Optimization of the gear finishing process: Increase of the resource efficiency of boundary layers in the tooth flank contact

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The resource efficiency of gears can be improved either by increasing their lifetime or by decreasing their friction in the tribological contact. Boundary layers protect tooth flanks from solid-state contacts and therefore influence friction and wear. The characteristics of boundary layers are influenced in the course of preconditioning (manufacturing and run-in). The research project BR 2905/44-1 highlights the potential of adequate finishing processes to improve the finite life fatigue of the test parts by 30% and their efficiency by 10%. Up to now, these investigations have not been transferred from twin disk contact to gear flank contact. Hence, the focus of the present project is on the gear contact.The aim of the research project is a gear finishing guideline for the adequate formation of manufac-turing induced boundary layers. The process parameters of gear finishing are optimized in order to improve the thermal and mechanical energy input into the workpiece. An adequate finishing process can improve the resource efficiency of gears by reducing friction and wear. Furthermore, the gain in efficiency and the influence of the boundary layer are captured in a local simulation model. Gear tests on load carrying capacity and efficiency are conducted to achieve the aim. Multiple vari-ants of differently finished gears are tested. Generating grinding is applied as finishing process because of its practical relevance. In current research projects the WZL is developing methods to describe the process forces and the temperature induction in generating grinding. Based on these methods the energy input during the grinding process can be analyzed in order to draw conclusions on the formation of boundary layers. The improvement of lifetime and efficiency allows a more sustainable and economical design of gears. The requirements for higher resource efficiency in drive systems are fulfilled.