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Simulation and experimental research on residual stress of honed gear based on scratch test

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Abstract

The residual compressive stress on the surface of the gear after the power honing process could significantly improve the service performance and life of the gear. In order to study the formation mechanism and special distribution of the residual stress, a spiral scratching experiment is designed for the gear steel samples. Meanwhile, the influence of preload force and groove spacing on the residual stress is studied. The result shows that the residual stress increases from − 252 MPa to − 344 MPa in the parallel feed direction and from − 317 MPa to − 541 MPa in the vertical direction as the spacing decreases. With the increase of preload force, the residual stress value decreases when the spacing is small and increases when the spacing is large. Then, the three-dimensional finite element model of double abrasive grains is established with ABAQUS. The residual stress value of the whole surface is distilled and compared with the experimental one. According to the experimental and simulation results, the residual compressive stress of power honing is mainly caused by plastic deformation and the reason for its special distribution is that a smaller scratch spacing is generated in the area of the pitch line of tooth surface.

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Funding

This work is funded by Key Projects of Strategic Scientific and Technological Innovation Cooperation of National Key Research and Development Program of China (Grant 2020YFE0201000).

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Authors and Affiliations

  1. College of Mechanical and Vehicle Engineering, Chongqing University, Chongqing, 400044, China

    Jiacheng Wang, Huajun Cao, Yuhu Liu & Xiaohui Huang

  2. State Key Laboratory of Mechanical Transmission, Chongqing University, Chongqing, 400044, China

    Jiacheng Wang, Huajun Cao, Yuhu Liu & Xiaohui Huang

Authors
  1. Jiacheng Wang
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  2. Huajun Cao
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  3. Yuhu Liu
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  4. Xiaohui Huang
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Contributions

Jiacheng Wang: investigation, methodology, numerical simulation, writing—original draft. Huajun Cao: supervision, project administration, writing—review and editing. Yuhu Liu: assistant for experiment, checking. Xiaohui Huang: materials and equipment support.

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Correspondence to Huajun Cao.

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Appendix

Appendix

In order to determine the relationship between the scratch width and the preload force in the experiment, a single scratch was scored using the same condition as the experiment, and a single scratch was performed at preload forces of 0.5 N, 1 N, 2 N, 3 N, and 4 N. The width of the scored scratch was subsequently measured using a super deep scene 3D microscope (VHX-1000, KEYENCE, Japan) and the depth of single groove was calculated. The result showed that the depth of grooves under force of 0.5 N, 1 N, 2 N, and 4 N was 13, 22.5, 32, and 41.5 μm respectively.

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Wang, J., Cao, H., Liu, Y. et al. Simulation and experimental research on residual stress of honed gear based on scratch test. Int J Adv Manuf Technol 123, 985–998 (2022). https://doi.org/10.1007/s00170-022-10096-4

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  • DOI: https://doi.org/10.1007/s00170-022-10096-4

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