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。     

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.     

Discontinuous profile grinding of multi-phase,case-hardened gears with improved load-carrying capacity

Highly-loaded transmission components like gears are case hardened for most applications to reach a load adapted strength. The surface layer microstructure as a function of heat treatment decisively determines the achievable load-bearing properties of the component as well as the technological limits of gear grinding. Against this background, this paper deals with the machinability (discontinuous profile grinding) of differently (carburizing and carbonitriding) case-hardened gears with various multi-phase microstructures and improved load-carrying capacity. Therefore, effects of different material phases, precipitates and their distribution in the surface layer on the gear-grinding process will be discussed.     

Surface layer modification charts for gear grinding

In this paper, an approach to predict thermo-mechanically induced changes of sub-surface properties during discontinuous profile gear grinding is presented. The approach faces industrial boundary conditions, such as varying material stock removal as well as the drawback of possible localized thermal damage on the ground tooth flanks. The basic idea is to consider the sub-surface properties after grinding as a function of “tempering time” and temperature due to the short-time heat treatment by the grinding process. Consequently, a time–temperature-diagram showing surface layer modifications for profile gear grinding based on the measurement of local contact zone temperatures has been set up.     

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。     

Minimization of effect of CBN wheel wear on ground gear errors

Resistance to wear of CBN grinding wheels is much higher than that of conventional (Al₂O₃) wheels. However, CBN grinding wheels are seldom used in gear grinding, when production scale is small, due to the difficulty in truing. Moreover, wear of the grinding wheel greatly affects the accuracy of tooth trace, in most cases. Considering this problem, the authors proposed new processes in which the accuracy of the tooth trace and tooth profile was hardly affected by wear of the wheel. While grinding was performed using a conventional method, a concave tooth-trace error of about 2 μm occurred after grinding only 30 teeth. In one of the proposed methods, the concave tooth trace error never occurred even when 2000 teeth were ground by the same wheel. In the third method, the CBN layer is effectively used for gear grinding by giving an additional motion which is independent of the tooth profile generating motion.     

超声纵振珩磨的切削模型及其临界速度研究

径向超声振动磨削与纵向超声振动磨削，其主要差别是磨粒与工件的接触状态不同，在径向超声振动磨削中，磨粒与工件的接触是间断性的，它的临界速度特征符合现有的振动切削理论，而在纵向超声振动磨削中，磨粒与工件是永久性接触，不存在磨粒与工件表面分离的特点。根据它们的差别作者建立了磨粒纵向超声振动切削模型，得到了纵向超声振动珩磨临界速度的新概念及其计算公式。     

砂带内孔珩磨工艺研究及应用

为了提高内孔珩磨质量和提高生产效率而设计制造了适用于内孔珩磨加工的砂带珩磨头,文中对砂带珩磨加工的原理及工艺参数进行了分析研究,并在立式珩磨机上成功地完成了内孔珩磨加工,提高了生产效率,大大降低了生产成本.     

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.     

锥面砂轮磨齿机磨削渐开螺旋面的理论验证

文章根据锥面砂轮磨齿机工作原理和齿轮啮合原理，利用齿形法线法，从齿形方程和渐开螺旋面两个方面对锥面砂轮磨齿机正确磨削斜齿圆柱齿轮渐开螺旋面进行了理论验证，该验证方法及推导过程有助于理解采用齿条形刀具磨削齿轮的原理，同时对提高磨齿加工精度具有理论指导意义。     

Modeling and predicting of surface roughness for generating grinding gear

Gear surface has a significant effect on the load-carrying capacity and plays a crucial role for wear, friction and lubrication properties of the contact. However, most mathematical model of a generating gear grinding process trends to focus on grinding forces and temperature distribution in gear tooth. A new method for predicting gear surface roughness with the generating grinding process is developed in this paper. An algorithm for geometrical analysis of the grooves on the gear surface left by idea conic grains is given. To determine the final gear surface roughness produced by thousands of grinding wheel grains with randomly distributed protrusion heights, a search technique is proposed to systematically solve the gear surface roughness, which starts from the addendum circle along the involutes direction and ends at the dedendum circle. The numerical calculated results show that the surface of gear root part is smoother than that of gear top part.     

外啮合珩齿珩轮修形新方法

外啮合珩齿是硬齿面齿轮加工的重要方法，本文分析了用齿轮式的金刚石修整滚轮对外珩磨轮进行修形的机理，并用自制的金刚石修形轮在Y4632A外啮合珩齿机上进行了修形及加工试验。     

Development of a honing process for the combination machining of hardened axisymmetric parts

This paper presents a novel concept to enhance the conventional combination machining ‘turning and grinding’ by a long-stroke honing process for finishing bores of axisymetric parts. Honing is the best choice when the surface integrity of tribologically highly-stressed parts is of vital importance. The presented approach reduces the required overall machining time when compared with that of the conventional machining sequence on separate machine tools, and also enhances the production accuracy through a single clamping setup. The fundamental details like tool design, infeed strategies and possible process-chains of the developed approach for honing on a combination machining center are explained. Experimental results of two different process-chains are analyzed: Firstly, the ‘turning-grinding-honing’ (TGH-chain), where honing is conducted after the grinding process; and secondly, the ‘turning-honing’ (TH-chain), where honing is applied directly after the rough turning. The experiments showed promising results for the applied position-controlled infeed strategy of the developed long-stroke honing process regarding the production efficiency.     

齿轮成形磨削能耗与表面粗糙度研究

齿轮成形磨削的能耗研究对于高精度齿轮的低碳制造具有重要意义.从数控成形磨齿机床的部件层面出发,分析齿轮成形磨削的能耗组成部分;基于磨削功率和材料切除率,建立齿轮成形磨削的净能耗密度模型;通过齿轮成形磨削试验发现,增加磨削能耗,会使表面粗糙度减小,但随着磨削能耗的持续增加,表面粗糙度减小幅度有限.研究结果为齿轮成形磨削的能耗与加工质量协同优化控制奠定了理论基础.     

New tool concept for grinding a plateau-like surface for tribological applications

One of the most important factors for energy efficiency is the reduction of friction in machine elements. The grinding process is often the final machining process in machining hardened steel parts and the resulting surface finish influences the tribological behavior. The combination of grinding with a honing process can generate a plateau-like surface to reduce friction and create an oil reservoir to decrease abrasive wear and improve the fluid film stability. Additional processes like laser machining, micro milling or etching are able to generate micro dimples to improve the reduction of friction. Today, grinding processes are limited to machine plateau-like surfaces. Within this paper, a new tool concept will be presented, composed of a grinding tool with two different grain sizes and a metallic bonding. The use of small abrasive grains generates a smooth surface with low roughness values. A few additional larger grains induce stochastic scratches and create the plateau-like surface. Grinding experiments are conducted to analyze the effect of feed rate, feed angle and ratio between small and large grains on the resulting surface.     

Optimization of Gear Tooth Surfaces

During the evolution of gearboxes, unwanted noise has been one of the most discussed subjects. Increasing demands on weight reduction and compactness of gearboxes, while preserving the same torque capacity, require optimal design of all parameters involved. Quiet running is especially desirable in a modern automotive gearbox. The very complicated geometry of helical gears, engenders the problem of a multi-variable optimization procedure. Errors of the microform as well as the macroform of the gears highly influence the sound activation. Effects of the macroform have been studied by many researchers and are widely known and predictable. Normally, finishing processes, such as grinding and honing, are used to achieve the predicted macroform of a gear tooth. As a consequence of applying these processes, the microform of the tooth is accomplished.This paper is concerned with the characterization of the gear tooth surfaces obtained with such processes. The characterization is performed with respect to the surface functional properties. These parameters which are interesting due to the noise activity, were identified when the literature available in the field of interest was reviewed. 3D measuring technique, form removal, functional filtering, and 2D spectral density analysis have been utilized in order to extract this information as surface functional parameters.Since the main aim of this paper is to discuss how to produce gears with optimal noise consequences, the principles of RZP-grinding, Fässler honing and Hurth green-shaving are discussed. During this work, the most significant process parameters have been identified utilizing two-level fractional factorial experiments, based on 3D evaluation of surfaces. The parameters identified together with the process principles were then used to predict the surface characteristics. Optimal strategies concerning all processes for production of low noise gears are suggested. The validity of arguments and results regarding the RZP-process was examined, while gears from a real manufacturing shop-floor were evaluated.     

超声振动珩磨表面残余应力数值模拟研究

目的磨削产生的残余应力对工件表面特性有重要影响,超声振动珩磨使磨粒具有极大的加速度而改变了材料去除机理,研究超声振动对工件表面残余应力的影响及产生机理。方法分析残余应力形成有限元理论,建立基于热弹塑性有限元法的超声振动单颗CBN磨粒切削40Cr Ni Mo A热力耦合有限元模型,并设置两次切削、卸载、约束转换及冷却等分析步。通过数值模拟得到不同振动参数下表面残余应力的分布情况,并对模拟结果进行分析。结果有限元计算得到的各分析阶段应力分布存在差别,超声振动参数设置达到仿真要求;对磨粒施加超声振动后珩磨力下降约26%,珩磨热降低约17%,切向残余压应力有所减小,垂直珩磨速度方向拉应力减小并向压应力转变。结论超声振动使珩磨力和珩磨热有一定程度降低从而改变了残余应力的分布及数值;振动频率在20 k Hz波动时对残余应力的影响不大;磨削速度减小,切向残余压应力增大,垂直磨削方向残余拉应力减小;振幅增大时,切向残余压应力减小,垂直方向残余应力增大。     

混合磨料珩磨油石的磨削性能研究

本文介绍了几种常用磨料(刚玉系列和碳化硅系列磨料)的磨削性能,设计了十几种按不同比例混合的多种磨料珩磨油石,对45#钢、不锈钢和钛合金等金属材料进行了珩磨对比试验,通过试验结果分析得出:①珩磨具有一定硬度的钢类零件,选用SA(90%)和GC(10%)的混合珩磨油石,磨削效果好,磨削比高,并且没有粘附现象,能充分发挥两种磨粒的磨削性能;②珩磨奥氏体不锈钢(1Cr18N i9Ti),选用WA(90%)和GC(10%)的混合珩磨油石,既能提高磨削比,又能减小油石的粘附现象;③对于钛合金材料,选用GC(70%)和SA(30%)的混合珩磨油石,磨削效率较高,油石粘附较少,并不易破碎,具有较好的磨削效果;④混合磨料珩磨油石在磨削一些金属材料时具有比单一磨料油石更好的磨削性能。     

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.