面向齿轮成形磨削力热分布均一化的结构化成形砂轮设计及其磨削性能研究

The mechanism of the structural characteristic parameters of grinding wheel on the homogenization of grinding force and heat distribution will be revealed according to analyze the influence law of the structural characteristic parameters of the grinding wheel on the grinding force, grinding temperature, grinding fluid flow state, grinding process stability and grinding wheel wear. The design strategy of grinding wheel with uniform distribution of grinding force and heat will be proposed based on the optimization of the structural feature matching relation of grinding wheel. The arrangement and combination scheme of the structural features of the form grinding wheel along the width of the grinding wheel will be obtained by multi-objective optimization. The form grinding wheel will be structured based on abrasive water jet machining. A comparative grinding experiment will be carried out between the structured form grinding wheel and the ordinary grinding wheel under the same experimental conditions to evaluate its machining performance and study its grinding mechanism. Considering the spatial dynamic distribution characteristics of the grinding force and heat on the tooth profile, a prediction model for the thermal damage of tooth form grinding induced by dynamic cycling force-thermal coupling in the grinding area will be established to accurately predict the tooth surface hardness and residual stress distribution, so as to determine the optimal gear form grinding parameters. The research achievements will provide new tools for high efficiency homogeneous nondestructive machining of large gears.

针对大型齿轮成形磨削时齿廓磨削力、热分布不均的问题，提出对成形砂轮工作面进行结构化，以改善局部磨削加工工艺性能，实现齿廓磨削力、热分布均一化成形磨削的研究思路。通过分析砂轮结构化特征参数对磨削力、磨削温度、磨削液流动状态、磨削过程稳定性、砂轮磨损的影响规律，揭示砂轮结构化特征参数对磨削力、热分布均一化的作用机理；提出基于优化砂轮结构化特征匹配关系的磨削力、热分布均一化成形砂轮设计策略，通过多目标优化求解得到成形砂轮结构化特征沿砂轮宽度的排布组合方案；基于磨料水射流加工，对成形砂轮进行结构化，开展结构化成形砂轮与普通砂轮在相同实验条件下的磨削对比实验，评估其加工性能，研究其磨削机理；考虑齿廓磨削力、热的空间动态分布特征，建立磨削区动态循环力－热耦合诱导齿廓磨削热损伤的预测模型，对齿面硬度、残余应力分布进行准确预测，确定最优的齿轮成形磨削工艺参数。为实现大型齿轮高效、均质、无损加工提供新工具。

高精度硬齿面齿轮是航空航天、风电核电、大型舰船、机车等的关键传动件，其制造精度和加工质量是制约我国一系列重大装备研制的瓶颈之一。成形磨削通常是齿轮表面硬化处理后修正热变形、获得所需精度和表面质量的最后一道工序，然而在齿轮成形磨削过程中砂轮－工件接触面积大，磨削液难以进入磨削区，增加了产生热损伤的风险；砂轮与齿廓呈复杂的三维几何接触关系，法向磨削深度、砂轮线速度、比材料去除率沿被磨齿轮齿廓非线性变化，使得齿面磨削力、磨削温度呈非均匀分布。过高且非均匀分布的应力场、磨削温度场将引起同一齿廓呈现多种硬度、残余应力状态和显微组织结构，造成同一齿廓磨削质量不一致，严重影响齿轮的强度、使用寿命和可靠性。为此，本项目结合结构化砂轮在降低磨削力、磨削比能、改善冷却润滑条件等方面的优势，探明了砂轮结构化参数、磨削工艺参数与磨削力、磨削温度的关联规律以及磨削力、磨削温度与磨削热损伤关联规律；在此基础上，考虑硬齿面齿轮成形磨削的工艺特征，以磨削质量均一化为目标，以磨削过程稳定性为约束，提出了基于优化砂轮结构化表征参数匹配关系的磨削质量均一化成形砂轮设计策略；阐明了结构化成形砂轮的磨削机理，揭示了硬齿面齿轮结构化成形砂轮磨削的热损伤形成及演变机制。项目研究成果为实现硬齿面齿轮高效、无损、均质成形磨削提供了新工具。