大齿轮变异主轴式滚磨光整加工方案设计及实验验证

发布时间：2018-01-15 11:48

本文关键词：大齿轮变异主轴式滚磨光整加工方案设计及实验验证　出处：《太原理工大学》2016年硕士论文　论文类型：学位论文

【摘要】：齿轮是现代机械装备中应用领域最广、使用量最大的机械传动件,是机械产品的重要基础零部件,齿轮的设计制造水平将直接影响机械产品的性能和质量。国内外研究表明:改善齿轮的表面质量,齿轮的使用性能和寿命可以大幅度地提高,运行传动噪音降低。齿轮制造中,采用光整加工可以改善表面质量,由于加工成本及效率的考虑,目前齿轮的光整加工技术在我国应用还不普遍,齿轮光整加工技术的研发也不够,生产出的齿轮表面质量达不到设计要求。因此,开发高效、低成本的齿轮光整加工工艺具有重要的现实意义。滚磨光整加工技术作为一种广泛使用的自由磨具光整加工技术,具有光整效果好,成本低等优点,应用到齿轮的表面光整加工中意义重大。本文根据齿轮光整加工的国内外现状,结合太原理工大学多年来在自由磨具光整加工方面的研究基础,提出了大齿轮滚磨光整加工的新工艺。在分析各种滚磨光整加工工艺在齿轮光整应用的基础上,针对其在齿轮加工的不足和大齿轮的特征,提出了两种大齿轮变异主轴式滚磨光整加工的工艺方案,并对这两种工艺的加工机理进行研究,分析了滚抛磨块与齿轮表面间复杂的相对运动,建立工艺运动模型,推导出计算滚抛磨块与齿轮表面间切削速度的公式,从理论上得出影响加工效果的主要参数,通过MATLAB软件分析各参数对切削速度的影响规律。利用离散元分析软件EDEM从滚抛磨块的运动入手,分析了旋流式和垂直交叉主轴式在加工齿轮时,滚抛磨块的运动特性,得出了垂直交叉主轴式更有利于齿轮的均匀加工。对齿轮垂直交叉主轴式滚磨光整进行了仿真分析,得出了不同滚筒转速、齿轮转速和齿轮摆角对滚抛磨块速度与滚抛磨块对齿面的平均法向接触力的影响情况,对齿轮垂直交叉主轴式滚磨光整加工设备的设计及应用具有一定指导意义。对齿轮垂直交叉主轴式滚磨光整加工各参数对加工效果的影响进行了实验研究,验证了理论和仿真分析的结果。同时利用该工艺对一齿轮光整后表面质量的改善进行了实验研究,结果表明:经过滚磨光整加工后,齿轮外表光亮,棱边倒圆,表面粗糙度Ra由0.698μm降至0.265μm,前一道工序的加工纹理和微裂纹消失,综合提高了齿面的表面质量,进而提高了齿轮的使用性能和寿命。
[Abstract]:Gear is the most widely used mechanical transmission in the field of modern machinery and equipment. It is an important basic part of mechanical products. The design and manufacture level of gears will directly affect the performance and quality of mechanical products. Studies at home and abroad show that: to improve the surface quality of gears, gear performance and service life can be greatly improved. In gear manufacturing, the surface quality can be improved by using smooth machining. Due to the consideration of processing cost and efficiency, the finishing technology of gears is not widely used in China. The research and development of gear finishing technology is not enough, the surface quality of the produced gear can not meet the design requirements. Therefore, the development of high efficiency. The low cost gear finishing process has important practical significance. As a widely used free abrasive finishing technology, rolling finishing technology has the advantages of good finishing effect and low cost. It is of great significance to apply to the surface finishing of gears. According to the present situation of gear finishing at home and abroad, this paper combines the research foundation of Taiyuan University of Technology in the field of free abrasive finishing for many years. A new technology of large gear rolling finishing is put forward. On the basis of analyzing the application of various rolling finishing processes in gear finishing, the defects in gear machining and the characteristics of big gear are pointed out. In this paper, two kinds of technology schemes of the variable spindle rolling finishing of large gear are put forward, and the machining mechanism of these two processes is studied, and the complex relative motion between the grinding block and the gear surface is analyzed. The process motion model is established and the formula for calculating the cutting speed between the grinding block and the gear surface is derived. The main parameters affecting the machining effect are obtained theoretically. The influence of the parameters on the cutting speed is analyzed by MATLAB software. The motion of the grinding block is started with the discrete element analysis software EDEM. In this paper, the motion characteristics of roller grinding block in gear machining are analyzed. It is concluded that the vertical cross spindle type is more favorable to the uniform machining of gears. The simulation analysis of gear vertical cross spindle roller polishing is carried out, and different drum speeds are obtained. The influence of gear rotation speed and gear swing angle on the speed of grinding block and the average normal contact force of grinding block on tooth surface. It has certain guiding significance for the design and application of gear vertical cross spindle rolling finishing equipment. The influence of various parameters of gear vertical cross spindle roller finishing processing on machining effect is studied experimentally. The results of theoretical and simulation analysis are verified. At the same time, the improvement of surface quality of a gear after finishing is studied by using this process. The results show that the surface of gear is bright and the edge is round after finishing. The surface roughness Ra is reduced from 0.698 渭 m to 0.265 渭 m. The surface quality of tooth surface is improved by the disappearance of machining texture and microcracks in the previous process. Furthermore, the service performance and service life of gears are improved.
【学位授予单位】：太原理工大学
【学位级别】：硕士
【学位授予年份】：2016
【分类号】：TG612

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