Design and experiments of transducer-horn of ultrasonic lapping of gears

We introduce the method of ultrasonic lapping of bevel gears,and use ultrasonic machining in lapping of gears.Based on the principle of four-terminal networks,equivalent electric circuit diagrams of the transducer-horn are constructed by using mechano-electrical analogy.Equations for frequency and the amplification factor of the transducer-horn are derived from the equivalent circuit.Based on the expressions,a set of transducer-horn with favorable resonance performance has been designed.Experiments of the ultr-asonic and conventional lapping have been carried out,and the material removal mechanics analyzed with SEM photographs of tooth surfaces.The experiments show that the material removal rate of ultrasonic lapping is three times that of the conventional ones.Ultrasonic lapping also produces better tooth surface quality with roughness Ra=0.2mm,section height c=1.2 μm.