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

提高齿轮的使用寿命和减少齿轮的摩擦接触可以提高齿轮的资源利用率。边界层保护齿面免受固态接触，因此影响摩擦和磨损。边界层的特性在预处理（制造和试运行）过程中受到影响。研究项目BR 2905/44-1强调了适当的精加工工艺的潜力，可以将测试部件的有限寿命疲劳提高30%，效率提高10%。到目前为止，这些研究还没有从双盘接触转移到齿面接触。因此，本项目的重点是齿轮的接触。研究项目的目的是齿轮精加工的制造诱导边界层的适当形成的指导方针。优化齿轮精加工的工艺参数，以提高输入工件的热能和机械能。适当的精加工工艺可以通过减少摩擦和磨损来提高齿轮的资源效率。此外，效率的增益和边界层的影响被捕获在本地仿真模型。为达到这一目的，进行了齿轮承载能力和效率试验。不同的成品齿轮的多个变量进行了测试。展成磨削因其实用性而被用作精加工工艺。在目前的研究项目中，WZL正在开发方法来描述展成磨削中的过程力和温度感应。基于这些方法，可以分析磨削过程中的能量输入，以便得出关于边界层形成的结论。寿命和效率的提高使得齿轮设计更加可持续和经济。满足了驱动系统中更高资源效率的要求。

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.