Analytical modeling of grinding force and experimental study on ultrasonic-assisted forming grinding gear

Yin, Longwei; Zhao, Bo; Huo, Bingjun; Bie, Wenbo; Zhao, Cuihua

doi:10.1007/s00170-021-07086-3

Cited by 7 publications

(3 citation statements)

References 24 publications

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“…The TUVAGG could enhance the residual compressive stress by 13.2%-29.3% compared with the CGG. 81 Yin et al 82 established the analytical modeling of grinding force on ultrasonic vibration-assisted forming grinding gear, and obtained the effect of processing parameters (ultrasonic amplitude, grinding wheel speed, grinding depth, and feed speed) on the grinding force. This results provided a reference for the investigation on the ultrasonic vibration-assisted grinding gear.…”

Section: Ultrasonic Vibration-assisted Grinding Gearmentioning

confidence: 99%

Ultrasonic assisted machining of gears with enhanced fatigue resistance: A comprehensive review

Bie

Zhao

et al. 2022

Advances in Mechanical Engineering

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In recent years, ultrasonic-assisted machining (UAM) has been widely implemented to improve the performance and element quality of machined products. This paper comprehensively reviews the ultrasonic vibration effects on such ultrasonic vibration-assisted (UVA) processes as hobbing (UVAH), lapping (UVAL), electrochemical gear machining (UVAEGM), honing (UVAH), and grinding (UVAG), respectively. Compared with the conventional machining, the UAM significantly reduced the surface roughness, improved the surface microstructure, and quality. Considering the UAM applications surface modification and surface strengthening, the available technologies of ultrasonic impact, ultrasonic shot peening, and ultrasonic deep rolling were analyzed for gears and similar components. It was concluded that the surface was strengthened under UAM through introducing the high-amplitude and large-depth residual compressive stresses, restraining crack propagation to a certain extent, and improving the gear fatigue resistance. Finally, the ultrasonic machining effect on gear fatigue resistance was theoretically substantiated from the ultrasonic vibration system and surface integrity standpoints. This review aims to optimize the application of ultrasonic-assisted machining, in order to produce gears with enhanced fatigue resistance and surface integrity.

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Section: Ultrasonic Vibration-assisted Grinding Gearmentioning

confidence: 99%

Ultrasonic assisted machining of gears with enhanced fatigue resistance: A comprehensive review

Bie

Zhao

et al. 2022

Advances in Mechanical Engineering

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“…The largest tensile stress was attained on grain rake face before the actual cutting depth reached the maximum value, indicating that the grit rake face was more easily fractured than the grit tip. Yin et al [20] proposed an analytical model for UVAG force considering the friction and material deformation. The ultrasonic vibration reduced the relative sliding speed and the friction coefficient on the tool-workpiece interface due to the equivalent softening effect, resulting in the lower friction force.…”

Section: Introductionmentioning

confidence: 99%

Intermittent cutting behavior and grinding force model in ultrasonic vibration-assisted grinding K4002 nickel-based superalloy

Cao,

Zhao,

Ding

et al. 2024

Int J Adv Manuf Technol

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The intermittent cutting behavior, performing as periodic contact phase and separation phase between abrasive grit and workpiece, is an important characteristic in the ultrasonic vibration-assisted grinding (UVAG). This study investigated the effect of intermittent cutting behavior on the grinding force in UVAG. At first, a grinding force model was established by determining the quantity of effective grits and the grinding force of a single grit. Then the influences of ultrasonic vibration phase on the intermittent cutting behavior and grinding force were discussed. Finally, the prediction accuracy of the model was tested through experiments. Results indicated that the quantity of effective grits, unchanged chip thickness and proportion of grits at the sliding, plowing, cutting stages were all changed with the vibration phase. A large unchanged chip thickness and 56% effective grits at the cutting stage were generated at the start of the grits-wheel contact phase. Then, the quantity of effective grits firstly increased to maximum 232 at the vibration phase of 0.5π and then decreased to zero when entering the grits-wheel separation phase. The maximum error of the grinding force model was 15%, indicating that the model was of high accuracy for the force prediction in UVAG.

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“…In order to reduce roughness, improve cutting force and surface precision, a compound generating method with ultrasonic-assisted motion was presented. Yin and Zhao discussed the process of surface grinding with ultrasonic-assisted motion or not, and established a mathematical model for the prediction of grinding force and surface quality [8][9][10]. Venkatesh considered the surface finishing of bevel gear, presented a finite element simulation for bevel gear with different input parameters [11].…”

Section: Introductionmentioning

confidence: 99%

Tooth surface Hobbing analysis for unconventional gears with ultrasonic-assisted motion

He¹,

Lin²

2022

J. vibroeng.

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As an atypical conventional gear pair, non-circular gear has a variable transmission ratio, which can be used to improve the structure and transmission characteristics in some applications, such as variable speed grinding mechanism, wool blending machine guide mechanism, continuously variable transmission structure and so on. According to the friction theory of conjugate surfaces, the transmission characteristics will be affected by the micro topography of tooth surface, but the shaped tooth surface of non-circular gear with normal hobbing method is not uniform, because of its variable radius and flank orientations of tooth surface. The research on the relationship between micro topography and parameters of non-circular gear is necessary, thus an improved manufacturing method with ultrasonic-assisted motion was presented in this paper, the mathematical equations for the theoretical tooth surface of non-circular gear with and without ultrasonic-assisted motion have been derived in this paper, also the equations for cutting parameters (step displacement, step rotating angle) have been proposed, shown that all the parameters (initial parameters of gear and gear hob, cutting parameters in manufacturing process) will affect the formed micro surfaces. In detail, the height Hm and width Sm of micro undulating tooth surface periodically increase and decrease, getting the maximum value at θn=π, where is the maximum radius. The height Hm and width Sm of micro tooth surface will increase with any control parameter increase, the height Hm of most micro peaks is near 6.5um in normal hobbing process. While, the tooth surface with ultrasonic-assisted motion is more regular and clearer with the maximum height Hm decrease from 6.5 um to 2.7 um, getting more compact cutting tracks and lower surface roughness. The experimental results shows that ultrasonic-assisted hobbing has obviously positive influence for micro tooth surface, provides the theoretical support for a further analysis and better application of unconventional gear pair.

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Analytical modeling of grinding force and experimental study on ultrasonic-assisted forming grinding gear

Cited by 7 publications

References 24 publications

Ultrasonic assisted machining of gears with enhanced fatigue resistance: A comprehensive review

Ultrasonic assisted machining of gears with enhanced fatigue resistance: A comprehensive review

Intermittent cutting behavior and grinding force model in ultrasonic vibration-assisted grinding K4002 nickel-based superalloy

Tooth surface Hobbing analysis for unconventional gears with ultrasonic-assisted motion

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