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

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Abstract

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.

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Availability of data and material

All data generated or analyzed during this study are included in the present article.

Abbreviations

TUVAGG:

Tangential ultrasonic vibration-assisted gear grinding

CGG:

Conventional gear grinding

v s :

Grinding wheel speed

a r :

Radial grinding depth

v w :

Gear feed rate

l 1 :

Length of horn’s cylindrical section I

l 2 :

Length of horn’s conical section II

l 3 :

Length of horn’s cylindrical section III

l 4 :

Length of horn’s cylindrical section IV

R 1 :

Radius of horn’s cylindrical section I

R 2 :

Radius of horn’s conical section II

R 3 :

Radius of horn’s cylindrical section III

R 4 :

Radius of horn’s cylindrical section IV

R 5 :

Radius of horn’s cylindrical section V

ξ 0 :

Maximal input displacement of the horn’s left end

ξ 1 :

Displacement function of horn’s section I

ξ 2 :

Displacement function of horn’s section II

ξ 3 :

Displacement function of horn’s section III

ξ 4 :

Displacement function of horn’s section IV

ξ 5 :

Displacement function of horn’s section V

k i :

Circular wave number of each section

S i :

Cross-sectional area function

a ij :

Coefficient of homogeneous equations

C mn :

Coefficients of aij

ρ i :

Material density

λ :

Wavelength

A :

Ultrasonic amplitude

A A :

FEM-predicted amplitude

A E :

Amplitude measured by the resonance test

A M :

Amplitude of the theoretical analysis

A AM :

Deviation between AA and AM values

A EM :

Deviation between AE and AM values

f :

Ultrasonic frequency

f A :

FEM-predicted frequency

f E :

Experimental resonance frequency

f M :

Theoretical design frequency

f AM :

Deviation between fA and fM values

f EM :

Deviation between fE and fM values

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Funding

This work was financially supported by the National Natural Science Foundation of China (Nos. U1604255 and 51905157).

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Authors and Affiliations

  1. School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo, Henan, China

    Wenbo Bie, Bo Zhao, Chongyang Zhao, Long Yin & Xingchen Guo

  2. School of Electrical and Mechanical Engineering, Pingdingshan University, Pingdingshan, Henan, China

    Wenbo Bie

Authors
  1. Wenbo Bie
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  2. Bo Zhao
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  3. Chongyang Zhao
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  4. Long Yin
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  5. Xingchen Guo
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Contributions

Wenbo Bie conceived the analysis and wrote the manuscript. Bo Zhao provided supervisions on experimentation and manuscript preparation. Chongyang Zhao collected the data and revised the manuscript. Long Yin and Xingchen Guo performed the experiment. The authors discussed each reference paper together and contributed useful ideas for this manuscript.

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Correspondence to Bo Zhao.

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Bie, W., Zhao, B., Zhao, C. et al. System design and experimental research on the tangential ultrasonic vibration-assisted grinding gear. Int J Adv Manuf Technol 116, 597–610 (2021). https://doi.org/10.1007/s00170-021-07459-8

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  • DOI: https://doi.org/10.1007/s00170-021-07459-8

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