The Theoretical Analysis And Experimental Research Of Ultrasonic Assisted Gear Honing

Ultrasonic Honing inner circle have been widely used in actual production, but the ultrasonic gear honing process are still at the experimental research stage. The process is a method of gear finishing, which is put forward based on the theoretical application of ultrasonic and the research of conventional honing techniques and tools design, and it can not only improve the efficiency of gear finishing machining, but also be able to reproduce the accuracy of honing wheel to the processed workpiece to improve the shape of precision gears and the uniformity of the gear contours.Studying of the processing efficiency of ultrasonic assisted gear honing and the accuracy of the workpiece is a very important research aspect. The paper will selective study the theoretical analysis and experimental research of ultrasonic assisted gear honing machining based on previous theoretical study. The details are as follows:1.Theoretical Analysis: (a) In this paper, the gear surface equations of single helical gear which participates the cross-axis meshing motion at the spherical coordinate system is given, and it is obtained the normal vector, the curvature parameter and main direction of single tooth surface. (b) a pair of staggered based on the transmission shaft gear meshing theory, the third chapter focuses on the formation of conjugate surface which the honing wheel and workpiece involved in process of ultrasonic gear honing, while the equation of instantaneous meshing line on the conjugate surface is derived by solving the coordinates value of any pointM on the two mating tooth surfaces∑1 and∑2 in the fixed coordinate system. (c) In the process of ultrasonic gear honing, the meshing motion between the honing wheel and the workpiece is spatial, the two meshing gears are located in two different spatial coordinate system, they must be transformed by coordinate transformation to the same fixed coordinate system to discuss their relative motion. According to coordinate transformation and the equation of ultrasonic harmonic vibration, the paper analyzed the kinematic theory of ultrasonic assisted gear honing machining and deduced the relative slip velocity at the meshing point between honing wheel and the workpiece. Then, the reason that the ultrasonic gear honing can improve the surface accuracy of gear could be analyzed by the additive effect of the contact line in the process of meshing. (d) In this paper, the longitudinal vibration and bending vibration equations of the amplitude transformer is obtained, the frequency equation is established based on the boundary conditions located at actual clamping position, and the arithmetic solution of the conical amplitude transformer have been solved. (e) The cutting tools can affect the accuracy and efficiency of machining gear, thus the forming process of tools and the mechanism of abrasive wear is a particularly important studying aspect. In this paper, the consolidation process of CBN abrasive is introduced, that is the laser soldering and the electroplating. And the damage mechanism of the CBN abrasive is focused on according to the abrasive wear conditions.2. Numerical Simulation: The modal analysis of the amplitude transformer is carried out with ANSYS, the amplitude varying curve of the amplitude horn along the length is obtained, and the natural frequency is obtained too. Then, the resonant frequency of ultrasonic vibration system is tested by the impedance analyzer, and the tested results are consistent with that of the software analysis.3. Experimental Research: (a) in the testing experiment, the curve that the amplitude and acceleration at the amplitude horn tip vary with the resonant frequency is given. (b) In the machining process, the experiment is respectively carried out in two ways. That is ultrasonic assisted gear honing and traditional gear honing. The machining parameters such as the spindle speed, cutting depth and amount of feed is changed during machining process. Then, the workpiece is observed by high-powered electron microscope and measured by the rough meter. The results showed that the surface accuracy of the parts that is processed by the ultrasonic vibration assisted machining is higher than that of the traditional honing.