Papers by Author: Shi Ying Wang

Abstract: In the machining of ultrasonic gear honing, gear’s dynamic characteristics have a significant impact on the designing of vibration system and machining quality of gear. Since the gear and solid horn produce resonance, it is necessary to give a comprehensive consideration of the interaction between the two. This paper utilized the boundary conditions of the plate and the horn at the connection surface and their own dynamical equations to establish dynamical model of composite structure of the gear and the horn, which providing a theoretical basis for the horn designing and the gear’s dynamic characteristics analysis in ultrasonic gear honing. The results of calculation example are consistent with that of test, it verifies that the proposed analytical method in this paper is feasible.

Abstract: Cutting force is an important parameter in machining. The static balance method and experience formulas had been adopted to find its value, but the theoretical calculated value is not good agreement with the experimental value for the same set of cutting conditions. In practical machining, the cutting tool has obvious impact effect on workpiece, so a dynamics analytical model for cutting process is established in this paper. Based on the proposed solution, a new formula for cutting force has been obtained. The suggested formula has shown to correspond well with the experimental data.

Abstract: Ultrasonic gear honing is a kind of precision processing technology with great application prospect. The gear is a special kind of load in ultrasonic machining, and its vibration characteristic and natural frequency has great influence on processing frequency of the system. According to the structure characteristic of the gear with stepped variable thickness, its equations of axisymmetric bending vibration frequency were derived on the basis of the thick plate theory in this paper, and then the gear’s natural frequency is obtained which is in accordance with the results of FEM computation. Besides, the main factors affecting the calculation accuracy are analyzed with some examples in this paper The analysis shows that within the application range of Mindlin’s plate theory, the gears’ frequency obtained by the suggested method is accurate.

Abstract: Ultrasonic vibration can reduce honing forces efficiently. As the honing wheel can be washed by ultrasonic cavitations of cooling liquid, its jams are decreased and the higher honing efficiency has obtained. Therefore, the combination of ultrasonic machining and gear honing is a method for gear fine machining with its wide application future. In the paper, to improve the rigidity, the ultrasonic vibration system adopted the structure of double supports as traditional honing machine, so the horn is symmetric. The machined gear was simplified into a circular thin plate with diameter of its reference circle and the horn was treated as its half as the symmetry; the frequency equations of the transformer were derived according to stress match under the condition that the half horn and plate of the transformer were considered at the same time; the frequency equations were derived based on the boundary conditions. Then the design parameters of the transformer were obtained as the frequency equation was solved computationally and expanded to the whole horn. The displacement, stress of the transformer was solved, too. Finally, the vibration mode of the transformer was analyzed by ANSYS. The results of theoretical and ANSYS analysis is consistent, which means the theoretical model and analysis method are correct.

Abstract: In the process of the ultrasonic machining, the machining efficiency is affected directly by material removal rate. In the paper, the material structure deformation under abrasive impacting is simulated by the LS-DYNA3D software, and the stresses occurring are analyzed numerically. In addition, the effects of some machining parameters on the amount of the material removal are investigated by the experiments.

Abstract: Ultrasonic vibration can reduce honing forces efficiently. As the honing wheel can be washed by ultrasonic cavitations of cutting fluids, its jams are decreased and the higher honing efficiency has been obtained. Therefore, gear honing combined with ultrasonic machining honing is a method for gear finish machining with its wide application future. Ultrasonic-assisted honing of gears is firstly proposed, its machining devices are manufactured based upon the design parameters derived by four-terminal network principle. Experiments of gear honing show that the machining traces on the tooth flanks in ultrasonic and traditional honing are different. The ultrasonic honing can produce a better tooth surface roughness (Ra 0.45 μm) than one obtained conventional honing (Ra 0.72 μm).

Abstract: This paper analyses the material removal and surface forming mechanism of ultrasonic auxiliary gear honing. According to the Huygens principle of diffraction, a theory is proposed firstly that the ultrasonic waves transmit through the being honed gear in toroidal form, and the mathematical equation of the abrasive trace is built that expresses the relative movement between CBN abrasive and the gear surface. The equation is accordant with the experimental result. The paper concludes that the material removal of the gear surface depends on two factors, one is that CBN abrasives scratch the gear surface, and the other is that the gear surface vibrating itself along its normal direction impacts the abrasives.

Abstract: Ultrasonic vibration can reduce honing forces efficiently. As the honing wheel can be washed by ultrasonic cavitations of cooling liquid, its jams are decreased and the higher honing efficiency has obtained. Therefore, the combination of ultrasonic machining and gear honing is a method for gear fine machining with its wide application future. However, the gears with big diameter and thickness machined by ultrasonic honing are special loads, which influence the machining frequency of vibration system heavily. Hence, the horn and gear must be considered at the same time while designing the vibration system. In this paper, the frequency equations are derived according to stress match, wherein, the gear is considered as a thin disc and catenary horn is adopted. Then the influences of vibration of transformer that consists of horn and gear are investigated with the variety of the horn length and the machining frequency. The theoretical analysis shows that the resonance frequency of the horn and detune frequency of transformer have the different value. The results are proved by FEM, too.

Abstract: In the paper, a new method of using rotating magnetic field generated by a stator of alternative electromotor to polish the inner surface of tube-type workpieces is proposed; a finishing device using the stator construction and inverter is designed; the finishing mechanism is analyzed and experiments are carried out. Experimental investigations show that filling amount of magnetic abrasive influences the surface roughness of workpiece directly and have an optimal value. The higher magnetic conductivity is, and the finer finishing effect is. The attraction force of magnetic particles depends on intensity of magnetic induction directly and has the optimal value. The higher the rotation speed is, and the lower the value of surface roughness. Under the optimal experimental condition, the new method can reduce the value of surface roughness more than 2 grades. Therefore, this technique has prospective application future.