System Design and Experimental Research on the Tangential Ultrasonic Vibration-assisted Grinding Gear

2021 ◽  
Author(s):  
Wenbo Bie ◽  
Bo Zhao ◽  
Chongyang Zhao ◽  
Long Yin ◽  
Xingchen Guo
Keyword(s):  
Ultrasonic Vibration ◽  
Longitudinal Vibration ◽  
Grinding Force ◽  
Frequency Equation ◽  
Tooth Surface ◽  
Machining Accuracy ◽  
Vibration System ◽  
Process Technology ◽  
Finite Elements Analysis ◽  
Ultrasonic Vibration Assisted Grinding

Abstract Gear plays an important role in transmitting motion and power system, and a new promising process should be utilized to enhance the machining accuracy and performance. In this paper, the ultrasonic vibration was superimposed into the gear to carry out the tangential ultrasonic vibration-assisted grinding gear (TUVAGG). The longitudinal resonant vibration system was designed based on the non-resonant theory. Firstly, the gear was simplified into a disc with the diameter of the reference circle, and the dynamic equation of each part was erected respectively. Then the frequency equation was derived according to the coupling conditions of the force and displacement during the combined surface of the vibration system. Simultaneously, the characteristic of displacement for the vibration system was also obtained. Secondly, the vibration system composed of the simplified disc and the gear was simulated by the finite elements analysis method, and verified by the resonant measurement experiment respectively. The measurement results exhibited a good agreement with the theoretical. Finally, the effectiveness of the vibration system was verified through the ultrasonic vibration-assisted grinding gear test. It was found that compared with the conventional grinding gear (CGG), the normal grinding force and tangential grinding force was reduced by 7.4-28.2% and 8.9-18.9% respectively during TUVAGG. Besides, the grinding temperature and the surface roughness was declined by 7.6-25.7% and 8.6-21.8% respectively, and the residual compressive stress of tooth surface was elevated by 13.2-29.3%. It was concluded that the non-resonant theory was suitable for the designation of longitudinal vibration system for TUVAGG, and also provided a novel process technology for gear machining.

Study on Grinding Force in Two-Dimensional Ultrasonic Grinding Nano-Ceramics

2010 ◽  
Vol 42 ◽  
pp. 204-208 ◽  
Author(s):  
Xiang Dong Li ◽  
Quan Cai Wang
Keyword(s):  
Mathematical Model ◽  
Ultrasonic Vibration ◽  
Contact Time ◽  
Reaction Force ◽  
Grinding Force ◽  
Two Dimensional ◽  
Indentation Fracture ◽  
Ultrasonic Grinding ◽  
The Impact ◽  
Ultrasonic Vibration Assisted Grinding

In this paper, the characteristic of grinding force in two-dimensional ultrasonic vibration assisted grinding nano-ceramic was studied by experiment based on indentation fracture mechanics, and mathematical model of grinding force was established. The study shows that grinding force mainly result from the impact of the grains on the workpiece in ultrasonic grinding, and the pulse power is much larger than normal grinding force. The ultrasonic vibration frequency is so high and the contact time of grains with the workpiece is so short that the pulse force will be balanced by reaction force from workpiece. In grinding workpiece was loaded by the periodical stress field, which accelerates the fatigue fracture.

Influence of gear parameters on dynamic characteristics of an ultrasonic vibration system

2018 ◽  
Vol 42 (3) ◽  
pp. 252-267
Author(s):  
De-Rong Zhu ◽  
Jian-Jun Yang ◽  
Xiao-Zhong Deng ◽  
Chuang Jiang ◽  
Ju-Bo Li
Keyword(s):  
Ultrasonic Vibration ◽  
Dynamic Characteristics ◽  
Frequency Equation ◽  
Bevel Gear ◽  
Vibration Measurement ◽  
Spiral Bevel Gear ◽  
Vibration System ◽  
Characteristic Parameters ◽  
Longitudinal Wave Propagation ◽  
Spiral Bevel

A spiral bevel gear is subject to a special load in ultrasonic lapping, which is not only a processing object but also a processing tool, it is necessary to study dynamic characteristics of an ultrasonic vibration system. First, the spiral bevel gear is reasonably simplified to a frustum, which is then combined with a horn to form a new type of composite horn. Based on the theory of plane longitudinal wave propagation, the resonance mathematical model of the gear’s ultrasonic vibration system is established, and the frequency equation of the vibration system with gear characteristic parameters is obtained. Second, the frequency and displacement characteristics of an ultrasonic vibration system are analyzed by means of design examples, and the influence of the law of gear characteristic parameters on dynamic characteristics of the vibration system is studied. Finally, ultrasonic lapping and vibration measurement experiments are carried out using two pairs of different hypoid gears. The results show that the change in dynamic characteristics of an ultrasonic vibration system has a large influence on the finished machining quality of the gear. Therefore, it is necessary to consider the gear characteristic parameters when ultrasonic vibration system is designed. The research results provide an accurate theoretical basis for the detailed design of an ultrasonic lapping vibration system.

Grinding Force of Ultrasonic Vibration Assisted Grinding Combined with EDM

2012 ◽  
Vol 500 ◽  
pp. 287-294 ◽  
Author(s):  
Peng Yan ◽  
Jian Hua Zhang ◽  
Guo Sheng Su
Keyword(s):  
Ultrasonic Vibration ◽  
Pulse Discharge ◽  
Processing Parameters ◽  
Grinding Force ◽  
Force Model ◽  
Grinding Process ◽  
Machining Parameters ◽  
Processing Efficiency ◽  
Machined Surface ◽  
Ultrasonic Vibration Assisted Grinding

In the ultrasonic vibration assisted grinding and EDM, grinding and pulse discharge machining are favorable conditions for each other, can significantly improve the processing efficiency by adjusting the processing parameters, and get high-quality machined surface. The grinding force is an important parameter in characterizing the grinding process, which is the g the main object of study in grinding process. The interaction of ultrasonic vibration, grinding and EDM is investigated. From the view of material removal volume, the volume of removal by EMD is calculated. Then the volume by grinding is gotten. The grinding force model of combined machining is established. The influence machining parameters on grinding force is studied, which is helpful for the detection and control of grinding force.

scholarly journals On the Grinding Performance of Alumina Wheels in Ultrasonic Vibration-Assisted Grinding of Hardened GCr15 Steel

2021 ◽  
Author(s):  
Yutong Qiu ◽  
Biao Zhao ◽  
Yang Cao ◽  
Wenfeng Ding ◽  
Yucan Fu ◽  
...  
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Wear Property ◽  
Wheel Wear ◽  
Machined Surface ◽  
Gcr15 Steel ◽  
Abrasive Grains ◽  
Ultrasonic Vibration Assisted Grinding

Abstract Composite manufacturing with multiple energy fields is an important source of processing technology innovation. In this work, comparative experiments on the conventional grinding (CG) and ultrasonic vibration-assisted grinding (UVAG) of hardened GCr15 steel were conducted with WA wheel. The grinding wheel wear patterns and chips were characterized. In addition, grinding force, force ratio, and ground surface quality were investigated to evaluate wheel performance. Results illustrate that the interaction between abrasive grains and workpiece in UVAG process has the characteristics of high frequency and discontinuity. The wear property of abrasive grains is changed and the grinding force is decreased because the generation of micro-fracture in abrasive grains improves the grinding wheel self-sharpening. Better surface quality is obtained, the surface roughness is reduced by up to 18.96%, and the number of defects on the machined surface is reduced through the superior reciprocating ironing of UVAG. Accordingly, WA wheel performance is improved by UVAG.

Study on the Cutting Deforming Force of Single Abrasive Grit for Ultrasonic Vibration Assisted Grinding along Normal Direction

2010 ◽  
Vol 102-104 ◽  
pp. 615-619 ◽  
Author(s):  
Hong Li Zhang ◽  
Jian Hua Zhang
Keyword(s):  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Brittle Material ◽  
Grinding Force ◽  
Normal Direction ◽  
Kinematics Analysis ◽  
Cutting Depth ◽  
Force Ratio ◽  
Conventional Grinding ◽  
Ultrasonic Vibration Assisted Grinding

Based on the kinematics analysis and the cutting depth calculation of single abrasive grit, the mathematics models of the cutting deforming force and the average cutting deforming force were made by introducing the unit grinding force, Fu. And the formula of the average cutting force during the grinding zone was calculated. The experiments on the grinding force ratio were conducted under conventional grinding(CG) mode and normal ultrasonic vibration assisted grinding(NUAG) mode. The results showed that the unit grinding force in NUAG was lower than that in CG under the same machining condition; the grinding force ration was decreased due to the normal ultrasonic vibration of the workpiece. And it was helpful to improve the machinablity of the hard-brittle material.

Investigation on Machining Characteristics for Tangential Ultrasonic Vibration Assisted Grinding

2010 ◽  
Vol 34-35 ◽  
pp. 282-286
Author(s):  
Wei Feng Lang ◽  
Hong Li Zhang
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Critical Speed ◽  
Grinding Force ◽  
Machining Parameters ◽  
Theory Analysis ◽  
Kinematic Characteristics ◽  
Ultrasonic Vibration Assisted Grinding ◽  
Machining Characteristics ◽  
Good Agreement

A critical speed formula was given based on the analysis of kinematic characteristics during tangential ultrasonic vibration assisted grinding (TUAG) process. By the formula, the machining parameters can be correctly set to insure the separate characteristics of TUAG process. The grinding force can be decreased and the machining surface quality can be improved during TUAG process with separability. Grinding experiments were conducted, and the experiment results are in good agreement with theory analysis results.

Design of Ultrasonic Transformer Vibrated Radically with Double Supports in Gear Honing

2009 ◽  
Vol 416 ◽  
pp. 159-163
Author(s):  
Lin Ma ◽  
Shi Ying Wang ◽  
Ming Lv ◽  
Gang Ya
Keyword(s):  
Theoretical Model ◽  
Ultrasonic Vibration ◽  
Vibration Mode ◽  
Frequency Equation ◽  
Design Parameters ◽  
Ultrasonic Machining ◽  
Vibration System ◽  
Analysis Method ◽  
Ansys Analysis ◽  
Gear Honing

Ultrasonic vibration can reduce honing forces efficiently. As the honing wheel can be washed by ultrasonic cavitations of cooling liquid, its jams are decreased and the higher honing efficiency has obtained. Therefore, the combination of ultrasonic machining and gear honing is a method for gear fine machining with its wide application future. In the paper, to improve the rigidity, the ultrasonic vibration system adopted the structure of double supports as traditional honing machine, so the horn is symmetric. The machined gear was simplified into a circular thin plate with diameter of its reference circle and the horn was treated as its half as the symmetry; the frequency equations of the transformer were derived according to stress match under the condition that the half horn and plate of the transformer were considered at the same time; the frequency equations were derived based on the boundary conditions. Then the design parameters of the transformer were obtained as the frequency equation was solved computationally and expanded to the whole horn. The displacement, stress of the transformer was solved, too. Finally, the vibration mode of the transformer was analyzed by ANSYS. The results of theoretical and ANSYS analysis is consistent, which means the theoretical model and analysis method are correct.

Study on Ultrasonic Vibration Assisted Grinding in Theory

2006 ◽  
Vol 532-533 ◽  
pp. 773-776 ◽  
Author(s):  
Hong Li Zhang ◽  
Jian Hua Zhang ◽  
Meng You Huo
Keyword(s):  
Ultrasonic Vibration ◽  
Vibration Amplitude ◽  
Axial Direction ◽  
Grinding Force ◽  
Wheel Speed ◽  
Machining Process ◽  
Grinding Wheel ◽  
Trace Length ◽  
Cutting Model ◽  
Ultrasonic Vibration Assisted Grinding

In ultrasonic vibration assisted grinding (UAG) along the axial direction, the machining process of an abrasive grit is introduced in this paper. During the internal UAG, the critical speed is determined by the amplitude and frequency of ultrasonic vibration. During the surface UAG, the cutting model of an abrasive grit is established and the cutting trace length of an abrasive grit and the grinding force making chips deformation is analyzed in theory. The analysis results show that the cutting trace length is longer by introducing ultrasonic vibration along the axial direction; the grinding force is decreased, the higher vibration amplitude and frequency is helpful to the decrease of the grinding force and the higher grinding wheel speed weakens the contributiveness of ultrasonic vibration to the decrease of the grinding force.

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