The Study On Contact Characteristics Simulation And Tool Dressing Method Of Internal Gear Power Honing

The development of the manufacturing industry is constantly making higher demands on gear processing.As one of the gear finishing methods,internal gear power honing can not only efficiently correct the gear machining error in the previous process,but also improve the tooth surface texture,greatly improve the performance and service life of workpiece,it's a high-precision,efficient gear processing technology.But,because of there is limited research on the mechanism and equipment of internal gear power honing so far in China,this technology has not yet been widely used in the processing of high-precision gears.Therefore,The CIMS Institute of HFUT has conducted a comprehensive study on the internal gear power honing.Based on part of contents,this paper analyzed and studied the dynamic contacting characteristics,honing force and tool dressing methods of internal gear power honing,The main research contents were as follows(1)Based on the conjugate contact between internal honing wheel and workpiece while machining,The mathematical relations satisfied when the honing wheel contact with the workpiece and the tooth surface equations of internal honing wheel were deduced,then honing wheel tooth surface model and honing wheel model were established respectively.The above provided formulas and model basis for subsequent chapters.(2)Regarding gear honing as contact between surfaces at the perspective of macro machining,the FM model of honing wheel and workpiece was established and the machining contact simulationis was conducted.Then the distribution of contact stress on the tooth surface in the meshing process was analyzed,and the surfaces contact condition under different crossed axised angle was analyzed too.(3)The model of abrasive grain random distribution on the surface of internal gear honing wheel was constructed,then the microscopic grain honing simulation was conducted.From the simulation results,the unit honing forces of the tooth surface contact area were calculated.Then,according to the unit honing force results and combined with the mathematical model of the contact line of the workpiece tooth surface,the honing force of a single contact line was calculated using a discrete approximation method.(4)Based on the mathematical relationship of machining contact between internal gear honing wheel and workpiece,the cause of the change in the tooth profile of workpiece after radial feed only dressing was analyzed,and its improved method,the fluctuating crossed axis angle was studied,through numerical simulation,it is confirmed that the change of surface contact state between the honing wheel and the workpiece can be effectively improved after the fluctuating crossed axis angle dressing method is used..Finally,the machining test in different crossed axis angle was conducted on the HMX-400 Fassler internal gear power honing machine,the tooth profile errors of workpiece were detected,found that the profile of workpieces in different crossed axis angles was maintained well,and the method was verified to be effective.