Design method for a vibration system of ultrasonic gear honing and its dynamic characteristics

Ultrasonic gear honing is a precision machining method of gears with good application prospects, and design of its vibration system is a key technique. Through analyzing the coupling relationship between its horn and gear, the vibration system was reasonably simplified. On this basis, a new design method for the vibration system was put forward by combining boundary conditions. Furthermore, using the proposed method, the horn was designed and the dynamic characteristics of its gear and horn was analyzed. Comparing the calculation results with those from finite element analysis and tests showed that the proposed theoretical model is reasonable and feasible, and the calculation results in examples are closer to the measured ones than the results from finite element analysis be. The corresponding conclusions provided a guidance for designing a vibration system of ultrasonic gear honing.