Prediction and test validation for the three-dimensional surface roughness in internal gear polish honing of the aeronautic cylindrical gear

HOU Jinbo; TANG Jinyuan; ZHOU Weihua; LI Fangcheng; YANG Yudian

doi:10.16578/j.issn.1004.2539.2026.08.009

Abstract：[Objective]Internal gear polish honing of aeronautic cylindrical gears can improve tooth surface quality and reduce transmission noise.A forward prediction method for three-dimensional surface roughness suitable for polish honing conditions was established to address the shortcomings of existing honing roughness prediction models,which can only characterize two-dimensional features and ignore the elastic compliance of honing wheels,and to provide support for process parameter optimization.[Methods]Firstly,the cutting depth and cutting times of abrasives driven by process parameters were derived based on conjugate meshing rules and abrasive cutting mechanism to provide parametric basis for quantitative calculation of material removal.Secondly,the progressive removal of micro-asperities on tooth surfaces by abrasives was equivalent to a"meshing contact-material removal"signal processing operator of three-dimensional height field to realize accurate mathematical characterization of the machining process.Then,adaptive denoising and morphology-preserving correction were performed on the measured initial tooth surface to restore the real initial machining topography.Finally,iterative calculation of post-honing tooth surface height data was carried out with Matlab software to complete the quantitative prediction of three-dimensional surface roughness.[Results]The results show that the average prediction errors of arithmetical mean height,root mean square height,and maximum height are 6.42%,5.29%,and 5.86%,respectively,and the maximum prediction error is less than 12.77%.The surface roughness decreases with the increase of honing wheel speed and increases with the increase of cutting rate.The proposed method can provide references for process optimization of internal gear polish honing and precision machining of complex curved surfaces.