Mechanism And Application Research Of Strong Spherical Inner Honing For Hardened Tooth Surface

Compared with traditional gear grinding technology,powerful spherical gear honing technology has outstanding performance in lowering gear noise,improving gear bearing capacity and reducing processing cost.The powerful spherical gear honing machine uses the electronic gear box system to realize the forced transmission between the inner honing wheel and the machining gear.Through spherical movement,the powerful spherical gear honing machine could repair the shape of tooth with arbitrary form.This processing technology can effectively improve the geometry of gear tooth surface,reduce radial runout of gear ring and gear indexing error.The new type of composite honing wheel can be used to remove the larger machining allowance.The maximum processing allowance of the single tooth surface reaches 40?m~80?m.The spherical honing technology could also generate non-periodic tooth profile on the tooth surface,which effectively reduces the gear noise.Spherical gear honing technology provides a low cost and high performance method for processing hard tooth surface precisely.But the technology is monopolized by foreign countries at present,which limits its application and development in China.The following studies have been carried out in this paper:(1)the related equipment and technology of the processing of spherical gear honing have been studied.the theoretical calculation method for solving the gear drum shape has been analyzed based on the actual requirements and software simulations.The requirements of the drum shape of the gear machining in actual production and processing have been considered.The contact stresses of gears and the theoretical deduction of the bearing capacities of the gears have been analyzed by simulation.ANSYS software has been used to simulate and analyze the stress of standard involute gear after the changing of drum shape.The drum shapes have been designed,verified and optimized.(2)the mechanism of hard tooth surface spherical gear honing technology has been analyzed.The parameter equation of inner meshing gear has been set up,and the spherical meshing compound motion relationship between the inner honing wheel and the working gear have been deduced.The relations between the axis angle and the drum shape of the gear machining have been solved,and the method of the spherical drum shape machining of the inner meshing gear honing machine tool has been studied.The UGNX,Adams,Matlab and other computer software have been used to verify the efficiency of the processing method of drum shape.(3)The actual production and processing of gears have been carried out.the gear processing parameters have been set up on the powerful spherical gear honing machine(Gleason-150SPH).The drum sizes and drum shapes of the produced gears have been tested.The accuracy of the selection of the processing parameters have been verified.In this paper,the design method of drum shape of tooth surface has been studied by combining theoretical analysis with simulation.The calculation formula of gear drum shape and the parameter equation of meshing gear have been deduced.The relationship between the axis angle and the drum machining of the meshing gear has been established.Finally,the final verification has been carried out through the actual production and processing on the powerful spherical gear honing machine(Gleason-150SPH).The studies provide a theoretical basis for the application of spherical honing machine.