System design and experimental research on the tangential ultrasonic vibration-assisted grinding gear

Abstract

Gear plays an important role in transmitting motion and power system, and a new promising process should be utilized to enhance the machining accuracy and performance. In this paper, the ultrasonic vibration was superimposed into the gear to carry out the tangential ultrasonic vibration-assisted grinding gear (TUVAGG). The longitudinal resonant vibration system was designed based on the non-resonant theory. Firstly, the gear was simplified into a disc with the diameter of the reference circle, and the dynamic equation of each part was erected respectively.Then the frequency equation was derived according to the coupling conditions of the force and displacement during the combined surface of the vibration system. Simultaneously, the characteristic of displacement for the vibration system was also obtained. Secondly, the vibration system composed of the simplified disc and the gear was simulated by the finite elements analysis method, and verified by the resonant measurement experiment respectively. The measurement results exhibited a good agreement with the theoretical. Finally, the effectiveness of the vibration system was verified through the ultrasonic vibration-assisted grinding gear test. It was found that compared with the conventional grinding gear (CGG), the normal grinding force and tangential grinding force was reduced by 7.4-28.2% and 8.9-18.9% respectively during TUVAGG. Besides, the grinding temperature and the surface roughness was declined by 7.6-25.7% and 8.6-21.8% respectively, and the residual compressive stress of tooth surface was elevated by 13.2-29.3%. It was concluded that the non-resonant theory was suitable for the designation of longitudinal vibration system for TUVAGG, and also provided a novel process technology for gear machining.

Simulation and Experimental Study of Non-Resonant Vibration-Assisted Lapping of SiCp/Al

“…The abrasive in the conventional lapping (CL) method is in continuous contact with SiCp/Al, and the strength difference between the aluminum matrix and SiC particles leads to surface damage of SiC particles during processing, so there are large heating and pits in the processing process [ 5 , 6 ]. Many studies have pointed out that ultrasonic vibration-assisted machining (UVM) technology and non-resonant vibration-assisted machining (NVM) technology can reduce force and surface damage by changing the motion path of the abrasive or tool [ 7 , 8 , 9 ]. Vibration-assisted machining technology based on ultrasonic vibration devices improves surface quality and surface integrity by making abrasive or tools hit the workpiece surface at high frequency [ 10 ].…”

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

“…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].…”