Process Machine Interaction In Gear Honing

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The full performance of modern gear honing machines can usually not be reached because of vibrations and the desired gear quality can not be achieved. The objective of this research is the prediction of excitation sources, the vibration behavior of the gear honing process and the illustration of possible self-excited oscillations. To this end, process and machine models need to be established. Depending on the cause and form of critical vibrations, a model of the entire machine or a partial model is coupled with the process model. As a basis for the process model and the excitation, the contact conditions of the gear honing process are transferred to an analogy process. For each gear flank in contact an analogy process is carried out under measurement of the process forces. Using these data, the honing process can be resolved spatially and temporally analyzed over the tooth profile. By superposition of the local cutting forces and a comparison with gear honing trials the process model is validated. The machine model (possibly partial model) is represented either by an approximation of the frequency response of coupled oscillators with a single degree of freedom or by an FE model. The design of the complete model is based on the standard model of machine and process interaction. The calculation of the dynamic behavior of the whole system is carried out for discrete time steps. The cutting forces are calculated using the presented process model and coupled with the machine model. The occurring displacements are passed of to the process model and the control loop is closed. The coupled model will enable the prediction of process forces and excitation behavior in gear honing.