Modelling of grinding worm profile wear at generating gear grinding

展成磨齿过程中，除了工艺参数外，刀具的规格和刀具的磨损对加工生产率、零件质量和刀具的磨损都有重要影响。因此，有必要了解刀具规格和工艺参数的交互作用对刀具损耗的影响。此外，还必须确定对工件质量和表面区的影响。然而，关于展成齿轮磨削过程中刀具磨损的基础实验研究仍然缺乏。提交的研究项目是在这一点上进来的。通过模拟试验，绘制了展成磨齿的条件图，将磨削蜗杆的载荷传递到齿条型面的砂轮上。由于砂轮侧面可自由接触，因此无需损坏刀具即可检测刀具磨损。用三维激光扫描显微镜对砂轮表面形貌进行了测量。此外，由于新设计的芯棒，砂轮可以在不同的时间测量，然后再次用于加工。通过这种方法，不仅可以记录磨损情况，而且可以记录磨损随时间和加工体积的变化过程。通过使用渗透率计算，可以针对每个试验确定诸如未变形的切屑厚度之类的特征值。根据经验数据和特征值，建立了蜗杆磨削齿廓磨损预测模型。为此，利用展成磨齿的运动学和几何学条件对现有模型进行了扩展。随后，用来自类比试验的经验数据对模型进行训练。为了验证模型的正确性，进行了展成齿轮的磨削试验，并确定了不同切削量下磨削蜗杆齿条轮廓的磨损情况。随后，使用第二个齿轮几何来测试结果和模型，以确保可转移到其他齿轮几何上。

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.