超声研齿的材料去除模型与试验

Study on Material Removal Mechanism of Ultrasonic Lapping Gears

提出了超声研磨弧齿锥齿轮的理论与方法。分析了超声研齿中磨粒锤击微切削、弹跳冲击与研磨液空化效应等材料去除机理,建立了超声研齿锤击微切削材料去除模型。进行了普通与超声研齿的对比试验,试验证明,超声研齿材料去除率可达到普通研磨的三倍,且齿面质量明显提高,齿面粗糙度Ra低至0.2μm,轮廓支承长度率Rmr100%的水平截距c为1.2mm。

The theory and method of ultrasonic lapping spiral bevel and hypoid gears are firstly purposed. The material removal mechanism of ultrasonic lapping gears specified as abrasives hammering to micro - cut, bouncing to impact and slurry cavitation is analyzed. The material removal model of ultrasonic lapping gears on the abrasives hammeting to micro - cut is set up. The experimental comparison on the conventional lapping gears and the ultrasonic ones show that the material removal rate of ultrasonic lapping gears is three times of the conventional ones, and produces a better tooth surface quality, roughness Ra 0. 2μm, section height c = 1.2μm for bearing length ratio of profile Rmr（ c ） = 100%.