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

doi:10.3901/JME.2022.07.295

Abstract

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

CLC Number:

TG580

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.

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