Foreword
Gears are the basic unit of mechanical transmission systems, widely used inaviation, ships, vehicles and other industries. With the improvement of industrial levelThe development of industry and the progress of aviation and aerospace industries require the high performance and high reliability of transmission systems.The demand for higher and higher quality gears is increasing, so the requirements for gear processing are moving towards high quality,High precision and high reliability development. But it is necessary to consider the overall gear processingFrom a technical point of view, the overall digitization of machine tools used in gear processing in China is notUnification, the accuracy of machine tools is often lower than the world’s advanced level or even the international standardaccurateThe exploration of gear processing methods and principles is still relatively backward compared to foreign countries.There is a certain gap, and the material and manufacturing process of machining gear tools are alsoThere is a significant gap, especially for high-precision, high-thrust-to-weight ratio gears.The existing processing technology is difficult to achieve, often requiringRepeated finishing of various processes (extrusion strengthening, shot peening, finishing, etc.)In order to meet the service requirements of precision gears, it is necessary to improve the manufacturing process of gears.The process of achieving high-performance gear precision and efficient machining is an inevitable trend in gear machining.Grinding is the main method for precision machining of key components such as gears.The method uses the micro-cutting effect of numerous abrasive particles on the working surface of the grinding wheel to remove materialThe material shows excellent cutting performance in high-precision processing of various difficult-to-process materials.The incomparable advantage of cutting processing is to ensure the accuracy andAn important process for surface quality. For efficient and precise grinding of gearsThe research on processing technology is currently mainly focused on the gear grinding process,grinding wheel performance, grinding surface integrity, production quality and efficiency, etc.During the gear grinding process, the grinding force and grinding temperatureThe degree is easier to measure during grinding as a diagnostic grinding state.evaluation parameters of state and adaptive control, and improve the surface quality of grinding workpiecesand the grinding performance of grinding wheel particles have an important influence. The grindingThe performance directly determines the processing efficiency and quality, the wear particles and the workpiece surfacethe effects of sliding, cutting, and plastic deformation of abrasive particles directly affectIt affects the removal rate and surface morphology of workpiece materials, thus affecting the gear grinding process.Surface integrity of the cutting process.
Gears are mechanical transmission components, especially under heavy load conditions.Under cyclic alternating loads, it is easy to cause fatigue wear and evenFracture, the surface quality of tooth surface machining determines the serviceability of gearsYes, grinding is a key process for the surface quality of gears.has attracted the attention of many scholars at home and abroad. This study briefly introduces theBased on the wheel forming grinding method and material removal mechanism, the paper summarizesDomestic and foreign scholars have conducted research on high-efficiency grinding, precision grinding, surface integrityResearch results in the field of composite machining technology for sexual and multipotent fields. This article mainlyIt should be divided into the following contents: the first part mainly introduces the gear grinding methods andThe removal mechanism of grinding materials is analyzed, and the advantages of grinding technology in toothThe importance of wheel machining; the second part is high-efficiency precision grinding of gearsThe current status of processing research; the third part is the current status of research on the integrity of gear surfacesThe fourth part mainly focuses on the research and development of multi-energy field composite manufacturing technology for gears.Summarize the current situation and content.
Gear grinding method
Based on the motion trajectory of the grinding wheel and the relative gear, the gear grinding methodThe method can be divided into generating grinding and form grinding. The two grinding methods areThere are differences in the accuracy, quality, and efficiency of gear grinding.The generation method of grinding process is achieved through the generation motion of grinding wheel.to control the tooth profile and pitch of the gear, with high precision, high efficiency,The advantage of adjustable precision, but requires high-precision equipment and technology.the processing difficulty is high and the production cost is high.The generating grinding of involute helical gears is studied using an approximate model.The relationship between tooth surface twist and gear parameters is demonstrated, and based on thisThe model analyzes the influence of gear parameters on the machining accuracy of the tooth flank. Based on the concept of generating grinding for bevel gears and the structure of gear grinder, a method for calculating the optimal grinding parameters is proposed.Adaptive design model for generating grinding of bevel gears on ordinary gear grindertype, combined with the generating grinding method and grinding characteristics of bevel gears, aGeneral mathematical model for evaluating worm wheel dressing during grindingand other factors on the accuracy of grinding gears, thereby improving the quality of gear grindingPrecision. Between material removal, grinding wheel and workpieceThe model of surface roughness for grinding spiral bevel gears is established through the kinematic analysis of the formation process.This model analyzes the relative motion between the grinding wheel and the workpiece; based on this,The influence of grinding parameters on surface roughness was evaluated.Gear forming grinding process is performed by grinding the shape of the grinding wheelThe shape and motion trajectory form the tooth profile of the gear, which has high precision and surfaceGood quality and wide range of processing applications. Forming method of gear grinding processThe tooth surfaces on both sides of the grinding wheel and the tooth groove can engage simultaneously with the full tooth height.Therefore, the grinding wheel wears slowly, the grinding efficiency is high, and the tooth profile accuracy is completely determined by the grinding wheel.Shape determines. However, compared to the generating method grinding process, the forming method grinding processLonger processing time is often required, especially for the processing of large or complex gears. To solve the problem ofWork efficiency and accuracy issues, establishing contact between the grinding wheel surface and the gear surfaceanalyzed whether the grinding wheel surface and the tooth space were affected byinterference, and adjust the installation position of the grinding wheel through experiment and calculation to avoidGrinding interference occurs. To solve the problem of toothSurface distortion phenomenon, quantify the distortion of grinding tooth surface, establishA tooth surface grinding error model is established, and the optimization of grinding wheel dressing parameters and dressing process is carried out.Modularization can reduce the machining error of tooth surface. Wang Long et al. [38] established aTheoretical model of grinding force and grinding temperature for shape grinding of gears is analyzedThe formation mechanism of temperature, and analyzed the characteristics of grinding wheel-material characteristics-The mapping relationship between grinding parameters and grinding temperature is finally determined through orthogonal testThe accuracy of the model was verified.
Both generating grinding and form grinding can be used for gear grinding.It is suitable for different types of gears, achieving high-precision gear processing.The exhibition method of grinding has advantages in efficient processing and tool life.Forming grinding has advantages in accuracy controllability and gear strength.Potential.
Research on the removal mechanism of gear grinding materials
High-efficiency grinding of gears is a research hotspot in the field of gear manufacturing.Domestic and foreign scholars and institutions have conducted extensive research on high-efficiency gear grinding.Quantitative research, including optimization of grinding processes (grinding parameters, cooling lubrication,Multiple process compound, etc.), grinding tool optimization (grinding wheel wear resistance, grindinggrain self-sharpening performance) and high-performance grinding machine tools (automation control, continuousprocessing, etc. [49], in order to achieve efficient gear grinding. High-speed grinding asAn important machining method for efficient grinding, due to its good grinding performance in difficult-to-machine materials, has gradually been applied to key components.The part is being processed.
High-speed grinding of gears is the process of using a high-speed rotating grinding wheel toThe method of grinding. Compared to traditional grinding methods, high-speedGrinding has higher processing speed and efficiency. High-speed grinding can quicklyRemove materials quickly, improve processing efficiency, and reduce thermal effects during grindingThe smaller area reduces thermal damage to the workpiece and shortens the processing time.Cycle, improve production efficiency.
Production efficiency of spiral grinding wheel gear grinderLow-speed problem, using CBN grinding wheel and high-speed CNC gear grinding machineIn the gear grinding test, two direct-drive motors are used to rotate the grinding spindle and workpiece.The speed of the main shaft is increased to 12000 r/min and 3000 r/min respectively.r/min, and developed a multi-threaded spiral in 2001Synchronized control of high productivity NC gear grinder with shaped CBN grinding wheelPC-based synchronous controller to reduce production costs,When using multi-threaded spiral CBN grinding wheels to improve gear grinding accuracy.Zhao Henghua et al. [57] summarized the development history andand analyzed the research status of ultra-high speed grinding at home and abroad.This provides data and theoretical support for ultra-high speed grinding of gears.
With the development of superhard materials, superhard material grinding wheels have been widely used in aviation,Grinding and processing of high-strength and high-hardness components such as aerospace and heavy-duty machineryThe application of superabrasives in grinding is becoming more and more extensive. Currently, the main types of superabrasives used in grinding areThere are synthetic diamond and cubic boron nitride (CBN). Diamond abrasive sandThe application of wheels is mainly for non-metallic hard materials such as optical glass and ceramics.grinding of materials [60]. CBN abrasives have strong chemical inertness with iron group elements, andIt has good thermal diffusivity and high hardness, so it is suitable for moldsgrinding of high-hardness iron group materials such as steel, bearing steel,CBN abrasives are ideal for grinding tools.
Grinding force is an important parameter in the process of gear grinding, which has a significant impact onThe stability of the grinding process, tool life, and machining accuracy are all important.The magnitude and distribution of grinding forces are influenced by multiple factorsInfluences, including cutting parameters, tool geometry, grinding fluid, workpieceCutting speed, feed rate, and grinding depth areAn important parameter affecting grinding force, increasing cutting speed and feed rateIt will lead to an increase in grinding force, and increasing the grinding depth will also increase the grinding force.Affect. The shape and grinding state of the grinding wheel also affect the grinding force.The grinding state of the abrasive particles will affect the cutting edge’s cutting andthe process, thereby affecting the grinding force. The type andThe use condition will also affect the magnitude of grinding force. Traditional gear grinding plusThe workers use a large amount of mineral oil-based metal processing fluid to pour into the grinding area,The cooling, lubrication, chip removal and rust prevention functions of the current processing process. However,However, cutting fluids formulated from non-renewable mineral oil do not meet the requirements of sustainable development.The principle of sustainable development, and the huge cost of cutting fluid treatment have significantly increased manufacturing costs. Therefore, the lubrication method for gear grinding processing needs to be transformed urgently.Micro-lubrication is a new process for forming clean and precise parts.By supplying traditional pouring type 1% to 5% of the amount of reducible iron powder to the cutting area,De-lubricant, which plays a role in lubricating and rust-proofing the cutting area.One step, using electrostatic field assisted atomization of micro-lubrication can achieve lubricationThe controlled transport and supply of lubricants. Micro-lubrication technology improves the wearThe friction behavior of the particle-workpiece interface reduces the grinding process during machininghardness, toughness, surface state and other characteristics of workpiece materials will affectThe grinding force has an impact, and materials with higher hardness will result in greater wear.Cutting force. Accurately predicting and controlling grinding force for stable grinding processSex and processing accuracy are very important. By reasonably selecting grinding parameters,Optimizing the geometry of the grinding wheel and using appropriate grinding fluid can reduceThe magnitude and fluctuation of grinding force, improving the stability andEfficiency, research on grinding force of gears or gear materials, both at home and abroadThey have done a lot of work.
The generation and transfer of grinding heat during gear grinding is very complex.In the precision grinding of gears, the tooth groove surrounds the grinding wheel contour,There is no gap; most of the grinding energy is converted into heat, making the grindingThe temperature of the cutting area rises sharply. The grinding temperature is too high, which can lead to severe damage to the workpiece surface.which is prone to problems such as thermal cracking, oxidation, or surface quality degradation.It is difficult to ensure the dimensional stability and surface accuracy of the workpiece, and at the same time, highTemperature can lead to increased wear of the grinding wheel, reducing its service life and making it difficult to improve the efficiency of gear processing. By reasonably controlling the grinding temperature,Optimizing process parameters and using grinding fluid reasonably can improve gear grindingprocessing quality, grinding wheel life and production efficiency.The slip technique can reduce the heat flux density at the heat source, but it has the problem of heat transfer energy loss.Technological bottlenecks due to insufficient resources. Therefore, scholars have conducted in-depth researchWe explore and develop nanometer-enhanced bio-lubricant micro-lubrication and lowNew processes such as warm auxiliary micro-lubrication reduce grinding temperatures.Accurately predicting the temperature field distribution in the gear grinding area is crucial for reducing grinding heat loss.Injury risk, improving gear accuracy, service life and reliability are of great importance.To influence. During the gear forming grinding process, the grindingThe distribution of the normal section of the contour is different, so the grinding force, grinding temperatureThe distribution of the degree and the wear rate of the grinding wheel along the contour of the workpiece is uneven, and the grindingThe distribution of heat sources and heat flow in the contact area depends on process parameters and tooth geometry.The boundary of different grinding temperature models is summarized based on the wheel geometry stateConditions, heat flux density equation, and applicability.
(1) Grinding is the main method for precision machining of key components such as gears.The method is an important process to ensure the accuracy and surface quality of the gear.Research on high-efficiency precision grinding technology for gears mainly focuses onDuring the gear grinding process, the grinding force, grinding temperature, wheel wear, workpieceOptimization of parameters, grinding surface topography, surface integrity, and finite element analysisBased on the motion trajectory of gear grinding, the gearGrinding is divided into generating grinding and forming grinding. Generating grinding isIt has advantages in efficient processing and tool life, while forming grindingIt has advantages in terms of controllable accuracy and gear strength.(2) With the development of superhard materials and machine tool performance, theHigh-efficiency grinding ensures grinding quality while improving grinding efficiency.High-speed grinding can quickly remove material and improve processing efficiency.The heat affected zone in the process is small, reducing thermal damage to the workpiece,It can shorten the processing cycle and improve production efficiency; through theoretical analysis,Analysis and experiments have confirmed that using CBN superabrasive grinding wheels for gear grinding can achieveGrinding can reduce grinding temperature and residual stress, improve processing stability,The quality of gear grinding and the life of the grinding wheel are superior to ordinary grinding wheels.(3) Grinding force and grinding temperature are important factors in the process of gear grinding.It is important to consider the stability of the grinding process, tool life, and processing accuracy.The degree of grinding has a significant impact. The research on grinding force mainly focuses onUsing mathematical modeling, experimental research, and finite element simulation methods,Analyzing the influence of gear grinding kinematics and grinding conditions on grinding force;The research on grinding temperature mainly focuses on the temperature in the gear grinding areaField distribution and its influence on surface state, by establishing a theoretical model of grinding zone movementThe dynamic heat source model simulates the grinding temperature changes during grinding, and combinesThe experimental analysis obtained the temperature distribution characteristics of the grinding surface, and theThe temperature field distribution is predicted to avoid grinding heat damage.(4) Grinding surface residual stress, surface morphology and surface microstructureHardness is an important indicator of surface integrity, and it is important for the wear resistance,The fatigue resistance and contact stress play a key role. Improving grindingsurface residual compressive stress, surface topography quality, and surface microhardness,It can effectively improve the transmission efficiency of gears, reduce transmission noise, and improveHigh gear service life.