超声加工在齿轮抗疲劳制造中的研究综述与展望  

Overview and Expectation on Gear Anti-fatigue Manufacture by Ultrasonic-assisted Machining

作　　者：别文博[1] 赵波[1] 王晓博[1] 陈凡 张跃敏[1] BIE Wen-bo;ZHAO Bo;WANG Xiao-bo;CHEN Fan;ZHANG Yue-min(Henan Polytechnic University,Jiaozuo 454003,China;Pingdingshan University,Pingdingshan 467000,China)

机构地区：[1]河南理工大学,河南焦作454003 [2]平顶山学院,河南平顶山467000

出　　处：《表面技术》2018年第7期35-51,共17页Surface Technology

基　　金：国家自然科学基金(U1604255;51475148)~~

摘　　要：深入分析齿轮在超声加工下的表面完整性对齿轮抗疲劳性能的影响,促进超声加工在齿轮抗疲劳制造中的应用。基于超声加工的优势,分别对目前应用于齿轮加工中的超声滚齿、超声研齿、超声电化学齿轮加工和超声珩齿加工等方法进行综合分析。基于残余应力和表层组织可控的齿面加工机理,结合超声加工在表面改性技术和表面强化方面的应用,分别对在齿轮等构件中的超声冲击、超声喷丸和超声深滚强化技术进行分析。与传统齿轮加工方法相比,经过超声加工后,齿轮的表面粗糙度大幅度降低,齿面的微观形貌得以改变,表面质量显著提高。经过超声强化后的齿轮表面,表层引入了高幅值、大深度的残余压应力,表面层得到硬化,在一定程度上对裂纹的扩展起到了抑制作用,工件的抗疲劳强度得以提高,从而提高齿轮的抗疲劳能力。鉴于此,超声加工不仅可以为齿轮的抗疲劳制造提供一种新的精密高效的加工方法,而且对我国高性能齿轮制造理论的完善与工艺技术的进步具有重要意义。The work aims to further analyze the effects of gear surface integrity under ultrasonic-assisted machining(UAM)on anti-fatigue performance,and also promote the application of UAM to gear anti-fatigue manufacture.Based on advantages of UAM,comprehensive analysis was performed to such methods as ultrasonic hobbing,ultrasonic lapping,ultrasonic electrochemical gear machining and ultrasonic gear honing which were now applied to gear machining,respectively.On account of gear surface machining mechanisms in which residual stress and surface structure were controllable and by combining with the application of UAM to surface modification and surface strengthening,technologies of ultrasonic impact,ultrasonic shot peening and ultrasonic deep rolling reinforcement were analyzed in gear and other components,respectively.Compared with the conventional gear machining method,surface roughness Ra was greatly reduced,surface microstructure was changed and surface quality was significantly enhanced after UAM.Furthermore,surface was hardened owing to introduction of high-amplitude and large-depth residual compressive stress after ultrasonic strengthening,which inhibited propagation of cracks to some extent.Consequently,fatigue strength of the workpiece was improved,and gear anti-fatigue ability was enhanced.For that reason,UAM not only provides a new precise and efficient processing method for gear anti-fatigue manufacture,but also has great significance on perfecting domestic manufacture theory of high-performance gear and making progress in technology.

关 键 词：齿轮 表面完整性 抗疲劳制造 超声加工 

分 类 号：TB559[理学—物理] TH132.4[理学—声学]