Schematic Design And Experimental Verification Of Variable Spindle Barrel Finishingmethod On Large Size Gear

As a mechanical transmission part widely used both in application fields and usage, gear is an important basic component among mechanical products in modern machinery and equipment industry. Gear’s design and manufacturing level will directly affect the performance and quality of mechanical products. The practical results at home and abroad indicate that improving gear’s surface quality can improve its performance and lifetime to a large extent, and reduce noises. Surface finishing can improve gear’s surface quality, consequently increase its performance and lifetime in the process of gear manufacturing. Due to take account of its costs and efficiency, the applications and scientific research investments on gear finishing are in a very few at present. As a consequence, many products can’t meet with the demand of use. In view of above, the development of high efficiency and low cost gear finishing technology has an important practical significance.As a widely used finishing technology, barrel finishing has a great significance applied in gear surface finishing due to its advantages such as low costs and fine surface quality etc. Based on research conditions in gear finishing at home and abroad, this paper proposes new processes of gear finishing technology combined the finishing study background of TYUT to improve gear’s surface quality, performance and lifetime.From the analysis of the various barrel finishing process in gear application, this paper proposes two spindle type barrel finishing technology methods and studies their processing mechanism in view of its deficiency in gear processing and the characteristics of the large size gear. By establishing mathematical model, this paper focuses on the complex relative motions of media and gear surface, gets this relative motion’s cutting speed calculating formula, theoretically finds out main parameters which influence the processing effect, and analyzes the influence of each parameter on the cutting speed by MATLAB software.This paper analyzes the motion characteristic of media in the rotational flow type finishing and vertically crossed spindle type barrel finishing and concludes that the vertically crossed spindle type is more favorable for the uniform processing of gears through discrete element software EDEM. By the simulation analysis of the vertically crossed spindle type barrel finishing, it concludes the influence of different barrel speed, gear speed and gear swing angle on media speed and the average contact force between media and the tooth surface, which has a certain guiding significance for design and application of the vertically crossed spindle type finishing equipment.The results of theoretical and simulation analysis for the influence of gear spindle vertically crossed finishing parameters on the processing effect was verified through experiments. At the same time, the improvement of the surface quality of gear finishing was studied by using this technique. It showed that gear after barrel finishing has a bright appearance, chamfering, lower surface roughness degree from 0.698μm down to 0.265μm, and texture and micro cracks caused by previous process machining disappeared, this processing technology improves gear surface quality comprehensively, and progress the use of gears and lifetime.