Thermo-mechanical coupling effect on surface residual stress during ultrasonic vibration-assisted forming grinding gear

Abstract

Abstract Gears are important motion and power transmission components and enhancing their machining accuracy and performance. In this work, a novel processing of ultrasonic vibration-assisted forming grinding gear (UVAFGG) is proposed, which involves the superimposition of ultrasonic vibration on the gear, and the thermo-mechanical coupling effect on surface residual stress is explored as well. Firstly, based on the local contact geometry relationship for forming grinding, the three-dimensional (3D) distribution model of the heat flux density along the tooth profile is established. In addition, the mathematical relationship models between the grinding force, grinding heat, residual stress, and grinding parameters are also given. Then, the effect of grinding parameters such as spindle speed and ultrasonic amplitude for the characteristics of residual compressive stress accumulation is obtained by comparing the single factor experimental and finite element simulation results. It is found that under the action of ultrasonic vibration, the grinding heat and grinding force reduce by 38.7% and 40.5 % and 40.5 %, respectively. The surface residual compressive stress gradually decreases with the increase in spindle speed, while with the increase in ultrasonic amplitude, it increases first and then decrease. Comparing with the conventional grinding gear (CGG), the average rate of increase of the surface residual compressive stress under the both parameters is 17.8 %–31.3 % and 20 % respectively. Meanwhile, the residual compressive stress along involute shows a negative correlation with the increase in the rolling angle. At the same time, the experimental and simulation results agree well with the theoretical model. In conclusion, the results of this study provide a novel process technology for gear machining, and a reference for the investigation on residual stress during UVAFGG.