齿轮超声加工振动系统的非谐振设计理论与实验研究

发布时间：2018-01-23 21:49

本文关键词： 齿轮超声加工非谐振设计纵向振动变幅器纵弯耦合振动变幅器谐振特性　出处：《太原理工大学》2015年硕士论文　论文类型：学位论文

【摘要】：齿轮是装备制造业的基础，对我国装备制造业的发展起着关键作用。目前，齿轮正朝着高精度、高速、高寿命、高效率、低噪声、大功率、小型化等方向发展，一种新齿轮加工工艺的研究与应用是关键。将超声振动引入齿轮加工工艺可以显著降低切削力、增加刀具寿命、提高齿轮加工精度、降低齿面粗糙度、提高加工效率、改善齿面的微观切削纹理，因此对齿轮超声加工工艺的研究具有重要意义。振动系统的设计是齿轮超声加工的关键技术，其谐振特性关系到齿轮超声加工的效果。齿轮超声加工振动系统普遍采用非谐振单元振动系统设计理论设计，但是这种设计理论并不完善，并且现有振动系统的输出振幅较小，限制了齿轮超声加工工艺的工程应用。本课题在非谐振单元振动系统设计理论的基础上，进一步研究了齿轮超声加工振动系统的设计和提高振动系统输出振幅的方法，并得到了山西省研究生优秀创新项目“超声珩齿机理与应用适应性研究（20133042）”和太原理工大学研究生科技创新基金项目“超声珩齿工程应用适应性研究（2013B095）”的资助。对齿轮超声加工振动系统的非谐振设计理论进行了如下研究：（1）纵向振动变幅器的设计利用理论解析法、等效电路法、传输矩阵法设计纵向振动变幅器，分析了三种设计方法的优缺点及各自的适用场合，为设计变幅器时选择适当的计算方法提供了理论依据。齿轮和变幅杆的材料不一致时，将变幅器简化为由变幅杆、齿轮等效圆环、心轴、螺母等效圆柱四部分组成的理论分析模型，根据各部分之间力和位移的连续条件、两端面的边界条件，建立变幅器的频率方程，实现纵向振动变幅器的设计。通过有限元分析和谐振特性实验验证了这种设计方法的可行性，完善了齿轮超声加工纵向振动变幅器的设计理论。（2）新型纵向振动变幅器的设计基于非谐振设计理论和全谐设计理论，设计一种新型齿轮纵向振动变幅器，变幅器由齿轮与圆柱杆耦合振动单元、半波长圆锥形变幅杆组成，齿轮与变幅杆耦合处振幅较大，增大了齿轮端面的输出振幅。圆锥形变幅杆的形状参数固定时，，齿轮分度圆直径和圆柱杆直径对齿轮端面的输出振幅没有影响，减小圆锥变幅杆小端直径可以增大齿轮端面的输出振幅。通过有限元分析和谐振特性实验验证了这种设计方法的可行性，研究结果为齿轮超声加工纵向振动变幅器提供了一种新的设计方法。（3）纵弯耦合振动变幅器的设计基于非谐振设计理论和Mindlin中厚板理论，分别设计了变幅杆材料为45钢、钛合金、黄铜、硬铝合金的圆锥形纵弯耦合振动变幅器，并研究了变幅器的谐振特性，结果表明：随着变幅杆材料的阻抗特性减小，齿轮分度圆处的振幅随之减小。为了增大齿轮分度圆处的振幅，设计了级联形纵弯耦合振动变幅器，齿轮分度圆处的振幅为12μm，较现有变幅器有了较大的提高。（4）新型纵弯耦合振动变幅器的设计利用非谐振设计理论设计一种新型纵弯耦合振动变幅器，将齿轮置于变幅杆振幅较大的位置，通过理论计算和有限元分析研究了变幅器的谐振特性，齿轮分度圆处的振幅大幅增加。研究结果为齿轮超声加工纵弯耦合振动变幅器的设计提供了一种新的设计方法。通过以上设计理论和实验研究，完善了齿轮超声加工振动系统的非谐振设计理论，提高了振动系统的输出振幅，为齿轮超声加工工艺的工程应用奠定了理论和实验基础。
[Abstract]:The basic gear is the equipment manufacturing industry, and plays a key role in the development of China's equipment manufacturing industry. At present, the gear is a high precision, high speed, high efficiency, high life, low noise, high power, small size direction of development, research and application of a new gear machining process is the key to the ultrasonic. Vibration to the gear machining process can significantly reduce the cutting force, increase tool life, improve the machining accuracy, reduce the tooth surface roughness, improve processing efficiency, improve the tooth surface texture of micro cutting, so the research on the process of gear ultrasound has important significance. The design of vibration system is the key technology of gear ultrasonic machining, the resonance in relation to the characteristics of gear ultrasonic machining. The effect of ultrasonic vibration system is widely used in gear machining non resonant design theory of unit vibration system design, but this design theory is not perfect, and the existing vibration system The output amplitude is small, the engineering application limits the processing technology of ultrasonic gear. This subject is based on the design theory of non resonant unit vibration system, further study of the design of gear vibration ultrasonic machining system and method to improve the output amplitude of the vibration system, and the research and application of ultrasonic honing mechanism Study on the adaptability of students in Shanxi Province outstanding innovation project "(20133042)" Research on the application of ultrasonic honing engineering and adaptability of Taiyuan University of Technology graduate innovation fund project "(2013B095)" of China. The non resonant design theory of ultrasonic machining vibration of gear system are studied as follows:
(1) design of longitudinal vibration amplitude transformer
By using the theory of analytic method, equivalent circuit method, the design of the transfer matrix method of longitudinal vibration of transformer, analyzes the advantages and disadvantages of three kinds of design methods and their applicability, provides a theoretical basis for the design of transformer when selecting the appropriate calculation method. The gear and horn materials are not the same, the horn is simplified by amplitude bar, equivalent gear ring, spindle nut model equivalent cylindrical four part theory, according to the continuity conditions between the various parts of the force and displacement boundary conditions, the frequency equation is established at both ends, transformer, transformer design to realize longitudinal vibration. Through finite element analysis and resonance characteristics of the experiment to verify the feasibility of this design methods, improve the design theory of gear ultrasonic machining of longitudinal vibration of transformer.
(2) design of a new type of longitudinal vibration amplitude transformer
Non resonant design theory and harmonic design theory based on the design of a new type of gear longitudinal vibration of transformer, transformer by gear and cylindrical rod coupling vibration unit, half wavelength of conical horn, horn and gear coupling at large amplitude, increasing the gear end output amplitude. The fixed shape parameter of conical horn when no influence of gear pitch diameter and the diameter of the cylindrical rod gear output amplitude, the output amplitude decreases conical horn small end diameter can increase the gear end. Through finite element analysis and resonance characteristics of the experiment to verify the feasibility of this design method, the research results provide a new design method for gear ultrasonic machining the longitudinal vibration of the horn.
(3) design of a longitudinal flexural coupling vibrator
The plate theory of non resonant design theory and Mindlin based on the design of horn material is 45 steel, titanium alloy, brass, a longitudinal bending coupling vibration of transformer aluminum alloy, and the resonant characteristics of the transformer, the results show that: with the decrease of the impedance characteristics of horn material, the amplitude of gear pitch circle. In order to decrease. The increase of the amplitude of gear pitch circle, cascade shaped longitudinal bending coupled vibration of transformer design, the amplitude of gear pitch circle is 12 m, has been greatly improved compared with the existing transformer.
(4) design of a new longitudinal flexural coupling vibrator
Design of a new type of longitudinal bending coupled vibration of transformer using non resonant design theory, the position of gear on the horn with large amplitude, resonance characteristics of the transformer through theoretical calculation and finite element analysis, the amplitude of gear pitch circle increased significantly. The results provide a new method for the design of the gear wheel ultrasonic machining of longitudinal bending coupled vibration of transformer.
Through the above design theory and experimental research, the non resonant design theory of the gear ultrasonic machining vibration system has been perfected, and the output amplitude of the vibration system has been improved, which has laid a theoretical and experimental foundation for the engineering application of the gear ultrasonic machining technology.

【学位授予单位】：太原理工大学
【学位级别】：硕士
【学位授予年份】：2015
【分类号】：TG61

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