基于超声深滚理论齿轮齿面光整强化研究
发布时间：2018-10-25 08:08
【摘要】：本文提出一种超声深滚齿面强化技术,通过动载冲击与滚压塑性变形的双重作用,用以提高齿轮齿面材料的表面力学性能,提高零件的使用寿命。设计一套适用于渐开线曲面的超声深滚齿面强化装置,实现复杂渐开线曲面的表面强化工作,实验装置由超声波发生器,超声波执行系统,压力进给装置以及加工工具等部分组成。超声加工工具采用L形状,且超声加工工具的宽度与被强化齿轮的齿宽相同,实现在强化过程中,超声加工工具以线接触的方式与被强化齿轮进行啮合,提高加工效率。 以模数3,齿数20的齿轮为例,利用表面粗糙度测量、X-射线衍射分析(XRD)、齿轮形状偏差检查等分析手段,对加工前、后的齿轮表面进行对比分析得出强化结果。研究了超声深滚加工工艺参数对齿轮表面完整性的影响规律,并通过正交试验对各影响因子进行显著性分析。由于齿轮形状的特殊性要求,分析工艺参数对形状精度的影响,以达到在不破坏表面形状精度的前提下,提高齿轮轮齿的表面质量,改善零件表面的应力状态的目的。 实验观察和分析表明：超声深滚齿面强化装置能够较好地完成对不同模数和齿数的齿轮轮齿表面的强化。超声深滚齿面强化加工是一种行之有效的齿面强化加工技术。超声深滚齿面强化加工,能够以保持齿轮精度为基础,提高磨削后齿轮表面质量,改善齿轮表面的加工纹理,通过改善齿轮的表面应力状态,提高齿轮的使用寿命。 超声深滚齿面强化工艺参数,以及加工工具的表面精度和材料性质,对于齿轮的表面粗糙度,齿轮的形状偏差以及表面残余应力有着不同程度的影响。在一定程度上增加挤压力和加工次数等参数,能够消除前一次加工中产生的表面缺陷,提高齿轮表面质量,改善齿面的应力状态,增加残余应力层的厚度,有利于提高齿轮的使用寿命和抗环境服役能力。但是超声深滚加工是一种表面形变加工,过分的塑性变形,会在表面产生微观疲劳裂纹,不利于齿轮使用寿命的提高。 分析正交试验结果,得出结论：挤压力的增大能够使表层晶粒克服材料屈服极限值,在表面形成塑性形变,优化了加工效果；对齿面进行往复加工能够改善上一次加工缺陷,使塑性变形更加均匀,改善强化效果：齿形和润滑油对强化效果影响极小。
[Abstract]:In this paper, a kind of ultrasonic deep hobbing surface strengthening technique is proposed, which can improve the surface mechanical properties of gear tooth surface material and improve the service life of parts through the dual action of dynamic impact and rolling plastic deformation. A set of ultrasonic deep hobbing surface strengthening device suitable for involute surface is designed to realize the surface strengthening work of complex involute surface. The experimental device is composed of ultrasonic generator and ultrasonic executive system. Pressure feed device and machining tools and other parts of the composition. The ultrasonic machining tool adopts L shape, and the width of ultrasonic machining tool is the same as that of strengthened gear. In the process of strengthening, ultrasonic machining tool meshes with strengthened gear in the way of line contact to improve machining efficiency. Taking gear with modulus 3 and tooth number 20 as an example, by means of surface roughness measurement and (XRD), gear shape deviation analysis by means of X- ray diffraction, the results of comparison and analysis of gear surface before and after machining are obtained. The influence of ultrasonic deep rolling process parameters on the surface integrity of gear was studied, and the significance of each factor was analyzed by orthogonal test. In order to improve the surface quality of gear teeth and improve the stress state of parts surface, the influence of process parameters on shape accuracy is analyzed because of the special requirements of gear shape, so as to improve the surface quality of gear teeth without destroying the surface shape accuracy. The experimental observation and analysis show that the ultrasonic deep hobbing gear surface strengthening device can effectively strengthen the tooth surface of gear with different modulus and number of teeth. Ultrasonic deep hobbing machining is an effective machining technology. Ultrasonic deep hobbing machining can improve the surface quality of gear after grinding, improve the machining texture of gear surface, and improve the service life of gear by improving the stress state of gear surface and improving the service life of gear. The process parameters of ultrasonic deep hobbing surface strengthening, as well as the surface precision and material properties of machining tools, have different effects on the surface roughness, gear shape deviation and surface residual stress of gear. To a certain extent, increasing the extrusion pressure and processing times can eliminate the surface defects produced in the previous machining, improve the surface quality of the gear, improve the stress state of the tooth surface, and increase the thickness of the residual stress layer. It can improve the service life of gear and the ability of resisting environment service. However, ultrasonic deep rolling is a kind of surface deformation processing, excessive plastic deformation, will produce micro-fatigue cracks on the surface, which is not conducive to the increase of the service life of gears. By analyzing the results of orthogonal test, it is concluded that the increase of extrusion pressure can make the surface grain overcome the yield limit value of the material, form plastic deformation on the surface, optimize the processing effect, and the reciprocating machining of the tooth surface can improve the defect of the last machining. Make plastic deformation more uniform, improve strengthening effect: tooth shape and lubricating oil have minimal effect on strengthening effect.
【学位授予单位】：大连理工大学
【学位级别】：硕士
【学位授予年份】：2012
【分类号】：TH132.41
[Abstract]:In this paper, a kind of ultrasonic deep hobbing surface strengthening technique is proposed, which can improve the surface mechanical properties of gear tooth surface material and improve the service life of parts through the dual action of dynamic impact and rolling plastic deformation. A set of ultrasonic deep hobbing surface strengthening device suitable for involute surface is designed to realize the surface strengthening work of complex involute surface. The experimental device is composed of ultrasonic generator and ultrasonic executive system. Pressure feed device and machining tools and other parts of the composition. The ultrasonic machining tool adopts L shape, and the width of ultrasonic machining tool is the same as that of strengthened gear. In the process of strengthening, ultrasonic machining tool meshes with strengthened gear in the way of line contact to improve machining efficiency. Taking gear with modulus 3 and tooth number 20 as an example, by means of surface roughness measurement and (XRD), gear shape deviation analysis by means of X- ray diffraction, the results of comparison and analysis of gear surface before and after machining are obtained. The influence of ultrasonic deep rolling process parameters on the surface integrity of gear was studied, and the significance of each factor was analyzed by orthogonal test. In order to improve the surface quality of gear teeth and improve the stress state of parts surface, the influence of process parameters on shape accuracy is analyzed because of the special requirements of gear shape, so as to improve the surface quality of gear teeth without destroying the surface shape accuracy. The experimental observation and analysis show that the ultrasonic deep hobbing gear surface strengthening device can effectively strengthen the tooth surface of gear with different modulus and number of teeth. Ultrasonic deep hobbing machining is an effective machining technology. Ultrasonic deep hobbing machining can improve the surface quality of gear after grinding, improve the machining texture of gear surface, and improve the service life of gear by improving the stress state of gear surface and improving the service life of gear. The process parameters of ultrasonic deep hobbing surface strengthening, as well as the surface precision and material properties of machining tools, have different effects on the surface roughness, gear shape deviation and surface residual stress of gear. To a certain extent, increasing the extrusion pressure and processing times can eliminate the surface defects produced in the previous machining, improve the surface quality of the gear, improve the stress state of the tooth surface, and increase the thickness of the residual stress layer. It can improve the service life of gear and the ability of resisting environment service. However, ultrasonic deep rolling is a kind of surface deformation processing, excessive plastic deformation, will produce micro-fatigue cracks on the surface, which is not conducive to the increase of the service life of gears. By analyzing the results of orthogonal test, it is concluded that the increase of extrusion pressure can make the surface grain overcome the yield limit value of the material, form plastic deformation on the surface, optimize the processing effect, and the reciprocating machining of the tooth surface can improve the defect of the last machining. Make plastic deformation more uniform, improve strengthening effect: tooth shape and lubricating oil have minimal effect on strengthening effect.
【学位授予单位】：大连理工大学
【学位级别】：硕士
【学位授予年份】：2012
【分类号】：TH132.41
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