A tangential ultrasonic vibration-assisted gear grinding (TUVAGG) system was proposed in this paper to enhance the machining accuracy and performance of gears. Firstly, the longitudinal resonant vibration system of the TUVAGG was designed based on the non-resonant theory. The frequency equation and the displacement characteristics for the vibration system were obtained for the particular boundary conditions. Secondly, the vibration system composed of simplified disc and gear was simulated by the finite elements analysis method (FEM) and verified by the resonant measurement test. Finally, the vibration system effectiveness was verified through the ultrasonic vibration-assisted gear grinding test. The normal and tangential grinding forces in TUVAGG were lower by 7.4–28.2% and 8.9–18.9%, respectively, than conventional gear grinding (CGG). Besides, the grinding temperature and surface roughness in TUVAGG declined by 7.6–25.7% and 8.6–21.8% respectively compared with CGG, while the former tooth surface residual compressive stress and microhardness exceeded the latter ones by 13.2–29.3% and 8.9–12.7%. 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.

本文提出了一种切向超声振动辅助磨齿（TUVAGG）系统，以提高齿轮的加工精度和性能。首先，基于非共振理论设计了TUVAGG的纵向共振振动系统。对于特定的边界条件，获得了振动系统的频率方程和位移特性。其次，采用有限元分析法(FEM)对简化盘和齿轮构成的振动系统进行了模拟，并通过共振测量试验进行了验证。最后，通过超声振动辅助磨齿试验验证了振动系统的有效性。TUVAGG 的法向和切向磨削力分别比传统齿轮磨削 (CGG) 低 7.4-28.2% 和 8.9-18.9%。除了，与CGG相比，TUVAGG的磨削温度和表面粗糙度分别下降了7.6-25.7%和8.6-21.8%，而前者的齿面残余压应力和显微硬度超过后者的13.2-29.3%和8.9-12.7%。非共振理论适用于TUVAGG纵向振动系统的设计，也为齿轮加工提供了一种新的工艺技术。