Modelling of grinding worm profile wear at generating gear grinding

在展成磨齿过程中，除了加工参数外，刀具规格和刀具磨损对加工生产率、零件质量和刀具磨损也有重要影响。因此，有必要了解刀具规格和加工参数的相互作用如何影响刀具的使用。此外，还必须确定对工件质量和表面区域的影响。然而，基础的实验研究，重点是在展成磨齿过程中的刀具磨损仍然缺乏。提交的研究项目在这一点上。通过模拟试验，这是必须在本研究项目中开发，展成磨齿的条件映射和磨削蜗杆的负载转移到一个具有齿条轮廓的砂轮。由于可以自由接近砂轮的侧面，因此可以检测刀具磨损，而无需损坏刀具。用3D激光扫描显微镜测量砂轮的表面形貌。此外，由于新设计的心轴，砂轮可以在不同的时间进行测量，然后再次用于加工。通过这种方法，不仅可以记录磨损，而且可以记录磨损随时间和加工量的变化。使用穿透计算可以确定每个试验的特征值，例如未变形的切屑厚度。根据经验数据和特征值，建立了蜗杆磨削刀具廓形磨损量的预测模型。为此，现有的模型扩展了展成磨齿的运动学和几何条件。随后，用类比试验的经验数据对模型进行训练。为了验证该模型，进行了展成磨齿试验，并确定了不同切削量下磨齿蜗杆齿条齿廓的磨损量。随后，研究结果和模型进行了测试与第二齿轮几何形状，以确保转移到其他齿轮几何形状。

During generating gear grinding in addition to the processing parameters, the tool specification and the wear of the tool have a significant impact on the process productivity, part quality and the wear of the tool. Therefore, it is necessary to know how interactions of tool specification and processing parameters influence the tool waer. Furthermore, the influence on the workpiece with regard to quality and surface zone has to be determined. However, basic experimental studies that focus on the tool wear during generating gear grinding are still missing. The submitted research project comes in at this point. With an analogy trial, which has to be developed in this research project, the conditions of generating gear grinding are mapped and the load of the grinding worm is transferred to a grinding wheel with rack profile. Due to the free accessibility of the flanks of the grinding wheel the tool wear can be detected with no need to destroy the tool. The surface topography of the grinding wheel is measured with a 3D laser scanning microscope. Furthermore, the grinding wheel can be measured at different times and then used again for machining due to the new designed mandrel. By this method, not only the wear but also the progress of wear can be documented over time and machined volume. Using a penetration calculation characteristic values such as undeformed chip thickness can be determined for each trial. With the empirical data and the characteristic values a model to predict the wear of the tool profile of a grinding worm will be developed. For this, existing models are extended by the kinematic and geometric conditions of generating gear grinding. Subsequently, the models are trained with the empirical data from analogy trails. To verify the model generating gear grinding trails are performed and the wear of the rack profile of the grinding worm is determined for different cutting volumes. Subsequently, the findings and the model are tested with a second gear geometry to ensure the transferability onto other gear geometries.