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Acoustic system design and experimental research on the ultrasonic forming grinding gear

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Abstract

In order to obtain high-performance gear elements with integrated shape, using non-resonant theory, the gear grinding experiment and ultrasound-assisted grinding acoustic system were established. Firstly, a theoretical model founded on the non-resonant proposed methodology was constructed. The frequency equation and displacement characteristics of the vibration system were established based on the specified boundary conditions, and the geometric size of the ultrasonic amplitude with a design frequency of 20 kHz was established. The acoustic system was simulated employing finite element software, and the analysis revealed that its frequency range was 19648 Hz, which was consistent with the design outcome. Meanwhile, the amplitude of the end surface of the tool gear reaches 5.59 µm, and the vibration was stable. Secondly, according to the solution of geometric parameters, the acoustic performance test was carried out. The error between resonant frequency (20387 Hz) and design frequency was 1.93 %, and the amplitude was 4.5 µm, which met the requirements of ultrasonic assisted grinding gear. Finally, the grinding test was carried out. The study results show that compared to conventional gear grinding, ultrasonic supported grinding lessens the grinding force by 11.5 % to 35.4 % and, at most, lowers the grinding temperature by 22.5 %.

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Abbreviations

k :

Circular wave number (k = ω/C)

ω :

Circular frequency (ω = 2πf)

β :

Deformation coefficient ((β = r1 − r2) / r1L2)

f x,f y,f z :

Design simulation and experimental frequency

ς :

Density

μ :

Poisson ratio

a p :

Radial feed

vw :

Feed speed

n:

Spindle speed

E :

Elastic modulus

A :

Amplitude

D, F :

Undetermined coefficients

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Acknowledgments

This work is supported by the National Natural Science Foundation of China (No.52005164 and No.51875179).

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Authors and Affiliations

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

    Xiaobo Wang, Mingqiang Wu, Jiangwei Jin & Bo Zhao

Authors
  1. Xiaobo Wang
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  2. Mingqiang Wu
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  3. Jiangwei Jin
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  4. Bo Zhao
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Corresponding author

Correspondence to Mingqiang Wu.

Additional information

Xiao-bo Wang is a doctor of Precision and Special Machining Technology and Equipment Laboratory of Henan Polytechnic University, mainly engaged in the research of precision and ultra-precision machining technology and equipment.

Ming-qiang Wu is a postgraduate student of Precision and Special Machining Technology and Equipment Laboratory of Henan Polytechnic University. His research direction is precision and ultra-precision machining technology and equipment.

Jiang-wei Jin is a postgraduate student of Precision and Special Machining Technology and Equipment Laboratory of Henan Polytechnic University. His research direction is precision and ultra-precision machining technology and equipment.

Bo Zhao is a Professor of Precision and Special Machining Technology and Equipment Laboratory of Henan Polytechnic University, mainly engaged in the research work of advanced manufacturing technology, theory and equipment of precision machining of hard and brittle materials.

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Wang, X., Wu, M., Jin, J. et al. Acoustic system design and experimental research on the ultrasonic forming grinding gear. J Mech Sci Technol 37, 3975–3983 (2023). https://doi.org/10.1007/s12206-023-0714-0

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  • DOI: https://doi.org/10.1007/s12206-023-0714-0

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