具有高淬硬性和强淬透性的AISI 9310齿轮钢（相当于10CrNi3Mo合金钢）是直升机传动齿轮的核心材料。磨齿通常作为齿轮制造工艺中的最终加工工序，承担着消除热处理工艺后的变形和提高齿轮形状精度与表面完整性的关键作用。由于齿轮钢淬硬表面硬度大（HRC55以上），使得磨削过程力大、温度高，长期存在加工表面易磨削烧伤、砂轮磨损严重、加工效率和表面质量难以保证的瓶颈难题。现阶段，超声振动辅助磨削技术已在航空航天高强韧和高硬脆难加工材料构件精密加工中得到快速发展，并探索了超声振动辅助磨削加工机理。但是，目前有关典型齿轮钢淬硬层的超声振动辅助磨削技术研究尚处于起步阶段，严重制约了超声振动辅助技术在齿轮磨削领域的进一步应用。有鉴于此，本文开展了AISI 9310钢淬硬层超声振动辅助磨削温度与砂轮磨损研究，对AISI 9310齿轮钢淬硬层的超声振动辅助磨削性能、磨削温度场预测与磨削烧伤、砂轮磨损控制进行了研究。

主要创新工作及成果如下：

（1）对比分析了AISI 9310齿轮钢淬硬层普通磨削和超声磨削的加工特性，从磨削力、磨削温度、表面粗糙度等方面综合评价了超声磨削的性能优势。研究发现：相比于普通磨削，超声磨削可以大幅降低磨削力（约40%）、磨削温度（约50%）以及表面粗糙度值（约40%），原因归结于超声磨削的断续切削行为增大了单颗磨粒厚度（约25.4%）；同时，超声振动下的软化效应有助于降低材料应变能，改善材料磨削加工性。

（2）构建了评价超声强化性能的分离系数模型与基于超声磨削切屑体积分布的矩-三角形热源分布模型，更准确地预测了超声振动条件下的磨削温度分布，与实验结果相符；在此基础上，提出了超声磨削的工艺策略。研究发现：结合传统三角形热源和超声磨削加工特征构建的矩-三角形热源分布模型能够更好地预测磨削温度，平均预测误差为7.13%，相比于三角形热源，预测精度提升了7.33%。提出了通过提高超声振幅、减少磨削切深和工件进给速度的工艺策略，能够提升超声磨削加工性能，有效降低磨削热的产生。

（3）明确了超声磨削过程中砂轮磨损的演变规律，阐明了砂轮磨粒磨损机理与演变行为，揭示了超声磨削表面创成机制。研究表明：超声磨削过程中，砂轮磨粒在多角度交变载荷作用下，呈现优异的自锐性能和排屑能力，砂轮锋利度得以长时稳定保持；相比普通磨削过程，超声磨削过程的稳定磨削阶段长23.07%。

研究成果有助于促进超声磨削技术在齿轮钢材料高质高效磨削加工中的应用，对于提升我国航空传动系统齿轮及难加工零件的磨削加工技术水平具有重要意义。

AISI 9310 gear steel represents a difficult-to-machine material with high hardenability and hardenability, which is the core material for key transmission gears of helicopters. In gear processing and manufacturing technology, grinding is usually used as the final processing of gears, which plays a key role in eliminating deformation after the heat treatment process and improving the shape accuracy of gears. However, due to the high hardness of the hardened surface of gear steel, there are processing problems such as high grinding forces, easy grinding burn on the machined surface and easy wear of tool, which make it difficult to guarantee the machining efficiency and surface quality. At present, ultrasonic vibration assisted grinding (UVAG) machining technology has been rapidly developed and applied in the manufacturing of difficult-to-machine materials with high toughness or hard brittle. The mechanism of UVAG has been studied superficially. The research on UVAG characteristics of the hardened layer of gear steel is inadequate, and the lack of in-depth research on grindability, prediction of grinding temperature filed, burn prevention and wear control of grinding wheel has seriously restricted the application of ultrasound-assisted technology in gear grinding.

For these abovementioned reasons, this paper carried out a research on the ultrasonic vibration assisted grinding temperature and grinding wheel wear of the quench-hardened layer of AISI 9310 steel. The ultrasonic vibration assisted grinding performance, grinding temperature field prediction, grinding burn and grinding wheel wear control of AISI 9310 gear steel were investigated.

The main research work and results are as follows:

(1) Comparative experiment of convention grinding and UVAG processes for the quench-hardened layer of AISI 9310 hardened gear steel was conducted to evaluate the performance advantages of UVAG. As results shown, with the application of ultrasonic vibration, UVAG reduces grinding forces by about 40%, grinding temperatures by 50% and surface roughness by 40%. It is mainly due to the fact that the interrupted cutting behavior increases the maximum undeformed chip thickness by 25.4%, and repeatedly irons the workpiece surface, while the ultrasonic softening effect and ultrasonic friction reduction effect reduce the material strain energy.

(2) Base on the separation coefficient model and the distribution of UVAG chip volume, the Moment-Triangle (MT) heat source distribution model was established, Evaluation of ultrasonic strengthening performance and accurate prediction of grinding temperature. As results shown, the moment-triangle heat source distribution model constructed by combining the conventional triangular heat source and ultrasonic grinding processing characteristics could predict the grinding temperature better, with the maximum grinding temperature prediction error ranging from 1.97% to 14.74% and the average prediction error of 7.13%. On this basis, the process strategy of increasing the ultrasonic amplitude, reducing the grinding depth and workpiece feed rate was proposed, which can improve the ultrasonic grinding processing performance and effectively reduce the grinding heat generation.

(3) The evolution of grinding wheel wear during ultrasonic grinding was revealed, the wear mechanism and evolution behavior of grinding wheel grains were elucidated, and the surface creation mechanism of ultrasonic grinding was revealed. The study showed that the grinding wheel grains showed excellent self-sharpening performance and chip removal ability under multi-angle alternating load during UVAG, and the grinding wheel sharpness was maintained stably for a long time. The stable grinding phase of ultrasonic grinding process was 23.07% longer than that of ordinary grinding process.

The research achievements were conductive to accelerate the application of ultrasonic vibration assisted grinding in high-efficiency grinding of gear steel materials, and then promote the development of grinding technology of aviation transmission gears and difficult-to-machine parts.

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