Modelling of grinding worm profile wear at generating gear grinding

在磨齿过程中，除加工参数外，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水。此外，还必须确定对工件质量和表面区域的影响。然而，针对直齿圆柱齿轮磨削过程中刀具磨损的基础实验研究仍然缺乏。这个时候提交的研究项目就到了。通过本课题需要开展的类比试验，绘制了产生齿轮磨削的条件图，并将磨削蜗杆的载荷传递给齿条齿形的砂轮。由于砂轮的两侧可自由接近，因此无需破坏刀具即可检测刀具磨损。采用三维激光扫描显微镜对砂轮表面形貌进行了测量。此外，由于新设计的心轴，可以在不同的时间测量砂轮，然后再次进行加工。通过这种方法，不仅可以记录磨损情况，而且可以记录磨损过程随时间和加工量的变化。通过渗透计算，可以确定每次试验的特征值，如未变形的切屑厚度。根据经验数据和特征值，建立了一种预测磨削蜗杆齿形磨损的模型。在此基础上，对现有模型进行了扩展，并考虑了磨齿的运动学和几何条件。然后，利用模拟轨迹的经验数据对模型进行训练。为了验证模型的正确性，对不同切削量下的磨齿蜗杆齿条轮廓进行了磨齿轨迹分析和磨齿蜗杆齿条轮廓磨损量的测定。随后，调查结果和模型与第二齿轮几何测试，以确保转移到其他齿轮几何。

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.