surface texture in internal gearing power honing process.The coordinate system of the internal gearing power honing machine has been built according to the motion principle of internal gearing power honing machine and the spatial coordinate position relationship between work-piece gear and honing wheel,based on the conjugate meshing theory of spatial curved surface,the 3D visualization model of contact line on tooth surface between honing wheel and work-piece gear has been built,and the 3D visualization model of honing wheel tooth surface has been built based on the linkage relations between honing and work-piece gear.The tooth surface texture model has been built based on the relative motion velocity of the grit on contact line,and the built tooth surface texture model has been verified by experiment.Finally,the effect rule of different cross axis angle on the tooth surface texture has been found based on the varied model,and obtained the range the cross axis angle causing unstable tooth surface texture.4.Study on the microscopic quality of gear tooth surface roughness in internal gearing power honing process.According to the meshing-grinding motion theory of internal gearing power honing process and the roughness formation mechanism under grinding process,this relative velocity between honing wheel and work-piece gear has been decomposed into the velocities along gear tooth profile direction and tooth longitudinal direction.The maximum height models of grit groove along the two directions on tooth surface have been built,and then the roughness models along the two directions have been built based on the relationship between the maximum height of grit groove and the roughness value.The actual honing experiment and tooth surface roughness measurement experiment for a certain type of gear have been carried out,through the comparison analysis between the actual and the predicted roughness values,the result verified the reliability of the built models.After that,based on the verified roughness models,the effect rules of different cross axis angle on the tooth surface roughness values have been carried out in the changed cross axis angle gear honing process,and finally,this paper has designed and developed a software for the analysis of gear tooth surface quality in internal gearing power honing process,which can direct the actual production.5.Study on the macroscopic quality of total gear profile error and process optimization in internal gearing power honing process.According to the analysis of the input process parameters and output gear profile errors indexes in internal gearing power honing process,the 4 factors and 3 indexes honing experiment has been carried out based on Box-Behnken DOE method within the given process parameters' range,and the experiment result of gear profile errors indexes have been measured on the gear measurement center.The gear profile errors models have been built after the ANOVA and significant analysis of the experiment results,and the effects of honing process parameters on the gear profile errors have been found.After that,a total gear profile error model has been built based on giving weighting coefficients to the different gear profile errors under the same gear precision level.Taking the minimum total gear profile error as the optimization target,the internal gearing power honing process parameter optimization has been carried out based on artificial intelligence optimization algorithm,and finally,the contrast experiment has been carried out through using the optimized honing process parameters and the empirical honing process parameters,the result shows that the internal gearing power honing process parameter optimization have achieved the goal of improving the accuracy of this process.