Digital surface morphology modeling of rotary ultrasonic auxiliary grinding spiral bevel gear

Abstract

Abstract Because the tooth surface micromorphology affects the performance of the gear and the finite element analysis and the grinding process of tooth surface through finite element analysis and simulation is complicated and time-consuming, the paper proposed a three-dimensional (3D) ultrasonic assistant grinding (RUAG) geometric simulation method to discover the micromorphology formation mechanism. Based on the motion path of a single grain, the 3D models of gear blank and the grinder was built. It helps to simulate the RUAG process. The morphologies of the simulated tooth surface were compared under conventional grinding (CG) and RUAG, which was consistent with the practice. It is proved that the geometric simulation method intuitively shows the micro dents on the tooth surface under different grinding parameters. The simulation method is helpful to analyze the surface morphology under different RUAG machining parameters and saves the cost and time of the actual production and processing.