Review of surface integrity in ultrasonic vibration⁃assisted gear grinding

ObjectiveGears are central components of power transmission systems, and their surface integrity fundamentally dictates the reliability and fatigue life of high-end equipment. Ultrasonic vibration-assisted grinding (UVAG) introduces high-frequency energy to mitigate excessive cutting forces and frictional heat accumulation, which are critical challenges in the precision manufacturing of high-performance gears. [Analysis] Through a systematic review of existing literature, this paper firstly delineates the evolutionary trajectory and core technical specifications of gear UVAG equipment. Secondly, it investigates the regulatory mechanisms of ultrasonic vibration on material removal behaviors based on surface integrity characterization methods, such as surface roughness, residual stress distribution, and subsurface damage control. Technical characteristics of different vibration application modes are comparatively analyzed.ConclusionUVAG demonstrates superior capabilities in improving gear surface quality and reducing thermal damage compared to conventional grinding. It provides a robust theoretical foundation for achieving “high precision and long life” in gear manufacturing. [Prospect] Future research should focus on the synergistic optimization of multi-physics fields during the UVAG process and the development of high-frequency, large-scale integrated equipment to meet the requirements of extreme service conditions in aerospace and industrial robotics.