本文選題：齒輪 + 滾磨光整加工��； 參考：《太原理工大學(xué)》2017年碩士論文

【摘要】：齒輪副是一種典型的摩擦副類零件,在工作過程中兩輪齒表面存在滑動摩擦,且滑動的大小和方向都在不斷變化。因此,齒輪的表面質(zhì)量,尤其是輪齒的齒廓表面質(zhì)量對齒輪的使用性能與使用壽命都有很大的影響。滾磨光整加工具有零件表面全方位加工,表面完整性特征參數(shù)綜合改善,加工成本低,加工效率高等特點(diǎn)。本文立足于研究開發(fā)適用于大模數(shù)齒輪的滾磨光整加工新工藝,通過提高齒輪的表面質(zhì)量,改善齒輪的表面完整性,進(jìn)而達(dá)到提高齒輪的使用性能等目的。針對課題組提出的用以齒輪光整加工的"垂直交叉主軸式齒輪滾磨光整加工方法",主要對齒輪的齒面加工均勻性,加工后的表面完整性以及加工后的使用性能等方面的內(nèi)容進(jìn)行了深入系統(tǒng)地研究。首先,在查閱大量相關(guān)文獻(xiàn)資料的前提下,列舉了影響齒輪使用性能的主要因素,介紹了目前國內(nèi)外普遍使用的各種齒輪光整加工方法,分析對比了現(xiàn)有的齒輪滾磨光整加工工藝的特點(diǎn)及其適用范圍,明確了本文所要研究的核心內(nèi)容,研究方法等。其次,使用EDEM軟件模擬加工過程,得出了齒輪偏角和滾筒轉(zhuǎn)速對加工作用力的大小以及顆粒的流動速度有較大影響,進(jìn)而分析其可能對齒輪齒面加工均勻性和加工質(zhì)量有重大影響。同時使用統(tǒng)計(jì)學(xué)軟件JMP,選用中心復(fù)合實(shí)驗(yàn)設(shè)計(jì)法進(jìn)行了實(shí)驗(yàn)方案的設(shè)計(jì)編排。通過實(shí)驗(yàn)驗(yàn)證,發(fā)現(xiàn)采用本文所研究的齒輪滾磨光整加工方法與磨齒比較,當(dāng)以輪齒表面粗糙度值為衡量指標(biāo)時,滾磨加工后的齒頂與齒根粗糙度值的標(biāo)準(zhǔn)差均小于磨齒,故認(rèn)為該種加工方法加工均勻,且在磨齒的基礎(chǔ)上,輪齒表面粗糙度Ra值能從0.7μm左右降至0.2μm左右。該工藝所涉及的齒輪偏角,滾筒轉(zhuǎn)速,加工時間等主要加工參數(shù)對齒面加工質(zhì)量有明顯的影響。接著,在前面的研究基礎(chǔ)上,對加工前后齒輪的表面完整性(針對影響齒輪使用性能的主要參數(shù),包括齒面粗糙度及微觀形貌,輪齒表面層顯微硬度,近表層金相組織,齒根殘余應(yīng)力狀態(tài)等)作了進(jìn)一步地研究。結(jié)果表明,滾磨光整加工對改善齒輪表面完整性具有十分顯著的效果。參考綜合模糊評價方法,建立了加工參數(shù)對輪齒表面完整性的模糊評價,得到的結(jié)論是滾筒轉(zhuǎn)速對齒輪表面完整性的影響最大。最后,通過對滾磨光整加工前后的齒輪進(jìn)行高周疲勞試驗(yàn)和摩擦磨損試驗(yàn),結(jié)果顯示,經(jīng)過滾磨光整加工后齒輪的抗彎疲勞強(qiáng)度和耐磨損性都獲得不同程度的提高,說明采用滾磨光整加工方法有助于提高齒輪的使用性能。綜上所述,本文所研究的齒輪滾磨光整加工方法能夠有效地提高齒輪的表面質(zhì)量,整體改善齒輪的表面完整性從而提高齒輪的使用性能。若能實(shí)現(xiàn)工業(yè)化應(yīng)用,將為我國高端齒輪產(chǎn)品提供有力的技術(shù)保障。
[Abstract]:Gear pair is a kind of typical friction pair parts. There is sliding friction on the surface of the two gear teeth during the working process, and the size and direction of the sliding are constantly changing. Therefore, the surface quality of gear, especially the surface quality of tooth profile, has great influence on the performance and service life of gear. Rolling finish machining has the characteristics of all-around machining of parts, comprehensive improvement of surface integrity characteristic parameters, low processing cost and high processing efficiency. This paper is based on the research and development of a new rolling finishing process suitable for large modulus gears. By improving the surface quality of gears and improving the surface integrity of gears, the performance of gears can be improved. In view of the "vertical cross spindle gear rolling finishing method" proposed by the research group for gear finishing, it mainly deals with the uniformity of gear tooth surface processing. The surface integrity and the performance of the machined surface are studied systematically and deeply. First of all, on the premise of consulting a large number of relevant literature, the paper lists the main factors that affect the gear performance, and introduces various gear finishing methods which are widely used at home and abroad. This paper analyzes and compares the characteristics and applicable scope of the existing gear rolling finishing process, and clarifies the core contents and research methods of this paper. Secondly, using EDEM software to simulate the machining process, it is concluded that the gear deflection angle and drum speed have great influence on the size of the machining force and the flow velocity of the particles. Furthermore, it is analyzed that it may have a great influence on the machining uniformity and machining quality of gear tooth surface. At the same time, using the statistical software JMP, the central composite experimental design method is used to design the experimental scheme. Through experimental verification, it is found that the standard deviation of tooth top roughness and tooth root roughness after hobbing is smaller than that of grinding teeth when the surface roughness value of gear tooth is taken as the measurement index, compared with the grinding tooth grinding method studied in this paper. Therefore, it is considered that the machining method is uniform, and on the basis of grinding, the surface roughness Ra value of gear tooth can be reduced from 0.7 渭 m to 0.2 渭 m. The main processing parameters, such as gear deflection angle, cylinder speed and processing time, have obvious influence on the machining quality of tooth surface. Then, on the basis of the previous research, the surface integrity of the gear before and after machining is analyzed. (aiming at the main parameters that affect the performance of the gear, including the tooth surface roughness and the micro-morphology, the micro-hardness of the surface layer of the gear tooth, the metallographic structure of the near surface layer, The residual stress state of tooth root is further studied. The results show that the surface integrity of gear is improved by rolling finishing. Referring to the comprehensive fuzzy evaluation method, the fuzzy evaluation of machining parameters on the surface integrity of the gear teeth is established. The conclusion is that the rotary speed of the drum has the greatest influence on the surface integrity of the gear. Finally, the high-cycle fatigue test and friction and wear test of gears before and after rolling finishing are carried out. The results show that the bending fatigue strength and wear resistance of gears are improved in varying degrees after rolling finishing. It is shown that the rolling finishing method is helpful to improve the performance of gears. To sum up, the gear rolling finishing method studied in this paper can effectively improve the surface quality of the gear, improve the surface integrity of the gear as a whole and improve the performance of the gear. If the industrial application can be realized, it will provide strong technical guarantee for the high-end gear products in our country.
【學(xué)位授予單位】：太原理工大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG616

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