Simulation to Microtopography Formation of CBN Active Abrasives on a Honing Wheel Surface

Yang Gao,Yuan Liang,Jiang Han,Fuwei Wang,Lin Liu,Xiaoqiang Ren

doi:10.3390/coatings11050540

Abstract

The microtopography of a honing wheel surface composed of active abrasive grains is the key factor affecting the honing characteristics, and control of it is a sufficient condition to realize high-efficiency precision honing. Based on the magnetron sputtering method and phase field method, a theoretical model of cubic boron nitride (CBN) coating formation on a honing wheel surface is established. The physical vapor deposition (PVD) discrete phase field equation is solved by the finite difference method. A MATLAB program is compiled to simulate the formation process and micromorphology of the CBN coating on the honing wheel surface. A Taguchi method is designed to study the relationships of the sputtering time, substrate temperature, gas flow rate, and reaction space with the number of active abrasives and the length, width, height, and size of the abrasives. The simulation results are highly similar to the scanning electron microscopy (SEM) examinations, which shows that the model can accurately and effectively simulate the abrasive morphology of the wheel surface under different process conditions and provide a theoretical basis for the prediction and control of the CBN wear morphology on a honing wheel surface.

Highlights

IntroductionWith the increasing requirements of gears for automotive dual clutch automatic transmissions (DCTs), robot joint cycloid reducers, etc., it has become essential to reduce gear noise and improve the accuracy, load capacity, and life span of hardened gears [1,2]
Comparison of the experimental and simulation results of the micromorphology of the comparison of the experimental and simulation results of the micromorphology of the honing wheel tooth surface is shown in Figures 9 and 10
Nine positions of I, J, K, L, M, N, O, P, and Q were selected in the scanning electron microscopy (SEM) plots for comparison with the simulated plots, and the results showed that the height, grain shape, and size of cubic boron nitride (CBN) grains simulated by the phase field method were in good agreement with the experimental results

Summary

Introduction

With the increasing requirements of gears for automotive dual clutch automatic transmissions (DCTs), robot joint cycloid reducers, etc., it has become essential to reduce gear noise and improve the accuracy, load capacity, and life span of hardened gears [1,2]. The gear honing technology, with the advantages of high machining efficiency, low cost, low residual stress, no burns on the tooth surface, and regular honing wheel pattern on the tooth surface that helps to reduce gear transmission noise, can be an alternative to grinding and has been applied to the finishing of hardened gears after quenching [6,13]

Objectives

Results

Conclusion