新型齿轮超声加工纵向振动系统的设计

Design of new longitudinal vibration system in gear ultrasonic machining

在传统的齿轮纵向振动系统中,齿轮与变幅杆耦合处振幅较小,导致齿轮端面输出振幅偏小,满足不了齿轮超声加工的要求.基于非谐振设计理论和全谐设计理论,设计了一种新型齿轮纵向振动系统,该振动系统由齿轮与圆柱杆耦合振动单元、换能器、半波长圆锥形变幅杆组成,齿轮与变幅杆耦合处振幅较大,增大了齿轮端面的输出振幅.圆锥变幅杆形状参数固定时,齿轮分度圆直径和圆柱杆直径对齿轮端面的输出振幅没有影响,减小圆锥变幅杆小端直径可以增大齿轮端面的输出振幅.通过有限元分析和谐振特性实验验证这种新设计方法的可行性.研究结果为齿轮振动系统提供了一种新的设计方法,对齿轮超声加工工艺的工程应用具有重要意义.

In existing gear longitudinal vibration system ,the amplitudes of gear and horn are small at the connection site ,so the output amplitude of gear is small and cannot meet the requirement of gear ultrasonic machining .Based on non‐resonant design theory and w hole resonant design theory ,a new gear longitudinal vibration system ,w hich consisted of a coupling vibration unit of gear and cylinder rod ,a half‐wavelength cone horn and a transducer ,was designed .The ampli‐tudes of gear and horn were large at the connection site of this new system ,and the output ampli‐tude of gear was increased as well .When the parameters of cone horn were certain ,the diameters of gear and cylinder rod made no influence on the output amplitude of gear .How ever ,the smaller the diameter of the small‐end cone horn was ,the larger the output amplitude of gear was .The feasibility and effectiveness of this new design method was verified by finite element analysis and resonant vibration experiment .A new design method for gear vibration system is provided w hich has important significance to the engineering application of gear ultrasonic machining .