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Development of a Cutting Force Model for the Optimization of the Process Design of Bevel Gear Grinding

开发用于优化锥齿轮磨削工艺设计的切削力模型

基本信息

批准号：
386689474
负责人：
Professor Dr.-Ing. Thomas Bergs, since 7/2019
金额：
--
依托单位：
Werkzeugmaschinenlabor - WZL
依托单位国家：
德国
项目类别：
Research Grants (Transfer Project)
财政年份：
2017
资助国家：
德国
起止时间：
2016-12-31 至 2021-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/386689474?language=en
关键词：
Development Cutting Force Model Optimization

项目摘要

Scientific investigations on profile grinding and generating grinding of cylindrical gears have shown the fundamental importance of the cutting force calculation for the prediction of the thermal influence on the workpiece. Studies on bevel gear grinding supply simplified methods for the calculation of contact volume and grinding burn prediction. Nevertheless, no model for the cutting force calculation in bevel gear grinding exists. Therefore, the results from the state of the art shall be joined and adapted to the properties of the manufacturing process in order to obtain a comprehensive process model. This will be based on a transfer of the results from the preceding DFG project onto bevel gear grinding. By means of the developed force model, the process understanding will be improved and the process design at the application partner shall be simplified and optimized. The aim of this project is the development of a force model for the optimization of the process design of bevel gear grinding.For the cutting force prediction, a model of the process kinematics will be developed that can be used to calculate the contact volume between grinding wheel and workpiece. The kinematics of the plunging bevel gear grinding process can be modelled by adapting the results of an earlier project. The cutting force will be approximated out of the contact volume with the method of WERNER. Based on the contact conditions of bevel gear grinding, analogy trials for the different process variants will be deduced. For these analogy trials the contact volume and the process force will be approximated. During the conduction of the analogy trials, the process force will be measured to parametrize the force model. Furthermore, an analysis of the ground workpieces will take place to determine the correlation between the thermal influence on the workpiece and the process force. Subsequently, the parametrized process force model will be validated in bevel gear grinding trials at the application partner Scania. Thus, the transferability of the results of the preceding DFG project and the analogy trials onto bevel gear grinding will be secured. Based on the grinding force model, a guideline for the optimization of the process design will be developed. Limiting values for the cutting force will be determined, from which a critical thermal influence can be expected. Through this transfer into the industrial environment the scientific results will be directly applicable for the user of the bevel gear grinding technology.

对圆柱齿轮的成形磨削和展成磨削的科学研究表明，切削力计算对于预测工件上的热影响至关重要。对锥齿轮磨削的研究为接触体积的计算和磨削烧伤的预测提供了简化的方法。然而，在锥齿轮磨削加工中，没有切削力的计算模型存在。因此，来自现有技术的结果应结合并适应制造过程的特性，以获得全面的过程模型。这将基于将先前DFG项目的结果转移到锥齿轮磨削上。通过开发的力模型，将提高对工艺的理解，并简化和优化应用合作伙伴的工艺设计。本研究的目的是建立锥齿轮磨削过程的力模型，为锥齿轮磨削过程的优化设计提供理论依据。插齿锥齿轮磨削过程的运动学可以通过调整早期项目的结果来建模。切割力将采用WERNER方法在接触体积外近似计算。根据锥齿轮磨削的接触条件，推导出不同工艺变量的模拟试验。对于这些模拟试验，接触体积和过程力将近似计算。在进行模拟试验期间，将测量过程力以参数化力模型。此外，还将对磨削工件进行分析，以确定工件上的热影响与加工力之间的相关性。随后，参数化的过程力模型将在应用合作伙伴斯堪尼亚的锥齿轮磨削试验中得到验证。因此，前面的DFG项目和锥齿轮磨削模拟试验的结果的可移植性将得到保证。基于磨削力模型，将为工艺设计的优化提供指导。将确定切削力的极限值，由此可以预期临界热影响。通过这种转移到工业环境中的科学成果将直接适用于锥齿轮磨削技术的用户。