Extending a cutting force model for generating gear grinding while regarding micro-geometrical influences

优化齿轮承载能力和安静性的最新技术是在热处理后对表面硬化齿轮进行精加工。精加工的一种选择是展成齿轮磨削工艺，由于其高生产率，该工艺在工业上得到广泛应用。尽管该工艺在工业上有广泛的应用，但科学研究却很少。一个可能的原因是刀具和齿轮齿面之间的接触条件复杂。在磨削过程中，不同的刀具齿面与不同的齿轮齿面啮合。这使得从其他研磨工艺中获得的知识的转移变得复杂。接触条件的变化可能导致明显的动态激励，这使得机器和控制工程的发展成为一个挑战。了解期望切削力及其特性对于描述动态过程和优化加工过程是必要的。实际的研究项目发展的切削力模型展成磨齿的外齿轮给出了第一种方法来计算的力量根据维尔纳和Kassen。然而，该模型简化了磨削蜗杆的切削。虽然必要的切削力参数估计的文献，该模型给出了一个很好的定性相关性的展成磨齿力测量。应用研究项目的目的是扩展已开发的切削力模型，用于计算所有活动刀具和展成齿轮磨削的齿面的局部切削力。扩展模型既考虑了宏观几何参数，又考虑了单个磨削网格的微观几何切削，确定了合适的切削力参数。通过对冷轧板栅和表面硬化钢的单格和多格划痕试验，确定了这些参数。迄今为止，对于这些典型的齿轮制造材料的划痕试验很少。将Werner和Kassen的参数定义和模型扩展到上述材料后，将知识转移到展成磨齿。模型的结果将通过磨削试验中的力测量进行优化，最后通过磨削参考齿轮和测量切削力进行验证。

State of the art for optimizing the load carrying capacity and quietness of gears is the fine finishing of case hardened gears after heat treatment. One option for fine finishing is the generating gear grinding process, which is a wide spread industrial application due to its high productivity. Despite the wide industrial application of the process, only few scientific investigations exist. One possible reason for this is that the contact conditions between tool and gear flank are complex During the grinding process, various tool flanks mesh with various gear flanks. This complicates the transfer of knowledge acquired form other grinding processes. The variation of the contact conditions can lead to a distinct dynamic excitation, which makes the development of the machine and the control engineering a challenge. Knowledge of the expecting cutting forces and their characteristics is necessary for describing the dynamics and optimizing the processes. The actual research project Development of a cutting force model for generating gear grinding of external gears gives a first approach for calculating the forces according Werner and Kassen. However this model simplifies the cutting by the grinding worm. Though necessary cutting force parameters were estimated by literature, the model gives a good qualitatively correlation to force measurements for generating gear grinding. Aim of the applied research project is the extension of the developed cutting force model for the calculation of the local cutting forces for all active tool and gear flanks for generating gear grinding. The extended model considers macro-geometrical parameters of the process as well as the micro-geometrical cutting of single grinding grids by determining appropriate cutting force parameters. With the help of single an multi grid scratch tests of corundum grids and case hardened steel the parameters are defined. Only few scratch tests were realized for these typical materials for the manufacturing process of gears so far. After the definition of the parameters and the model regarding to Werner and Kassen has been expanded for the mentioned materials, the knowledge will be transferred to generating gear grinding. The results of the model will be optimized by force measurements in grinding trials and finally verified by grinding a reference gear and measure the cutting forces.