垂直交叉主轴式滚磨光整加工工艺改善齿轮表面完整性及使用性能的实验研究

发布时间：2018-05-10 17:51

本文选题：齿轮 + 滚磨光整加工　；参考：《太原理工大学》2017年硕士论文

【摘要】：齿轮副是一种典型的摩擦副类零件,在工作过程中两轮齿表面存在滑动摩擦,且滑动的大小和方向都在不断变化。因此,齿轮的表面质量,尤其是轮齿的齿廓表面质量对齿轮的使用性能与使用寿命都有很大的影响。滚磨光整加工具有零件表面全方位加工,表面完整性特征参数综合改善,加工成本低,加工效率高等特点。本文立足于研究开发适用于大模数齿轮的滚磨光整加工新工艺,通过提高齿轮的表面质量,改善齿轮的表面完整性,进而达到提高齿轮的使用性能等目的。针对课题组提出的用以齿轮光整加工的"垂直交叉主轴式齿轮滚磨光整加工方法",主要对齿轮的齿面加工均匀性,加工后的表面完整性以及加工后的使用性能等方面的内容进行了深入系统地研究。首先,在查阅大量相关文献资料的前提下,列举了影响齿轮使用性能的主要因素,介绍了目前国内外普遍使用的各种齿轮光整加工方法,分析对比了现有的齿轮滚磨光整加工工艺的特点及其适用范围,明确了本文所要研究的核心内容,研究方法等。其次,使用EDEM软件模拟加工过程,得出了齿轮偏角和滚筒转速对加工作用力的大小以及颗粒的流动速度有较大影响,进而分析其可能对齿轮齿面加工均匀性和加工质量有重大影响。同时使用统计学软件JMP,选用中心复合实验设计法进行了实验方案的设计编排。通过实验验证,发现采用本文所研究的齿轮滚磨光整加工方法与磨齿比较,当以轮齿表面粗糙度值为衡量指标时,滚磨加工后的齿顶与齿根粗糙度值的标准差均小于磨齿,故认为该种加工方法加工均匀,且在磨齿的基础上,轮齿表面粗糙度Ra值能从0.7μm左右降至0.2μm左右。该工艺所涉及的齿轮偏角,滚筒转速,加工时间等主要加工参数对齿面加工质量有明显的影响。接着,在前面的研究基础上,对加工前后齿轮的表面完整性(针对影响齿轮使用性能的主要参数,包括齿面粗糙度及微观形貌,轮齿表面层显微硬度,近表层金相组织,齿根残余应力状态等)作了进一步地研究。结果表明,滚磨光整加工对改善齿轮表面完整性具有十分显著的效果。参考综合模糊评价方法,建立了加工参数对轮齿表面完整性的模糊评价,得到的结论是滚筒转速对齿轮表面完整性的影响最大。最后,通过对滚磨光整加工前后的齿轮进行高周疲劳试验和摩擦磨损试验,结果显示,经过滚磨光整加工后齿轮的抗弯疲劳强度和耐磨损性都获得不同程度的提高,说明采用滚磨光整加工方法有助于提高齿轮的使用性能。综上所述,本文所研究的齿轮滚磨光整加工方法能够有效地提高齿轮的表面质量,整体改善齿轮的表面完整性从而提高齿轮的使用性能。若能实现工业化应用,将为我国高端齿轮产品提供有力的技术保障。
[Abstract]:Gear pair is a kind of typical friction pair parts. There is sliding friction on the surface of the two gear teeth during the working process, and the size and direction of the sliding are constantly changing. Therefore, the surface quality of gear, especially the surface quality of tooth profile, has great influence on the performance and service life of gear. Rolling finish machining has the characteristics of all-around machining of parts, comprehensive improvement of surface integrity characteristic parameters, low processing cost and high processing efficiency. This paper is based on the research and development of a new rolling finishing process suitable for large modulus gears. By improving the surface quality of gears and improving the surface integrity of gears, the performance of gears can be improved. In view of the "vertical cross spindle gear rolling finishing method" proposed by the research group for gear finishing, it mainly deals with the uniformity of gear tooth surface processing. The surface integrity and the performance of the machined surface are studied systematically and deeply. First of all, on the premise of consulting a large number of relevant literature, the paper lists the main factors that affect the gear performance, and introduces various gear finishing methods which are widely used at home and abroad. This paper analyzes and compares the characteristics and applicable scope of the existing gear rolling finishing process, and clarifies the core contents and research methods of this paper. Secondly, using EDEM software to simulate the machining process, it is concluded that the gear deflection angle and drum speed have great influence on the size of the machining force and the flow velocity of the particles. Furthermore, it is analyzed that it may have a great influence on the machining uniformity and machining quality of gear tooth surface. At the same time, using the statistical software JMP, the central composite experimental design method is used to design the experimental scheme. Through experimental verification, it is found that the standard deviation of tooth top roughness and tooth root roughness after hobbing is smaller than that of grinding teeth when the surface roughness value of gear tooth is taken as the measurement index, compared with the grinding tooth grinding method studied in this paper. Therefore, it is considered that the machining method is uniform, and on the basis of grinding, the surface roughness Ra value of gear tooth can be reduced from 0.7 渭 m to 0.2 渭 m. The main processing parameters, such as gear deflection angle, cylinder speed and processing time, have obvious influence on the machining quality of tooth surface. Then, on the basis of the previous research, the surface integrity of the gear before and after machining is analyzed. (aiming at the main parameters that affect the performance of the gear, including the tooth surface roughness and the micro-morphology, the micro-hardness of the surface layer of the gear tooth, the metallographic structure of the near surface layer, The residual stress state of tooth root is further studied. The results show that the surface integrity of gear is improved by rolling finishing. Referring to the comprehensive fuzzy evaluation method, the fuzzy evaluation of machining parameters on the surface integrity of the gear teeth is established. The conclusion is that the rotary speed of the drum has the greatest influence on the surface integrity of the gear. Finally, the high-cycle fatigue test and friction and wear test of gears before and after rolling finishing are carried out. The results show that the bending fatigue strength and wear resistance of gears are improved in varying degrees after rolling finishing. It is shown that the rolling finishing method is helpful to improve the performance of gears. To sum up, the gear rolling finishing method studied in this paper can effectively improve the surface quality of the gear, improve the surface integrity of the gear as a whole and improve the performance of the gear. If the industrial application can be realized, it will provide strong technical guarantee for the high-end gear products in our country.
【学位授予单位】：太原理工大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG616

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