Papers by Author: Tao Yu

Abstract: Surface roughness is an important parameter to evaluate the quality of high-speed machining (HSM). This paper establishes a mechanical model based on the molecular-mechanical theory of friction to study factors that influence the surface roughness in HSM. The relationship between flow stress and the remnant height on the machined surface is obtained. The HSM process of AISI-1045 steel is simulated by using finite element method (FEM) based on DEFORM-2D and the flow stress is obtained. The surface roughness of workpiece machined by HSM is calculated based on the value of flow stress and the mechanical model. The result shows that the surface roughness of workpiece in HSM is acceptable, and the mechanical model supplies a method to study the surface roughness in HSM.

Abstract: The gear honing process is a widely used process for gear finishing after heat-treated. The honing ring is profiled by diamond dressing gear, which have the profile of the workpiece to be machined and bonded a single layer of diamond particles. The paper has inroduced the traditional manufacturing methods of diamond dressing gears, positive electroplating and negative electroplating. Then put forward a new manufacturing method, Electroless nickel coating. Composition and condition of electroless composite plating solution, process steps are given. Several diamond dressing gears are made by this new method. Honing experiment testified that it is an applied method and has many advantages.

Abstract: Gear honing with globoid honing worms is seldom used because it has no distinct advantages to honing with internal geared honing rings. The paper puts forward a new process to honing gear with globoid honing worms on hobbing machines. First the globoid honing worm is profiled by diamond dressing gears, which has the same geometric parameters with the machined gears. Then the profiled globoid honing worm is used to hone workpieces. Both the profiling process and honing process are implemented on same hobbing machines. Meshing and Tooth contact analysis of globoid honing worm profiling has been considered. Meshing equation of profiling process and equation of globoid honing worm tooth flank after profiling are obtained. Experiment testified that it is an applied process and has many advantages.

Abstract: The gear honing process is a widely used process for gear finishing after heat-treated, and may be divided into the variants “internal-tooth honing” and “external-tooth honing”. External- tooth honing is seldom used in gear finishing due to lower overlapping ratio and relatively low precision. But its process cost is much lower than internal-tooth honing and gear grinding. The paper puts forward a new method to improve the precision of external-tooth honing, i.e. honing ring is profiled by diamond dressing gears, which have the profile of the workpiece to be machined. Meshing and Tooth contact analysis of honing ring profiling has been considered. Meshing equation of profiling process and equation of honing ring tooth flank after profiling are obtained. Experiment testified that it is an applied method and has many advantages.

Abstract: The gear plunge shaving process is a widely used process for soft finishing of gears in the gear manufacturing industry. But it is difficult and expensive to profile plunge shaving cutter, because the cutter must be ground by a cone grinding wheel on a special grinder. A new method, profiling gear shaving cutter on the shaving machine, i.e. a CBN dressing gear which has the same parameters with the machined gear is clamped in place of the workpiece on the shaving machine and profiling the cutter in shaving process, is put forward. Meshing and Tooth contact analysis of shaving cutter profiling has been considered. Meshing equation of profiling process and equation of shaving cutter gear blank after profiling are obtained. Experiment testified that it is an applied method and has many advantages.