齿轮式金刚石修整轮在外啮合珩齿新工艺中的应用

外啮合珩齿工艺是一种效率高、成本低的硬齿面齿轮加工工艺,但对齿轮精度的提高有限。本文采用自制的金刚石修整滚轮在Y4632A外啮合珩齿机上对外啮合珩磨轮进行修形,明显提高了外啮合珩齿的加工精度,使外啮合珩齿有可能应用于硬齿面齿轮精加工。在此基础上,进一步提出了用金刚石修整轮代替珩磨轮直接珩齿的新工艺,试验证明,新工艺省去了珩磨轮的制作和修形过程,进～步提高了加工效率和加工精度,操作容易,加工成本不高,直接使用外啮合珩齿机,相对于设备价格昂贵的内啮合珩齿机和磨齿机,节约了大量设备投资,适于中小企业生产,是一种切实可行的硬齿面齿轮精加工方法。     

齿轮式金刚石修整滚轮在珩齿加工中的应用

分析了齿轮式金刚石修整滚轮对珩磨轮的修整机理。用自制金刚石修整滚轮在内、外啮合珩齿机上进行了修整及珩齿加工试验，结果证明其修整精度完全可满足珩齿加工要求。     

重载齿轮的电化学齿向修形

对重载齿轮电化学齿向修形中电流密度的分布规律进行了探讨，得出沿齿向各处金属蚀除厚度与电流密度分布的关系，对工程机械齿轮进行了电化学修形加工，加工后的齿轮达到了齿向修形形状和修形量的要求。     

齿轮式金刚石修整滚轮在齿轮精加工中的应用研究

齿轮式金刚石修整滚轮是多种齿轮精加工工艺的修整工具，本文探讨了它的制作方法和注意事项，并用自制的金刚石修整滚轮在内啮合珩齿机、蜗杆砂轮磨齿机上对内珩轮、蜗杆砂轮进行了修磨，试验证明，自制的金刚石修整滚轮精度完全符合使用要求。     

盾构机主轴承内啮合齿轮修形优化设计

齿轮修形是降低轮齿啮入、啮出时冲击,降低齿轮副齿面应力峰值,缓解应力沿齿宽分布不均现象,使得传动平稳性提高的重要手段。结合盾构机实际工作载荷,基于KISSsoft对盾构机主轴承齿轮进行齿廓、齿向修形优化研究,针对单因素齿廓修形、单因素齿向修形、综合修形方案进行横向对比,通过对齿轮进行接触性能分析,对比修形前、后的传动误差幅值、赫兹接触应力在齿宽方向分布情况以及最大齿根弯曲应力。通过Ansys Workbench软件对未修形和确定的最优修形方案进行有限元仿真,验证其振动加速度和动态啮合应力优化程度。结果证明,采用适当的修形方案可以减小齿轮传动误差幅值,避免了轮齿啮入时出现载荷突变的情况,并且优化了齿面偏载的情况,进而使得齿轮啮合传动性能得到了提高,传动更加稳定。     

一种新的修形策略的动态分析

线外啮合,特别是齿顶尖角接触,会引起齿轮的啮合冲击。因此,先前的研究常采用齿廓修形来避免齿顶尖角接触,但是线外啮合可能依然存在。为了进一步减小线外啮合带来的啮合冲击,提出了一种新的修形策略:首先,在理论啮入点或者理论啮出点,沿配对齿的齿廓切线方向去除另外一个轮齿的齿顶部分;然后用一段角域中的正弦曲线将被切形成的直线与原齿廓曲线光滑连接起来。并用6自由度的直齿轮动力学模型仿真计算了修形前后的动态啮合力,仿真结果显示:由线外啮合造成的啮合冲击较线性修形进一步减小了。因此,为了进一步减小啮合冲击,提出了一种计算修形量和构造修形曲线的行之有效的方法。     

齿轮电化学修形中电场测试研究

采用电化学加工方法，对圆柱直齿轮进行修形加工，是获得修形齿轮的方法之一。为了获得合适的修形量和修缘高度，要对电化学加工中，工作周围的电力线走向、密度进行检测，以此作为估算去除量的依据。本文介绍了测量原理、测量装置结构、测量过程。     

齿轮的电化学修形工艺研究

提出简便实用的斜齿轮修形量计算方法，并运用电场控制理论完善了电化学修形工艺。该工艺不仅适用硬齿面齿轮，还适用于因受齿轮结构限制而不能实行机械修形的各种齿轮。     

基于齿面拓扑修形的驱动桥主减齿轮啸叫分析与优化

针对某轻型客车在减速滑行阶段出现的驱动桥齿轮啸叫问题,提出一种齿面拓扑修形方法来优化驱动桥齿轮啸叫噪声。利用LMS Test.Lab设备进行路试测试,识别出噪声源来自驱动后桥主减齿轮的啮合振动。对主减齿轮当前齿面接触性能进行分析,在此基础上,提出采用齿面拓扑修形方法对当前齿面接触区和传动误差进行修正。对修形前后的齿面加载啮合性能和NVH仿真曲线进行对比分析,仿真结果表明:修形后齿轮啮合性能和NVH性能都得到了提升。对修形前后的主减齿轮进行了路试测试实验,实验结果表明:齿面修形后齿轮啸叫问题得到了明显改善。     

RV减速器摆线轮拓扑修形齿廓研究

为使摆线轮具有良好的啮合性能,根据计算的摆线轮实际工作范围,将摆线轮齿廓分为工作段和非工作段齿廓,采用拓扑修形方法来满足工作段和非工作段的间隙要求。工作段采用转角修形,使修形后工作段为共轭齿廓,并保持一定的齿侧间隙。非工作段采用变等距修形,使齿顶与齿根部分产生合理的间隙,得到合理的修形齿廓。推导了摆线轮拓扑修形齿面方程,可以通过调整修形参数获得满足工作要求的齿廓间隙。从初始啮合间隙、载荷分布、回差分析方面验证了拓扑修形的合理性。     

Gear finishing by abrasive processes

Based on the position of hard finishing in the process chain of gear manufacturing, the dominant processes with a geometrically non-defined cutting edge are analysed. While processes like continuous profile grinding and discontinuous generating grinding with double cone discs became less important in the last couple of years, the processes continuous generating gear grinding, discontinuous profile grinding and honing of tooth flanks gain rising importance. The analyses of the processes include functionality, the development status, respectively, maturity as well as identifiable trends. Process superior aspects like dressing of the grinding wheel and honing rings and the problem of grinding burn will be considered and evaluated separately.     

Cutting force model for gear honing

In gear honing the low robustness of the process is a challenge in process design. The forces resulting from the machining interact with the dynamic behavior of the system which influences the quality of the workpiece and the tool life. Due to these reasons, the process forces during gear honing must be determined locally and temporally resolved. Therefore, a force model was derived and parameterized with gear honing analogy trials. This force model was combined with a process simulation for gear honing and an analytical calculation of the velocities. The model for gear honing was validated with gear honing trials.     

Critical review of electrochemical honing: sustainable and alternative gear finishing process. Part 2: effects of various process parameters on surface characteristics and material removal rate

Part 1 of this review discussed conventional gear surface finishing processes and their advantages and limitations, and introduced the electrochemical honing (ECH) process (and its extension of pulsed electrochemical honing (PECH)), to improve the surface characteristics of different types of gears, working principles, mechanism of material removal and equipment details. Part 2 gives a review of past work, and discusses effects of various process parameters on surface characteristics and finishing productivity (i.e. material removal rate), advantages and limitations, and its other applications. The objective of this review paper is to present ECH/PECH as one emerging alternative, economical, productive and sustainable gear finishing process.     

Analysis of the influence of gear dimensions on cutting speed and contact conditions during the gear honing process

In many cases, gear honing represents a cost-efficient process for gear manufacturers. Another advantage of gear honing is the generation of a surface structure on the tooth flank which improves the noise behavior of the gear. Previous research activities have resulted in reliable gear honing processes, particularly for automotive gears with a tip diameter of up to 150 mm. Problems occur, however, when honing larger gears with a tip diameter of more than 150 mm, thereby rendering a robust manufacturing process is difficult. In the course of this paper, an analysis will be carried out of the geometrical and kinematic conditions that will lead to a better understanding of the process. The aim of this report is to provide an overview of the current basic conditions of the gear honing process. Theoretical studies are conducted to identify differences in gear honing processes with various tip diameters. This analysis forms the basis for optimizing process design, with the aim of generating a cost-efficient gear honing operation for gears with a tip diameter of more than 150 mm.     

Grinding of Gears with Vitreous Bonded CBN-Worms

Among the industrial gear grinding processes, continuous generating grinding allows the highest material removal rates due to its kinematics. The process capabilities can be further increased by using CBN as a more efficient abrasive material. The research work described in this paper proves the high potential of vitreous bonded CBN grinding worms. Compared to corundum worms, the CBN tools offer significantly better behavior with regard to process stability, gear quality and residual stress on the machined gear tooth flanks. The results also show that a well adapted dressing technology is not only an important prerequisite for the efficient application of CBN worms but it also offers excellent and further possibilities to increase the grinding process performance. Dressable CBN grinding worms have not yet been introduced to industrial gear grinding processes. The paper gives an insight into the preparation and application of these innovative tools not only for academia but also for industry.     

磨削中凸轮、修缘形齿轮砂轮修整简便方法的研究

本文研究了一种新的修磨中凸形齿轮的成形磨齿方法，该方法扩充了整体基圆式代８渐开线法修整器的功能，只需作简单的调整，即调整修速器基圆中心线在水平面的偏角，同时相应调节修整器高度和金刚石笔的伸长量，就能修磨出中凸形齿形。     

成形砂轮高精度修整技术研究

介绍成形磨齿的原理与现状.分析数控插补修正砂轮中金刚石工具自身形状误差对砂轮修整精度的影响;并提出相应的解决措施,即在修整过程中,通过工具的旋转,以保持工具与砂轮间实际修整作用点不变,从而消除工具误差对砂轮修整精度的影响.并设计出具体修整装置.实践表明:采用该方法不仅可以保持高的工作精度,而且可以延长工具的使用寿命.     

汽缸套平台网纹加工专用金刚石珩磨油石性能的研究

本文介绍了用于加工发动机汽缸套内表面平台网纹珩磨油石的研制过程。结合剂以铜粉、铁粉为主要原料,加入添加剂HP1、添加剂HP2、添加剂HP3等金属粉末。选用170/200金刚石制造珩磨油石,并进行珩磨试验。研究了不同结合剂组分对油石硬度和抗折强度的影响。结果表明,当铜为50%、铁为20%、添加剂HP1为10%、添加剂HP2为15%、添加剂HP3为5%时,珩磨油石的硬度值达到HRB100.2,抗折强度值达到231.3MPa。最佳烧结工艺为:温度760℃,保温时间4min,成型压力3MPa。珩磨后的汽缸套达到欧Ⅲ排放要求。