Research And Experiment On Machining Quality Of Gear Honing Of Casehardened Gear

Casehardened gear has the advantages of reducing the weight of the equipment,minifying the transmission system,improving the bearing capacity and working speed of the machine,and reducing the transmission noise,etc.It is widely used in key transmission devices such as robot reducer,automobile gearbox and wind power generator.Honing,as a new technology of casehardened gear finishing,not only can effectively reduce the noise of gear transmission,extend the working life,improve the accuracy of tooth profile and working surface quality,but also can achieve high efficiency and large machining margin excision.Honing precision and surface roughness are the key factors that restrict the performance of casehardened gear.Based on the honing basic theory,this paper studied the micro-morphology of honing gear tooth surface,designed the machining model and test of casehardened gear tooth surface with multi-grinding micro edge honing,and analyzed the influence of dynamic machining characteristics of abrasive particles with different morphologies and honing process parameters on the honing machining precision and surface roughness.The results are as follows:(1)Understand the headway process,analyze the honing principle,and establish a mathematical model.From two aspects of honing wheel tool and process parameters were analyzed,and among them,the influence of honing wheel on machining quality is mainly embodied in the honing wheel geometry modification and micro grits,the influence of processing parameters on the processing quality in the honing wheel spindle speed and axial workpiece feeding speed,the radial feeding and honing wheel shaft Angle,etc.(2)According to the principle of gear reversal,the modification of the workpiece is used to guide the processing of the steel matrix of the diamond dressing wheel.The diamond dressing wheel is made by electroplating diamond particles on the tooth surface of the steel matrix.The diamond dressing wheel is used to finish the honing wheel,and the finished honing wheel is processed into qualified workpiece.The geometrical size,morphology,spacing and effective number of abrasive particles were studied,and the variation trend of surface residual stress under different honing speeds(abrasive edge cutting Angle)was obtained by using finite element software with other factors unchanged.(3)Spherical symmetry test was designed.Through nonlinear fitting of test data,functional relationships were determined between processing parameters(spindle speed of the honing wheel,axial feed speed of the workpiece and radial feed of the honing wheel)and the total deviation of gear profile and the cumulative total deviation of gear spacing.Then,with the minimum gear comprehensive error as the optimization goal,particle swarm intelligence optimization algorithm is used to determine the best process parameter combination within the range of process parameters,and test verification is carried out.In the same way,the processing parameters of the minimum gear roughness(spindle speed of the honing wheel,workpiece axial feed speed and axial Angle)are determined by using similar methods.