小模数齿轮的缓进深切成形磨削实验

易军; 李治宏; 周炜

doi:10.13394/j.cnki.jgszz.2022.0163

小模数齿轮的缓进深切成形磨削实验

doi: 10.13394/j.cnki.jgszz.2022.0163

易军^{1, 2,},
李治宏²,
周炜^{1, 2}

1.
难加工材料高效精密加工湖南省重点实验室, 湖南湘潭 411201
2.
湖南科技大学机电工程学院, 湖南湘潭 411201

基金项目: 国家自然科学基金（51905168）; 湖南省自然科学基金（2020JJ5192）。

详细信息

作者简介:
易军，男，1987年生，副教授。主要研究方向：精密超精密加工。E-mail：yj_hnust@163.com

中图分类号: TG58; TG74; TQ164
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- 被引次数: 0
出版历程
- 收稿日期: 2022-09-26
- 修回日期: 2022-11-07
- 录用日期: 2022-11-07
- 刊出日期: 2023-06-20

Experimental research on creep feed deep profile grinding of small-module gears

YI Jun^{1, 2
,},
LI Zhihong²,
ZHOU Wei^{1, 2}

1.
Hunan Provincial Key Laboratory of High Efficiency and Precision Machining of Difficult-to-cut Materials, Xiangtan 411201, Hunan, China
2.
College of Mechanical and Electrical Engineering, Hunan University of Science and Technology, Xiangtan 411201, Hunan, China

摘要

摘要: 针对高精度齿轮加工工艺路线长的问题，提出小模数齿轮缓进深切成形磨削方法并开展磨削实验，分析不同进给速度对磨削功率、工件磨削烧伤、砂轮磨损等的影响规律，且采用复刻法研究砂轮的磨损过程。结果表明：磨削功率峰值随进给速度的增加而增大；当进给速度超过150 mm/min时，工件表面发生磨削烧伤，其磨削表面的硬度明显高于工件初始表面的硬度，且工件表层发生了马氏体相变；距离磨削表面的深度增加，其硬度值均呈下降趋势，且齿底位置的硬化层深度小于齿廓两侧的硬化层深度；砂轮的磨损过程分为初期磨损、稳定磨损和快速磨损阶段3个阶段，其中稳定磨损阶段的材料去除体积约为2 000 mm³，过大的进给速度将引起砂轮的严重磨损。
- 齿轮 /
- 缓进深切成形磨削 /
- 磨削功率 /
- 磨削烧伤 /
- 砂轮磨损
Abstract: In view of the long process route of high-precision gear machining, a method of creep feed deep profile grinding of small-module gears was proposed. The experiments of creep feed deep profile grinding of small-module gears were carried out. The effects of different feed speeds on the grinding power, the workpiece grinding burn and the grinding wheel wear were analyzed. The wear process of grinding wheels was studied by replica method. The results show that the grinding power peak increases with the increase of feed speed. When the feed speed exceeds 150 mm/min, the grinding burns occur on the workpiece surface. Besides, the hardness of the grinding surface is significantly higher than that of the initial hardness, and the martensitic phase transformation occurs on the workpiece surface. As the depth from the grinding surface increases, the hardness values show a downward trend, and the depth of the hardness layer at the tooth bottom is smaller than that at the both sides of the tooth profile. The wear process of grinding wheels is divided into initial wear stage, stable wear stage and rapid wear stage. The material removal volume of stable wear stage is about 2 000 mm³. Excessive feed rate will cause severe wear of the grinding wheel.
- gear /
- creep feed deep profile grinding /
- grinding power /
- grinding burn /
- grinding wheel wear

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图 1 磨削实验装置

Figure 1. Grinding experimental device

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图 2 砂轮修整过程

Figure 2. Grinding wheel dressing process

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图 3 砂轮复印示意图

Figure 3. Diagram of grinding wheel copying

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图 4 砂轮轮廓获取流程图

Figure 4. Flow chart of grinding wheel contour acquisition

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图 5 磨削功率信号

Figure 5. Signals of grinding power

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图 6 磨削功率峰值随进给速度的变化

Figure 6. Variation of grinding power peaks with feed speed

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图 7 进给速度对磨削表面硬度的影响

Figure 7. Effect of feed speeds on surface hardness

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图 8 硬度沿深度的分布

Figure 8. Distribution of hardness along depth

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图 9 工件的初始显微组织

Figure 9. Initial microstructure of workpiece

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图 10 磨削加工后放大的齿槽横截面形貌

Figure 10. Cross-sectional morphology of the tooth groove with magnification after grinding

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图 11 磨削加工后放大的右侧齿廓边缘横截面形貌

Figure 11. Cross-sectional morphology of the right tooth profile edge with magnification after grinding

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图 12 图像处理

Figure 12. Image processing

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图 13 磨削前后砂轮的轮廓对比

Figure 13. Profile comparison of grinding wheel before and after grinding

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图 14 砂轮累积磨损体积与工件材料去除体积之间的关系

Figure 14. Relation between accumulated wear volume of grinding wheel and material removal volume of workpiece

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图 15 砂轮的磨损形式

Figure 15. Wear form of grinding wheel

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表 1 磨削工艺参数

Table 1. Grinding process parameters

实验组号	砂轮线速度 v_s / (m·s⁻¹)	磨削深度 a_p / mm	进给速度 v_w /（mm·min⁻¹）	磨削次数n₁
1	60	2.456	10，20，40，60， 80，100，200	7
2			10	6
3			60	6
4			80	6
5			90，100，110，120， 130，150，180	7
6			110	6
7			120	6

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