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

优化齿轮的承载能力和安静性的最新技术是对热处理后的淬火齿轮进行精加工。精加工的一个选择是产生齿轮磨削工艺，这是一个广泛的工业应用，由于其高生产率。尽管该工艺在工业上有广泛的应用，但科学研究却很少。造成这种情况的一个可能原因是刀具与齿轮齿面接触条件复杂，在磨削过程中，各种刀具齿面与各种齿轮齿面相互啮合。这使得从其他磨削过程中获得的知识的转移变得复杂。接触条件的变化会导致不同的动态激励，这给机床的发展和控制工程带来了挑战。了解预期的切削力及其特性对于描述动力学和优化工艺是必要的。实际的研究项目“外齿轮磨削的切削力模型的开发”为根据Werner和Kassen计算力提供了第一种方法。然而，该模型简化了磨削蜗杆的切削。虽然文献中估计了必要的切削力参数，但该模型与磨齿的力测量结果具有良好的定性相关性。应用研究项目的目的是扩展已开发的切削力模型，用于计算所有主动刀具和齿侧的局部切削力，以产生齿轮磨削。该扩展模型通过确定合适的切削力参数，既考虑了加工过程的宏观几何参数，又考虑了单磨网格的微观几何切削。通过刚玉栅格和淬火钢的单栅格和多栅格划伤试验，确定了参数。在齿轮制造过程中，对这些典型材料进行的划伤试验很少。在对上述材料的Werner和Kassen的参数定义和模型进行扩展后，将知识转移到产生齿轮磨削。通过磨削试验中的力测量对模型结果进行优化，最后通过磨削参考齿轮和测量切削力对模型结果进行验证。

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.