【摘要】：本文提出一種超聲深滾齒面強化技術(shù),通過動載沖擊與滾壓塑性變形的雙重作用,用以提高齒輪齒面材料的表面力學(xué)性能,提高零件的使用壽命。設(shè)計一套適用于漸開線曲面的超聲深滾齒面強化裝置,實現(xiàn)復(fù)雜漸開線曲面的表面強化工作,實驗裝置由超聲波發(fā)生器,超聲波執(zhí)行系統(tǒng),壓力進給裝置以及加工工具等部分組成。超聲加工工具采用L形狀,且超聲加工工具的寬度與被強化齒輪的齒寬相同,實現(xiàn)在強化過程中,超聲加工工具以線接觸的方式與被強化齒輪進行嚙合,提高加工效率。 以模數(shù)3,齒數(shù)20的齒輪為例,利用表面粗糙度測量、X-射線衍射分析(XRD)、齒輪形狀偏差檢查等分析手段,對加工前、后的齒輪表面進行對比分析得出強化結(jié)果。研究了超聲深滾加工工藝參數(shù)對齒輪表面完整性的影響規(guī)律,并通過正交試驗對各影響因子進行顯著性分析。由于齒輪形狀的特殊性要求,分析工藝參數(shù)對形狀精度的影響,以達到在不破壞表面形狀精度的前提下,提高齒輪輪齒的表面質(zhì)量,改善零件表面的應(yīng)力狀態(tài)的目的。 實驗觀察和分析表明：超聲深滾齒面強化裝置能夠較好地完成對不同模數(shù)和齒數(shù)的齒輪輪齒表面的強化。超聲深滾齒面強化加工是一種行之有效的齒面強化加工技術(shù)。超聲深滾齒面強化加工,能夠以保持齒輪精度為基礎(chǔ),提高磨削后齒輪表面質(zhì)量,改善齒輪表面的加工紋理,通過改善齒輪的表面應(yīng)力狀態(tài),提高齒輪的使用壽命。 超聲深滾齒面強化工藝參數(shù),以及加工工具的表面精度和材料性質(zhì),對于齒輪的表面粗糙度,齒輪的形狀偏差以及表面殘余應(yīng)力有著不同程度的影響。在一定程度上增加擠壓力和加工次數(shù)等參數(shù),能夠消除前一次加工中產(chǎn)生的表面缺陷,提高齒輪表面質(zhì)量,改善齒面的應(yīng)力狀態(tài),增加殘余應(yīng)力層的厚度,有利于提高齒輪的使用壽命和抗環(huán)境服役能力。但是超聲深滾加工是一種表面形變加工,過分的塑性變形,會在表面產(chǎn)生微觀疲勞裂紋,不利于齒輪使用壽命的提高。 分析正交試驗結(jié)果,得出結(jié)論：擠壓力的增大能夠使表層晶粒克服材料屈服極限值,在表面形成塑性形變,優(yōu)化了加工效果；對齒面進行往復(fù)加工能夠改善上一次加工缺陷,使塑性變形更加均勻,改善強化效果：齒形和潤滑油對強化效果影響極小。
[Abstract]:In this paper, a kind of ultrasonic deep hobbing surface strengthening technique is proposed, which can improve the surface mechanical properties of gear tooth surface material and improve the service life of parts through the dual action of dynamic impact and rolling plastic deformation. A set of ultrasonic deep hobbing surface strengthening device suitable for involute surface is designed to realize the surface strengthening work of complex involute surface. The experimental device is composed of ultrasonic generator and ultrasonic executive system. Pressure feed device and machining tools and other parts of the composition. The ultrasonic machining tool adopts L shape, and the width of ultrasonic machining tool is the same as that of strengthened gear. In the process of strengthening, ultrasonic machining tool meshes with strengthened gear in the way of line contact to improve machining efficiency. Taking gear with modulus 3 and tooth number 20 as an example, by means of surface roughness measurement and (XRD), gear shape deviation analysis by means of X- ray diffraction, the results of comparison and analysis of gear surface before and after machining are obtained. The influence of ultrasonic deep rolling process parameters on the surface integrity of gear was studied, and the significance of each factor was analyzed by orthogonal test. In order to improve the surface quality of gear teeth and improve the stress state of parts surface, the influence of process parameters on shape accuracy is analyzed because of the special requirements of gear shape, so as to improve the surface quality of gear teeth without destroying the surface shape accuracy. The experimental observation and analysis show that the ultrasonic deep hobbing gear surface strengthening device can effectively strengthen the tooth surface of gear with different modulus and number of teeth. Ultrasonic deep hobbing machining is an effective machining technology. Ultrasonic deep hobbing machining can improve the surface quality of gear after grinding, improve the machining texture of gear surface, and improve the service life of gear by improving the stress state of gear surface and improving the service life of gear. The process parameters of ultrasonic deep hobbing surface strengthening, as well as the surface precision and material properties of machining tools, have different effects on the surface roughness, gear shape deviation and surface residual stress of gear. To a certain extent, increasing the extrusion pressure and processing times can eliminate the surface defects produced in the previous machining, improve the surface quality of the gear, improve the stress state of the tooth surface, and increase the thickness of the residual stress layer. It can improve the service life of gear and the ability of resisting environment service. However, ultrasonic deep rolling is a kind of surface deformation processing, excessive plastic deformation, will produce micro-fatigue cracks on the surface, which is not conducive to the increase of the service life of gears. By analyzing the results of orthogonal test, it is concluded that the increase of extrusion pressure can make the surface grain overcome the yield limit value of the material, form plastic deformation on the surface, optimize the processing effect, and the reciprocating machining of the tooth surface can improve the defect of the last machining. Make plastic deformation more uniform, improve strengthening effect: tooth shape and lubricating oil have minimal effect on strengthening effect.
【學(xué)位授予單位】：大連理工大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2012
【分類號】：TH132.41

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