间齿强力珩齿机理与关键技术研究

Gear honing is one of the continuous chip-removing precision machining processes to improve gear accuracy, and its kinematics is basically analogous to gear shaving. It was detected that gear honing not only cleaned the gear flanks but that the surface texture generated by the demanding gear honing kinematics has a positive effect on gear noise and gear wear in action. Today's honing technology allows honing gear flanks directly after heat treatment in a fast and capable process relatively independent of the pre machining. In this project, an interrupted-tooth gearing theory is used for the first time in gear honing to avoid the problems of concave profile formed in external honing and short working time of honing wheels. The basic idea is that the honing wheel is designed based on the tooth-skipped gearing theory, which results in a less than one contact ratio. Thus, the concave tooth profile is avoided. Meanwhile, as the relative slipping speed at the addendum and dedendum area is higher than that at the middle of the tooth, a convex profile is naturally formed. According to the designed tooth profile of gears and the tooth profile modified effect caused by friction force distribution along the profile, the honing wheel is modified to ensure that an accuracy tooth can be formed. By optimal designing of the material and structure of the honing wheel, the enduring time of the wheel is increased. As no tooth shaving process is needed, the manufacturing process is greatly simplified. Compared with the interval honing process, the proposed method shows the advantages of low cost, a simple structure of machine tool, ease of operation and great potential value in industrial application

珩齿作为一种硬齿面齿轮精加工工艺，具有提高齿轮加工精度，降低齿轮噪声的作用。目前国外正在大力推广采用"滚齿－热处理－强力珩齿"这一加工新工艺。本项目针对外啮合珩齿产生中凹齿形和珩轮精度保持时间短的两个问题，首次提出采用间齿啮合原理进行强力珩齿加工。该原理的基本思想是采用间齿啮合原理使珩齿加工时重叠系数小于1或等于1，避免产生中凹齿形；同时，利用齿顶和齿根部相对滑动速度大于齿高中部的滑动速度，自然形成中凸齿形。根据被加工齿轮的设计齿形，结合在齿面不同位置由于珩磨轮摩擦去除材料多少的不同，对珩磨轮进行修形，实现被加工齿轮的精确成形。通过对珩磨轮的材料、结构等参数进行优化设计，提高珩磨轮寿命。该原理可免除齿轮剃齿修形工序，简化齿轮加工工艺，同时相对于内齿珩齿具有成本低、机床结构简单、操作方便等优点，具有极大的应用价值。

齿轮是机械系统中的关键基础零件，其中硬齿面齿轮具有体积小、质量轻、承载能力大、寿命长和传动质量好等特点，被广泛用于汽车、航空航天、高铁和风电等行业。齿轮的主要加工工艺有滚齿、剃齿、插齿、刮齿、磨齿和珩齿等，其中磨齿和珩齿工艺加工齿轮的精度高，表面质量好，适用于硬齿面齿轮加工的最后一道工序。与磨齿相比，珩齿后的齿轮传动噪声低，齿面耐磨损性好，因此更加适合加工硬齿面齿轮。珩齿技术可分为内啮合珩齿和外啮合珩齿，其中内啮合珩齿机结构复杂，完全依赖国外进口，机床价格昂贵；外啮合珩齿机加工齿轮会产生中凹齿形，并且珩磨轮精度保持性差，这些问题限制了珩齿技术在国内应用和推广。本文通过理论创新与技术创新，解决了间齿珩齿加工过程中的啮合原理、间齿珩齿加工工艺的机理、基于间齿珩齿加工的全齿面拓扑修形方法、齿面加工误差反调修正技术、珩磨轮对珩磨速度的影响和珩磨轮形状对齿廓偏差的影响等关键问题，为间齿珩齿加工工艺在硬齿面齿轮加工中的成功应用提供了支撑。研究表明，间齿珩齿加工工艺可用于硬齿面齿轮的高精度加工，并且可以加工任意形状的齿面拓扑修形。