Hard gear finishing viewed as a process of abrasive wear
Hard gear finishing viewed as a process of abrasive wear
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DOI：
10.1016/j.wear.2004.09.032
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发表时间：
2005
期刊：
影响因子：
5
通讯作者：
E. Brinksmeier;A. Giwerzew
中科院分区：
文献类型：
--
作者：
E. Brinksmeier;A. Giwerzew
磨料加工是齿轮加工的关键技术之一。在淬火齿轮的磨削精加工工艺中，以低至0.3-5m/S的切割速度为特征的加工在过去20年中变得越来越重要。已经花费了大量的努力来提高这种低速磨削过程的生产率。这项工作的一部分是开发新的磨料工具，这涉及到大量的实证调查，因此非常耗时和成本高。本研究旨在更深入地了解不同砂轮的工艺行为差异。为此，磨削过程被分析为磨粒磨损过程。所选择的研究方法意味着磨削实验和分析计算的结合。为了表征磨削过程中的加工量和工作结果，使用了磨料磨损图。此外，还计算了最大单晶切屑厚度、平均单粒法向力和残余亚表面应力的X射线测量结果。研究结果表明，在一定的磨削条件下，最大单颗粒切屑厚度决定了刀具的性能。此外，已观察到磨削的基本功结果与接触区的总摩擦系数相关，而与所使用的刀具无关。这些结果可用于新型磨具的工业开发和进一步的基础研究。
Abrasive machining is one of the key technologies in gear manufacturing. Amongst abrasive finishing processes of hardened gears, operations characterised by cutting speeds as low as 0.3–5m/s have been becoming more and more important during the last 20 years. A lot of effort has been spent to increase the productivity of such low speed grinding processes. A part of this effort is the development of new abrasive tools, which involves much empirical investigation and is, therefore, very time and cost intensive. The present study is aimed at a deeper understanding of differences in the process behaviour of various grinding wheels. For this purpose, the grinding process has been analysed as a process of abrasive wear. The chosen research approach implied a combination of grinding experiments and analytical calculations. To characterise the process quantities and work results in grinding, an abrasive wear map was used. Furthermore, calculations of the maximum single grain chip thickness, the mean single grain normal forces and X-ray measurements of residual subsurface stresses were made. Results of the investigations show that at constant grinding conditions, the maximum single grain chip thickness determines the tool performance. Additionally, the essential work results in grinding have been observed to correlate with the overall friction coefficient in the contact area regardless of the used tool. These results can be advantageously used for both industrial development of new abrasive tools and further fundamental research.