Process Machine Interaction In Gear Honing

现代珩齿机的全部性能通常由于振动而达不到，无法达到所需的齿轮质量。这项研究的目的是预测激励源，齿轮珩磨过程的振动行为，并说明可能的自激振动。为此，需要建立工艺和机器模型。根据临界振动的原因和形式，整个机器的模型或部分模型与过程模型耦合。作为建立过程模型和激励的基础，将珩齿过程的接触条件转化为类比过程。对于接触的每个齿轮齿面，在测量过程力的情况下进行类比加工。使用这些数据，可以在空间和时间上分析齿廓上的研磨过程。通过局部切削力的叠加和与珩齿试验的比较，验证了该工艺模型的有效性。机器模型(可能是局部模型)可以用单自由度耦合振子的频率响应的近似表示，也可以用有限元模型表示。完整模型的设计是基于机器和过程交互的标准模型。整个系统的动态行为计算是按离散时间步长进行的。利用所提出的工艺模型计算切削力，并与机床模型进行耦合。发生的位移被传递给过程模型，并且控制回路闭合。该耦合模型将能够预测齿轮珩磨过程中的作用力和激励行为。

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.