The Design Theory And Vibration Experiment Research Of Ultrasonic-Based Gear-Honing Device

Referring to the theory and application of ultrasonic and the technique of hardened-gear-honing and research of cutter, ultrasonic-based gear-honing is brought forward. The ultrasonic theory is applied on the hardened-gear-honing to improve the honing quality using its vibration with high frequency and make use of technique of gear-honing sufficiently; it overcomes both the low efficiency of gear-grinding and the deficiency of incapability of shaped in tradition honing; and the application field of ultrasonic theory is enlarged.The designing of vibration system is a key technology of the thesis. The paper establishes an appropriate model of vibration system composed of horn and gear. The transmission of ultrasonic is changed from longitude wave into transverse wave; the gear vibrates in flections mood and obtain larger vibration displacement in the grinding region.Firstly, referring and summing up the achievement of gear-honing and ultrasonic machining, the purpose and meaning of ultrasonic-based gear-honing is expatiated in the paper. Followed, based on the basic theory of ultrasonic-based gear-honing, the transmission characteristic of energy in the ultrasonic vibration system is analyzed. The basic theory includes mechanical impedance, analogy of force and electricity, elastic medium parameter and resonance theory.Then, the structure of vibration system is brought forward, the composite vibration system composed of conical horn and disc. Summing up the design methods of horn, the parameter relation of conical horn is analyzed using resolution and finite element method; the vibration theory of disc is analyzed using the finite element software ANSYS, providing the theory foundation for the designing of composite vibration system; and design a composite vibration system according to the requirement.Later, the experiments are carried out to validate the design theory. There are two experiments, one is vibration experiment, first, the transducer, horn and disk (simulation gear) are joined in turn, then, the vibration experiment is carried out and the distribution of wave-node circle of the disk in deflection vibration can be observed using fine sand; the other is vibration characteristic experiment, the amplitude of various points of the disk can be measured respectively by means of the amplitude measurement system, and the distribution curve of vibration displacement axially can be obtained.Finally, the sum-up and prospect are carried out, and the deficiencies of the paper and the later development orientation are brought forward.