Calculation and test verification of residual stress in ultrasonic vibration-assisted grinding of aerospace gears based on crystal plasticity finite element model

ZOU Runxiang; TANG Jinyuan; ZHOU Weihua; YE Shijie; LI Fangcheng; YANG Yudian

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Calculation and test verification of residual stress in ultrasonic vibration-assisted grinding of aerospace gears based on crystal plasticity finite element model

更新时间：2026-04-13

- Calculation and test verification of residual stress in ultrasonic vibration-assisted grinding of aerospace gears based on crystal plasticity finite element model
- Journal of Mechanical Transmission Pages: 1-14(2026)
- 作者机构：
  
  1.中南大学极端服役性能精准制造全国重点实验室，长沙 410083
  2.中南大学机电工程学院，长沙 410083
  3.中国航发湖南动力机械研究所，株洲 412002
  4.中国航发中传机械有限公司，长沙 410200
- 作者简介：
- 基金信息：
- DOI：
  CLC： TG58
- Received：06 November 2025，
  
  Revised：2026-01-14，
  
  Online First：13 April 2026，
- 稿件说明：
移动端阅览
邹润湘，唐进元，周伟华，等.基于晶体塑性有限元的航空齿轮超声振动辅助磨削残余应力计算与试验验证［J］.机械传动，XXXX，XX（XX）：1-14.

ZOU Runxiang，TANG Jinyuan，ZHOU Weihua，et al.Calculation and test verification of residual stress in ultrasonic vibration-assisted grinding of aerospace gears based on crystal plasticity finite element model［J］.Journal of Mechanical Transmission，XXXX，XX（XX）：1-14.
邹润湘，唐进元，周伟华，等.基于晶体塑性有限元的航空齿轮超声振动辅助磨削残余应力计算与试验验证［J］.机械传动，XXXX，XX（XX）：1-14. DOI：

ZOU Runxiang，TANG Jinyuan，ZHOU Weihua，et al.Calculation and test verification of residual stress in ultrasonic vibration-assisted grinding of aerospace gears based on crystal plasticity finite element model［J］.Journal of Mechanical Transmission，XXXX，XX（XX）：1-14. DOI：

摘要

目的

航空齿轮对表面完整性要求严苛，超声振动辅助磨削（Ultrasonic Vibration-Assisted Grinding

UVAG）有助于提升齿面残余压应力与抗疲劳性能，但其热-力-微观塑性耦合机制仍需进一步阐明。为此，建立同时考虑超声振动与热-力耦合的晶体塑性有限元模型（Crystal Plasticity Finite Element Model

CPFEM），以实现齿面残余应力的正向预测，并揭示超声调控机制。

方法

构建齿面随动坐标系与磨削接触几何，推导UVAG条件下的摩擦衰减、切向磨削力与瞬态热流模型；在CPFEM中引入超声软化项与温度软化项，完成12Cr2Ni4A合金钢材料参数的标定，并建立表层/层深双尺度多晶模型；在Abaqus-UMAT框架下开展不同磨削参数与工况仿真；搭建UVAG试验平台，采用嵌入式热电偶对磨削温升进行校核，并通过X射线衍射（X-Ray Diffraction

XRD）逐层剥除法测量齿面及层深残余应力，实现模型验证。

结果

基准工况下，模型预测的齿面残余压应力峰值约为-369 MPa，100 μm处约-50 MPa，与XRD实测的偏差≤20%；不同工况下，表面验证平均误差约为21%，模拟值与试验值变化趋势一致。相较常规磨削，UVAG条件下残余压应力峰值提升20%~30%，作用层深提高约50%。结果表明，UVAG通过抑制摩擦致热并促进多滑移协同与位错增殖，可降低平均Taylor因子、提升滑移活动度、重构跨尺度应力场；所建模型可用于航空齿轮UVAG残余应力预测与工艺参数优化。

Abstract

Objective

Aerospace gears have strict requirements for surface integrity. Ultrasonic vibration-assisted grinding (UVAG) can enhance the residual compressive stress and fatigue resistance of gear surfaces

but the thermal-mechanical-microplastic coupling mechanism remains to be further clarified. Therefore

a crystal plasticity finite element model (CPFEM) considering both ultrasonic vibration and thermal-mechanical coupling was established to predict the residual stress on the gear surface and reveal the ultrasonic control mechanism.

Methods

A gear surface following coordinate system and grinding contact geometry were constructed

and models for friction attenuation

tangential grinding force

and transient heat flow under UVAG conditions were derived. The ultrasonic softening term and temperature softening term were introduced into the CPFEM

and the material parameters of 12Cr2Ni4A alloy steel were calibrated to establish a surface/depth dual-scale polycrystalline model. Simulations under different grinding parameters and conditions were conducted in the Abaqus-UMAT framework. An UVAG test platform was built

and the grinding temperature rise was verified by embedded thermocouples. The residual stress on the gear surface and at different depths was measured by the X-ray diffraction (XRD) layer-by-layer peeling method to validate the model.

Results

Under the reference condition

the model predicts a peak residual compressive stress of approximately -369 MPa on the gear surface and about -50 MPa at 100 μm

with a deviation from the XRD measurement of no more than 20%. Under different conditions

the average verification error of the surface is approximately 21%

and the trend of the simulated values is consistent with the test values. Compared with conventional grinding

the peak residual compressive stress under UVAG conditions increases by 20%-30%

and the effective depth of action increases by about 50%. The results show that UVAG can reduce the average Taylor factor and increase the slip activity by suppressing frictional heating and promoting multi-slip coordination and dislocation proliferation

thereby reconstructing the cross-scale stress field. The established model can be used for residual stress prediction and process parameter optimization of UVAG in aerospace gears.

关键词

Keywords

references

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