珩轮齿面CBN涂层多磨粒微刃珩削加工特性研究

CBN honing gear is an effective way to solve the problem of high quality hardened gear manufacturing in the process of gear honing. However, when dealing with the CBN abrasive micro-blade honing, it is still unclear that how the microstructure of abrasive grain and the parameters of honing process influence the machining characteristics of workpiece tooth surface, which hinders the further development of the application of internal power honing processing technology in production of high quality hardened gears. For these reasons, the following investigations will be carried out: First, built the microstructure of abrasive grain of honing gear, form the debris-workpiece continuum disintegrated model, and establish the processing model of multiple CBN abrasive in honing process; second, systematically study the microstructure of abrasive grains on the surface of honing gear teeth, analyze the dynamic evolution of abrasive grains’ microstructure, and design the coating morphology of CBN honing gear; thirdly, formulate the abrasive wear principle, and investigate how the characteristics of CBN abrasive grains influence the honing principle in different honing areas; lastly, investigate the mechanism of how the geometrical morphology of abrasive grains, honing force, and honing speed influence processing characteristics of high quality honing gear on the basis of improved BP neural network. With these efforts, the project hopes to improve the surface quality of high quality hardened gear, process efficiency and accuracy of fine finishing, and promote the application of internal engagement power honing technology in manufacturing of high-quality hardened gear.

在强力内珩齿加工中，CBN珩轮是解决高质量硬齿面齿轮制造难题的有效途径，但涉及CBN磨粒微刃珩削时，磨粒微观形貌和珩削工艺参数对工件齿面加工特性的影响机制尚不清楚，制约了内啮合强力珩齿加工技术在高质量硬齿面齿轮应用研究方面的进一步发展。为此，项目将开展以下研究：建立珩磨轮齿面微观磨粒形貌模型、磨屑-工件连续体结构解体模型和CBN多磨磨粒微刃珩削加工模型；系统地研究珩轮齿面磨粒微观形貌模型，分析磨粒微观组织的动力学演变机制，设计CBN珩磨轮涂层形貌；研究磨粒特性对不同区域的珩削规律和磨粒磨损特性；最后基于改进的BP神经网络算法，重点研究CBN涂层磨粒微观几何形貌、珩削力和珩削速度对高质量硬齿面齿加工特性的作用机理。通过项目实施，提高高质量硬齿面齿轮的齿面质量、加工效率和精加工精度，推动内啮合强力珩齿加工技术在高质量硬齿面齿轮制造中的应用。

随着汽车、风力发电机、机器人等对齿轮传动精度高、载荷大、寿命长和噪音低的要求与日俱增，制造高性能硬齿面齿轮成为亟待解决的难题。内啮合强力珩齿是实现高性能硬齿面齿轮加工的有效方法。但是多磨粒微刃珩削时，珩磨轮齿面随机分布的不规则磨粒所构成的微观形貌对工件齿面加工特性作用规律尚不清楚，制约了内啮合强力珩齿技术在高性能硬齿面齿轮精加工阶段的广泛应用。本项目针对此问题，以内啮合强力珩齿理论、多磨粒微刃珩削机理、相场法、近场动力学等为基础，将内啮合强力珩齿等效转化为随机分布的有效磨粒微刃切削过程，建立了CBN磨粒断裂损伤模型和多磨粒微刃珩削加工模型，系统地研究了磨粒-工件相互作用机理。揭示了CBN磨粒断裂机理和工件材料去除过程，分析了磨粒特性对加工精度、效率、表面质量影响规律。研究成果在研发的YK4825数控内啮合强力珩齿机和加工的高性能硬齿面齿轮进行了实际应用，并在企业实现了转化。