Study on Surface Integrity Distribution of Tooth Root of Aviation Gear after Profile Grinding and Ultrasonic Rolling Processes

doi:10.3901/JME.2025.05.343

Abstract

Abstract: The evaluation model of equivalent initial microcrack and stress concentration coefficient under the action of surface texture is proposed. The surface integrity distribution of tooth root after profile grinding is investigated and the parameter optimization of grinding process is conducted. A test device for ultrasonic rolling process (USRP) of aviation gear is designed and built, which is applied to the root strengthening, and the surface integrity distribution after USRP is analyzed. The results show that the equivalent initial crack length and stress concentration coefficient of the tooth root reach up to 5.09 μm and 2.6, respectively after profile grinding. The depth of microstructure deformation layer is about 30 μm. The depth of the compressive residual layer and work hardening layer is about 30 μm and 200 μm, respectively. High grinding speed, high feed rate and small cutting depth help to reduce the equivalent crack length and stress concentration coefficient of the root surface while low grinding speed, low feed rate and small cutting depth help to increase the residual stress amplitude. USRP can improve the surface finish of tooth root, reduce the equivalent initial crack length to 0.28 μm, introduce a deeper plastic deformation layer, and significantly increase the depth of compressive residual stress layer compared with grinding and mechanical shot peening processes.

Key words: ultrahigh strength steel, tooth root, profile grinding, ultrasonic rolling, surface integrity

CLC Number:

TG306

DANG Jiaqiang, AN Qinglong, LI Yugang, MING Weiwei, WANG Haowei, LIU Zhongming, CHEN Ming. Study on Surface Integrity Distribution of Tooth Root of Aviation Gear after Profile Grinding and Ultrasonic Rolling Processes[J]. Journal of Mechanical Engineering, 2025, 61(5): 343-353.

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