弧齿锥齿轮超声双频激励研齿的齿面高阶修形机理与研齿路径规划研究

Traditional gear lapping has its limitations such as poor material removal rate, non-uniform lapping over tooth surface, low inefficiency in improving tooth profile accurac，no obvious effectiveness in improving the micro texture of gear surface, and so forth. In this project, the ultrasonic exciting with different frequency and vibration amplitude are applied to gear and pinion respectively to increase the machining efficiency. The interference and superposition of stress field on surface of gear and pinion will be analyzed respectively. The optimal matching relationship for frequency and vibration amplitude of ultrasonic exciting will be studied. The dynamic model of gear lapping system under dual-frequency ultrasonic exciting will be constructed. The dynamic force by ultrasonic exciting between gear surfaces will be studied, as well as the mechanism of ease-off topography correction in the process of ultrasonic gear lapping. The mathematic relationship with ease-off values and transmission error curve will be established. Based on the tooth contact theory for real gear surface, the sensitive matrix for VHJ adjustment and lapping point moving will be established. According to the optimal lapping process parameters, the key topic to this project is to achieve gear flank high-order correction through gear lapping path planning, to study the influence of ultrasonic exciting on material removal rate and microstructure of gear flank, to find the feasibility of the ultrasonic low amplitude rolling strengthening on gear surface material. The research results will be testified by gear flank measuring, transmission error measuring, vibration & noise experiments，surface microstructure observation and surface stress analysis. The aim of this subject is to increase gear lapping efficiency, to optimize the shape of the transmission error curve, to strengthen the gear surface, to improve the transmission quality. This proposed ultrasonic gear lapping methodology can be served as a basis for developing a general technique of flank modification for other gear types.

传统的弧齿锥齿轮研齿加工存在材料去除率低、齿面研磨不均匀、对齿面偏差改善有限等不足，限制了齿轮啮合性能的提高。本项目基于已有的研究基础，将不同频率、振幅的超声激励分别施加在弧齿锥齿轮的大轮和小轮上，构成超声双频激励研齿系统。通过分析超声应力场在大轮和小轮接触齿面间的干涉和叠加情况，研究超声频率、振幅的最佳匹配关系。借助超声双频激励研齿动力学模型的构建和求解，建立动态研磨力的计算模型。研究齿面超声互研修形的机理，确立齿面失配量与高阶传动误差的数学关系。利用实测齿面接触分析技术，建立VHJ调整量与齿面研磨点位置移动的敏感矩阵，优化工艺参数，规划研齿路径，进行齿面主动高阶修形，改善传动性能。探明超声激励对齿面微观形貌的影响，验证超声低载滚压强化对齿面改性的适用性。通过齿面偏差、传动误差、振动噪声测量以及齿面应力和微观形貌观测分析，验证上述研究内容，为弧齿锥齿轮的特种精加工提供理论依据。

针对弧齿锥齿轮传统研齿加工材料去除率低，对齿面修正有限等问题，本项目将超声加工技术应用于弧齿锥齿轮的研齿加工中，在相关的理论和试验研究基础上，得到如下结论：.1）将超声振动分别施加在小轮和大轮上，分析了振动系统中变幅杆和螺旋锥齿轮组合体的动力学特性，通过有限元仿真，实例分析和试验测试得到了振动系统的谐振频率和振幅特性，建立了超声研齿系统频率和振幅的匹配方法。.2）基于齿面啮合理论和齿轮动力学理论，通过超声双频激励下研齿动力学模型的建立和求解，分析了齿面动态研磨力对于齿面的强化研磨作用，由于超声激励，使齿轮副处于双边碰撞状态中，使得驱动齿面和非驱动齿面均能得到研磨。.3）基于超声研齿系统，研发了螺旋锥齿轮超声研齿加工的工艺装备，通过试验验证了超声研齿加工各工艺参数对齿轮啮合质量的影响，相对普通研齿，超声研齿能有效改善齿面接触区性能，提高齿面接触特性，降低传动噪声，齿面误差相对得到减少。.4）通过预置齿轮副的啮合重合度以及的传动误差曲线、接触椭圆参数等关键数据，构造了大小轮共轭齿面的Ease-off差曲面，以密切曲面进行了啮合仿真，获得了具有高阶传动误差的螺旋锥齿轮齿面接触区大小形状、接触迹线方向、抛物线失配与齿面失配量的关系。.5）对齿面超声互研修形的机理进行深入研究，根据实测齿面，建立了基于NURBS曲面拟合的齿面接触分析模型，获得了热后齿面高阶传动误差与齿面修形量的数学关系。建立了VHJ调整量与齿面研磨点位置移动的数学模型，规划研齿路径。通过滚检试验可以看出该方法能够实现全齿面研磨，实现齿面主动高阶拓扑修形，改善传动性能。