磨料流精加工同时改善直齿、直齿锥齿轮的微观几何和表面质量

A. Petare, N. Jain, I. Palani
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引用次数: 3

摘要

本文报道了挤压压力、磨料粒度和体积浓度对直齿和直齿锥齿轮流磨加工同时降低表面粗糙度和微几何误差的影响。研制了双向AFF的立式配置实验装置,并研制了精加工齿轮夹具。基于Box-Behnken设计方法,采用响应面法进行试验研究,以确定最佳参数组合。结果表明,磨料粒径和体积浓度越高,表面粗糙度和微几何误差降低的百分比越大。对精加工质量最好的齿轮的粗糙度轮廓、承载面积曲线、显微硬度、表面形貌和耐磨性进行了研究。对精加工的直齿和直齿锥齿轮的齿面区域进行表面形貌分析,发现齿面区域光滑,无裂纹和毛刺。往复磨损试验结果表明,与未完成齿轮相比,AFF完成齿轮的耐磨性更高。AFF还提高了成品齿轮的显微硬度,从而提高了齿轮的使用性能和使用寿命。该研究表明,AFF是一种灵活、经济、高效、易于操作和可持续的非传统齿轮精密加工工艺,可以同时改善成品齿轮的微观几何形状、表面光洁度、显微硬度、表面形貌、耐磨性和残余应力。齿轮制造商和用户将受益于这项研究的结果。JEL代码:C00, C20
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Simultaneous improvement of microgeometry and surface quality of spur and straight bevel gears by abrasive flow finishing process
This article reports on influence of extrusion pressure, abrasive particle size and volumetric concentration on simultaneous reduction of surface roughness and microgeometry errors of spur and straight bevel gear by abrasive flow finishing (AFF) process. A vertical configured experimental apparatus was developed for two-way AFF and developed fixtures for finishing gears. Experimental investigations were conducted to identify optimum parametric combination, using response surface methodology, based on Box–Behnken design approach. Results revealed that higher values of abrasive particle size and volumetric concentration yield more percentage decrease in surface roughness and microgeometry error. Roughness profile, bearing area curve, microhardness, surface morphology, and wear resistance of the gear having best quality finishing were studied. Surface morphology analysis of the flank regions of the best finished spur and straight bevel gears found them to be smooth and free from cracks and burrs. Reciprocating wear test results revealed higher wear resistance of the AFF finished gears as compared to the unfinished gears. AFF also enhanced microhardness of the finished gears, which would enhance their operating performance and service life. This study shows that AFF is a flexible, economical, productive, easy to operate, and sustainable nontraditional process for precision finishing of gear that can simultaneously improve microgeometry, surface finish, microhardness, surface morphology, wear resistance, and residual stresses of the finished gears. Gear manufacturers and users will be benefited by the outcome of this study. JEL codes: C00, C20
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