切向超声振动辅助成形磨削齿轮的切削系数建模与试验研究

doi:10.3901/JME.2022.07.295

机械工程学报 ›› 2022, Vol. 58 ›› Issue (7): 295-308.doi: 10.3901/JME.2022.07.295

扫码分享

切向超声振动辅助成形磨削齿轮的切削系数建模与试验研究

别文博^1,2, 赵波¹, 高国富¹, 向道辉¹, 赵重阳¹, 唐进元³

1. 河南理工大学机械与动力工程学院焦作 454000;2. 平顶山学院电气与机械工程学院平顶山 467000;3. 中南大学高性能复杂制造国家重点实验室长沙 410083

收稿日期:2021-04-18 修回日期:2021-08-19 出版日期:2022-05-20 发布日期:2022-05-20
通讯作者: 赵波(通信作者),男,1956年出生,博士,教授,博士研究生导师。主要研究方向为先进制造技术、超声加工技术、精密加工技术及装备。E-mail:zhaob@hpu.edu.cn
作者简介:别文博,男,1987年出生,博士研究生。主要研究方向精密超精密加工技术与装备。E-mail:wenbo187120@163.com;高国富,男,1970年出生,博士,教授,博士研究生导师。主要研究方向为精密与特种加工技术、精密检测及表面技术、数字化设计与制造技术。E-mail:gaogf@hpu.edu.cn;向道辉,男,1971年出生,博士,教授,博士研究生导师。主要研究方向精密超精密加工技术与装备。E-mail:dhxiang@hpu.edu.cn;赵重阳,男,1985年出生,博士,讲师。主要研究方向精密超精密加工技术与装备。E-mail:zhaocy@hpu.edu.cn;唐进元,男,1962年出生,博士,教授,博士研究生导师。主要研究方向为齿轮动力学、数字化制造。E-mail:jytangcsu@163.com
基金资助:
国家自然科学基金资助项目(U1604255，51905157)。

Analytical Modeling and Experimental Investigation on Cutting Coefficient during Tangential Ultrasonic Vibration-assisted Forming Grinding Gear

BIE Wenbo^1,2, ZHAO Bo¹, GAO Guofu¹, XIANG Daohui¹, ZHAO Chongyang¹, TANG Jinyuan³

1. School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo 454000;2. School of Electrical and Mechanical Engineering, Pingdingshan University, Pingdingshan 467000;3. State Key Laboratory of High Performance Complex Manufacturing, Central South University, Changsha 410083

Received:2021-04-18 Revised:2021-08-19 Online:2022-05-20 Published:2022-05-20

摘要/Abstract

摘要： 通过对磨粒-工件的运动特性分析，研究了切向齿轮超声成形磨削过程中分离加工机理，建立了超声振动作用下磨粒-工件的切削系数模型，得到了加工参数(砂轮速度、进给速度、超声频率和超声振幅)对切削系数的影响规律。针对切向齿轮超声成形磨削分离加工的特点，进行了齿轮超声成形磨削和普通磨削加工试验，获得不同加工参数对磨削力、磨削温度、残余应力和表面粗糙度的影响规律，并对磨削后表面的微观组织进行分析。试验结果表明：与普通磨削相比，在超声磨削过程中，磨削力、磨削温度和表面粗糙度在一定程度上得到有效的降低。三者的降低幅度随着砂轮转速、进给速度的增加而减小，磨削力、磨削温度的降低幅度随着超声振幅的增加而增大，而表面粗糙度的降低幅度随着超声振幅的增加呈先增加后减小的趋势；同时，齿面的残余压应力得到提高，其增加幅度随着砂轮转速、进给速度的增加而降低，随着超声振幅的增加而增大。此外，超声磨削可以显著改善齿面的纹理状态和表层的显微组织，并实现晶粒的细化。

关键词: 齿轮, 超声成形磨削, 切削系数, 磨削力, 磨削温度, 显微组织

Abstract: The separated machining mechanism in tangential ultrasonic vibration-assisted forming grinding gear (TUVAFGG) is investigated and the cutting coefficient model of grain-workpiece is erected on the basis of the kinematic analysis of the grain and the workpiece. And the relationship between the processing parameters (grinding wheel speed, feed rate, ultrasonic frequency and ultrasonic amplitude) and cutting coefficient is acquired. The TUVAFGG and conventional forming grinding gear (CFGG) experiment is performed to explore the characteristics of separated machining. A detailed comparative study of grinding force, grinding temperature, residual stress and surface roughness during the both machining methods is conducted to obtain the effect of various parameters on them, and analyze the microstructure of the gear surface. The experimental results presents that compared with CFGG, the grinding force, grinding temperature and surface roughness are effectively reduced to a certain extent with the increase of grinding wheel speed, feed rate and ultrasonic amplitude during TUVAFGG. The reduction ratio of the three decreases with an increase of grinding wheel speed and feed rate. The grinding force and grinding temperature reduction ratio increased with an increase of ultrasonic amplitude, however, the surface roughness reduction ratio first increases and then decreases. Simultaneously, the residual compressive stress of the tooth surface is improved, and the increase ratio decreases with the increase of grinding wheel speed and feed rate, while enhance with the increase of ultrasonic amplitude. In addition, under the action of ultrasonic vibration, the surface texture state and microstructure of the surface layer can be significantly improved, and the grain can be refined compared with CFGG.

Key words: gear, ultrasonic vibration-assisted forming grinding, cutting coefficient, grinding force, grinding temperature, microstructure

中图分类号:

TG580

别文博, 赵波, 高国富, 向道辉, 赵重阳, 唐进元. 切向超声振动辅助成形磨削齿轮的切削系数建模与试验研究[J]. 机械工程学报, 2022, 58(7): 295-308.

BIE Wenbo, ZHAO Bo, GAO Guofu, XIANG Daohui, ZHAO Chongyang, TANG Jinyuan. Analytical Modeling and Experimental Investigation on Cutting Coefficient during Tangential Ultrasonic Vibration-assisted Forming Grinding Gear[J]. Journal of Mechanical Engineering, 2022, 58(7): 295-308.

参考文献

[1] 高玉魁,赵振业. 齿轮的表面完整性与抗疲劳制造技术的发展趋势[J]. 金属热处理,2014,39(4):1-6. GAO Yukui,ZHAO Zhenye. Development trend of surface integrity and anti-fatigue manufacture of gears[J]. Heat Trement of Metal,2014,39(4):1-6.
[2] 郭东明,孙玉文,贾振元. 高性能精密制造方法及其研究进展[J]. 机械工程学报,2014,50(11):119-134. GUO Dongming,SUN Yuwen,JIA Zhenyuan. Methods and research progress of high performance manufacturing[J]. Journal of Mechanical Engineering,2014,50(11):184-191.
[3] 别文博,赵波,王晓博,等. 超声加工在齿轮抗疲劳制造中的研究综述与展望[J]. 表面技术,2018,47(7):35-51. BIE Wenbo,ZHAO Bo,WANG Xiaobo, et al. Overview and expectation on gear anti-fatigue manufacture by ultrasonic-assisted machining[J]. Surface Technology, 2018,47(7):35-51.
[4] KARPUSCHEWSKI B,KNOCHE HJ,HIPKE M. Gear finishing by abrasive processes[J]. CIRP Annals- Manufacturing Technology,2008,57(2):621-640.
[5] YI J,JIN T,ZHOU W,et al. Theoretical and experimental analysis of temperature distribution during full tooth groove form grinding[J]. Journal of Manufacturing Processes,2020,58:101-115.
[6] WANG Y,LIU Y,CHU X,et al. Calculation model for surface roughness of face gears by disc wheel grinding[J]. International Journal of Machine Tools and Manufacture, 2017,123:76-88.
[7] 隈部淳一郎. 精密加工振动切削基础与应用[M]. 北京:机械工业出版社,1985. KUMABE J. The foundation and application of precision vibration cutting[M]. Beijing:China Machine Press, 1985.
[8] TAWAKOLI T,AZARHOUSHANG B. Influence of ultrasonic vibration on dry grinding of soft steel[J]. International Journal of Machine Tools and Manufacture, 2008,48(14):1585-1591.
[9] 丁凯,傅玉灿,苏宏华,等. 基于单颗磨粒磨削的超声振动参数与磨削参数匹配性研究[J]. 机械工程学报, 2017,53(19):59-65. DING Kai,FU Yucan,SU Honghua,et al. Study on matching performance of ultrasonic vibration and grinding parameters based on a single abrasive grinding[J]. Journal of Mechanical Engineering,2017,53(19):59-65.
[10] YANG Z,ZHU L,ZHANG G,et al. Review of ultrasonic vibration-assisted machining in advanced materials[J]. International Journal of Machine Tools and Manufacture, 2020,156:103594.
[11] LIANG Z,WANG X,WU Y,et al. An investigation on wear mechanism of resin-bonded diamond wheel in elliptical ultrasonic assisted grinding (EUAG) of monocrystal sapphire[J]. Journal of Materials Processing Technology,2012,212(4):868-876.
[12] CHEN H,TANG J,SHAO W,et al. An investigation of surface roughness in ultrasonic assisted dry grinding of 12Cr2Ni4A with large diameter grinding wheel[J]. International Journal of Precision Engineering and Manufacturing,2018,19(6):929-936.
[13] 冯平法,王健健,张建富,等. 硬脆材料旋转超声加工技术的研究现状及展望[J]. 机械工程学报,2017,53(19):3-21. FENG Pingfa,WANG Jianjian,ZHANG Jianfu,et al. Research status and future prospects of rotary ultrasonic machining of hard and brittle materials[J]. Journal of Mechanical Engineering,2017,53(19):3-21.
[14] 牛赢,焦锋,赵波,等. 纵扭超声铣削残余应力三维有限元仿真与试验[J]. 机械工程学报,2019,55(13):224-232. NIU Ying,JIAO Feng,ZHAO Bo,et al. 3D finite element simulation and experimentation of residual stress in longitudinal torsional ultrasonic assisted milling[J]. Journal of Mechanical Engineering,2019,55(13):224-232.
[15] TAWAKOLI T,AZARHOUSHANG B,RABIEY M. Ultrasonic assisted dry grinding of 42CrMo4[J]. The International Journal of Advanced Manufacturing Technology,2009,42(9-10):883-891.
[16] NIK M G,MOVAHHEDY M R, AKBARI J. Ultrasonic-assisted grinding of Ti6Al4V alloy[J]. Procedia CIRP,2012,1:353-358.
[17] ZHANG J J,WANG D Z. Investigations of tangential ultrasonic vibration turning of Ti6Al4V using finite element method[J]. International Journal of Material Forming,2019,12:257-267.
[18] LANG W F,ZHANG H L. Investigation on machining characteristics for tangential ultrasonic vibration assisted grinding[J]. Applied Mechanics and Materials,2010,34-35:282-286.
[19] SUI H,ZHANG X Y,ZHANG D Y,et al. Feasibility study of high-speed ultrasonic vibration cutting titanium alloy[J]. Journal of Materials Processing Technology,2017,247:111-120.
[20] 张翔宇,隋翯,张德远,等. 高速超声振动切削钛合金可行性研究[J]. 机械工程学报,2017,53(19):120-127. ZHANG Xiangyu,SUI He,ZHANG Deyuan,et al. Feasibility study of high-speed ultrasonic vibration cutting titanium alloy[J]. Journal of Mechanical Engineering,2017,53(19):120-127.
[21] 王立江,赵继,谭庆昌. 超声波振动车削的运动学及其加工表面质量[J]. 兵工学报,1987,8(3):24-31. WANG Lijiang,ZHAO Ji,TAN Qingchang. Kinematics of ultrasonic vibration-cutting and a study of resulting surface quality[J]. Acta Armamentarii,1987,8(3):24-31.
[22] XIAO M,KARUBE S,SOUTOME T, et al. Analysis of chatter suppression in vibration cutting[J]. International Journal of Machine Tools and Manufacture, 2002,42:1677-1685.
[23] NATH C,RAHMAN M. Effect of machining parameters in ultrasonic vibration cutting[J]. International Journal of Machine Tools and Manufacture,2008,48:965-974.
[24] NI C,ZHU L,LIU C,et al. Analytical modeling of tool-workpiece contact rate and experimental study in ultrasonic vibration-assisted milling of Ti-6Al-4V[J]. International Journal of Mechanical Sciences,2018, 142-143:97-111.
[25] XIANG D,ZHOU Z,LIU Z,et al. Abrasive wear of a single CBN grain in ultrasonic-assisted high-speed grinding[J]. International Journal of Advanced Manufacturing Technology,2018,98(1-4):1-9.
[26] 张洪丽. 超声振动辅助磨削技术及机理研究[D]. 济南:山东大学,2007. ZHANG Hongli. Study on the technology and mechanism of ultrasonic vibration assisted grinding[D]. Jinan:Shandong University,2007.

切向超声振动辅助成形磨削齿轮的切削系数建模与试验研究

Analytical Modeling and Experimental Investigation on Cutting Coefficient during Tangential Ultrasonic Vibration-assisted Forming Grinding Gear

PDF

可视化

摘要/Abstract

引用本文

使用本文

参考文献

相关文章 15

编辑推荐

Metrics

本文评价

[1]	石照耀, 赵保亚, 于渤, 郭晓忠. 齿轮三维误差表征与分解[J]. 机械工程学报, 2022, 58(6): 1-9.
[2]	苏睿明, 贾咏馨, 胡诗扬, 曲迎东, 李荣德. 二次时效对Al-Cu-Mg合金组织及性能的影响[J]. 机械工程学报, 2022, 58(4): 102-110.
[3]	刘怀举, 张博宇, 朱才朝, 魏沛堂. 齿轮接触疲劳理论研究进展[J]. 机械工程学报, 2022, 58(3): 95-120.
[4]	余晓霞, 邓蕾, 汤宝平, 夏乙, 李琪康. 小样本条件下元学习门控神经网络的齿轮退化趋势预测研究[J]. 机械工程学报, 2022, 58(3): 149-156.
[5]	王龙, 汪刘应, 唐修检, 阳能军, 刘顾, 李若亭, 油银峰. 成形法磨削齿轮的磨削温度模型构建与分析[J]. 机械工程学报, 2022, 58(3): 295-304.
[6]	陈勇, 李金锴, 臧立彬, 刘意气, 毕旺洋, 杨小朋. 疲劳点蚀斜齿轮动力学仿真预测与故障识别试验研究[J]. 机械工程学报, 2021, 57(9): 61-70.
[7]	黄伟国, 李仕俊, 毛磊, 马玉强, 王俊, 沈长青, 阙红波, 朱忠奎. 多源稀疏优化方法研究及其在齿轮箱复合故障检测中的应用[J]. 机械工程学报, 2021, 57(7): 87-99.
[8]	于秋颖, 贺晓勇, 谢孝昌, 方爽, 李能, 黄帅, 熊华平. 不同成分下铸态 AlMoNbTaTiZr 高熵合金显微组织的研究[J]. 机械工程学报, 2021, 57(6): 96-105.
[9]	茅健, 赵嫚, 张立强. 晶粒取向对微细加工磨削力作用机理及试验研究[J]. 机械工程学报, 2021, 57(5): 262-272.
[10]	李伟, 秦羽满, 李艳国, 张明, 杨志南, 张福成, 尤蕾蕾, 龙晓燕. 热处理工艺对纳米贝氏体渗碳轴承钢表层组织和性能的影响[J]. 机械工程学报, 2021, 57(4): 63-72.
[11]	张海燕, 侯力, 罗岚, 梁爽, 冷松. 变双曲圆弧齿线圆柱齿轮专用机床的模块化设计[J]. 机械工程学报, 2021, 57(3): 77-86.
[12]	陈龙, 郝婵娟, 汪中厚, 冯文斌, 杨易明. 单齿啮合的齿轮接触等几何分析[J]. 机械工程学报, 2021, 57(3): 107-115.
[13]	李尧, 党晓凤, 陈凯, 何卫锋. 感应加热对激光增材修复高温合金DZ125L组织和力学性能的影响[J]. 机械工程学报, 2021, 57(22): 52-59.
[14]	魏静, 姜东, 张爱强, 程浩. 时变位姿下行星齿轮传动系统动应力计算模型及其参数影响研究[J]. 机械工程学报, 2021, 57(21): 150-159.
[15]	王璞, 肖红, 沈厚发, 陈希青, 陈列, 兰鹏, 张家泉. 结晶器电磁搅拌对高强齿轮钢大圆坯凝固行为的影响[J]. 机械工程学报, 2021, 57(2): 105-111.