Abstract: A simulation model for tooth surface waviness considering installation errors was proposed to address the problem of low product qualification rate caused by the difficulty in regulating surface waviness during worm wheel grinding of new energy vehicle gears.The influence of gear installation errors on tooth surface waviness in worm wheel grinding was studied.The gear installation error in worm grinding machining was analyzed by studying the relative positions of the gear and the grinding worm.Based on the envelope principle of gear generating machining,a geometric model of grinding worm was established,and the grinding trajectory of tooth surface was calculated.Considering gear installation errors,the material removal mechanism in continuous generating grinding of tooth surfaces was revealed.Based on the entire process of digital evolution of tooth surface morphology,a simulation model for tooth surface waviness was established.The influence of installation error on the waviness of worm wheel grinding tooth surface was analyzed based on the simulation model.The research results indicated that gear installation errors affected the frequency distribution and amplitude of the tooth profile waviness spectrum,but only affected the frequency amplitude of the tooth profile waviness.

Key words: new energy vehicle gears, worm wheel grinding, tooth surface waviness, machine tool errorsnew energy vehicle gears, worm wheel grinding, tooth surface waviness, machine tool errors

摘要： 针对新能源汽车齿轮蜗杆砂轮磨削表面波纹度调控困难导致产品合格率低的问题,提出了考虑齿轮安装误差的齿轮蜗杆砂轮磨削表面波纹度仿真模型,研究了各项齿轮安装误差对齿面波纹度的影响。通过研究齿轮和蜗杆砂轮相对位置,分析了蜗杆砂轮磨削加工中的齿轮安装误差。基于齿轮连续展成加工包络原理,建立了蜗杆砂轮几何模型,计算了齿面磨削加工轨迹。考虑齿轮安装误差,揭示了连续展成磨削齿面材料去除机理。基于全流程齿面形貌数字化演变过程,建立了齿面波纹度仿真模型。最后,基于齿面波纹度仿真模型,分析了安装误差对蜗杆砂轮磨削齿面波纹度的影响。研究结果表明,齿轮安装误差影响齿形波纹度频谱频率分布和频率幅值,仅影响齿向波纹度的频率幅值。

关键词: 新能源汽车齿轮, 蜗杆砂轮磨削, 齿面波纹度, 机床误差