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Analytical modeling of grinding force and experimental study on ultrasonic-assisted forming grinding gear

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Abstract

This study aimed to propose an ultrasonic-assisted forming grinding (UAFG) gear processing method that would enhance the processing efficiency of traditional forming grinding (TFG) gears and reduce the surface damage of gears caused by excessive grinding force. The actual cutting arc length of the grain was deduced by analyzing the separation time of the adjacent grain of the forming wheel. This was combined with the actual cutting depth of the grain to establish the grinding force in the UAFG method. The established theoretical model could predict the grinding force. The results indicated that the grinding force of TFG was larger than that of UAFG under the same condition. In this process, the effect of each processing parameter on the grinding force was in the following sequence: ultrasonic amplitude, grinding wheel speed, grinding depth, and feed speed. The influence of the grinding force on the surface quality was examined based on the grinding force model. The results showed that UAFG helped remove the gear tooth surface material and improve grinding surface quality. The study provided a new research method to improve the machining efficiency and surface quality of the forming grinding gear.

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Availability of data and material

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

Funding

The study was supported by the National Natural Science Foundation of China through Grant No. U1604255. The Institute of Advanced Manufacturing Technology of Henan Province Key Laboratory, Henan Polytechnic University, provided crucial support.

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Authors and Affiliations

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

    Long Yin, Bo Zhao, Bingjun Huo, Wenbo Bie & Chongyang Zhao

Authors
  1. Long Yin
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  2. Bo Zhao
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  3. Bingjun Huo
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  4. Wenbo Bie
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  5. Chongyang Zhao
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Contributions

Long Yin: Methodology, writing original the draft. Bo Zhao: Funding acquisition, methodology, writing — review and editing. Bingjun Huo: Methodology, experimental research. Wenbo Bie: Experimental research. Chongyang Zhao: Investigation, review. 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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Yin, L., Zhao, B., Huo, B. et al. Analytical modeling of grinding force and experimental study on ultrasonic-assisted forming grinding gear. Int J Adv Manuf Technol 114, 3657–3673 (2021). https://doi.org/10.1007/s00170-021-07086-3

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  • DOI: https://doi.org/10.1007/s00170-021-07086-3

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