Numerical analysis and experimental study on thermal-mechanical coupling in ultrasonic vibration grinding of gears

Ultrasonic vibration grinding is an effective process for addressing the machining challenges of high-strength gears, playing a crucial role in enhancing gear manufacturing quality. A nonlinear thermo-mechanical coupling model for gear ultrasonic vibration grinding is proposed based on sequential coupling modes. By solving this model, the formation processes of tooth surface grinding temperature and residual stresses under ultrasonic vibration were analyzed, and the accuracy of the proposed model was experimentally validated. Research findings indicate that ultrasonic vibration grinding significantly reduces peak grinding temperatures while generating greater residual compressive stresses on gear surfaces. Under ultrasonic vibration, both the temperature field and grinding stress field exhibit non-uniform dynamic distributions, which positively suppress thermal damage and maintain surface compressive stresses. Furthermore, appropriately reducing grinding wheel speed enhances the advantages of ultrasonic vibration.