Modeling of the behavior of elastically bonded tools in gear honing

对齿轮性能要求的不断提高使得齿轮的硬精加工在许多情况下是必不可少的，以纠正粗加工和热处理的偏差。珩齿是硬齿面精加工领域中的一种高生产率的加工工艺，特别是中小型齿轮的珩齿加工。由于对齿面表面粗糙度的要求越来越低，将现有的弹性粘结磨具磨齿工艺应用到珩齿工艺中是重要的一步。对于珩齿，使用弹性粘合珩齿工具产生超细表面的潜力尚未被研究。弹性粘合的珩磨环在加工过程中会变形。这种弹性变形会导致齿轮的几何偏差。在弹性结合珩磨环的修整过程中，必须对这些偏差进行修正。由于用于齿轮珩磨的修整工具在待生产的几何形状方面是不灵活的，因此必须在修整工具中已经提供齿轮的几何校正。因此，该研究项目的目标是建立弹性结合珩磨环修整过程中的切削力模型，以预测珩磨环变形以及随后在齿轮珩磨过程中对齿轮几何形状产生的影响。该研究项目的独特之处在于开发了一种基于弹性修整力模型和弹性珩齿力模型的齿轮几何形状预测方法。这将是第一次有可能预测齿轮几何形状在齿轮珩磨过程中作为一个功能的修整工具的几何形状和珩磨环的几何形状和弹性。科学的挑战在于一方面在现有的珩磨力模型的修整过程中，考虑到其运动学特性的转移。另一方面，由弹性引起的延伸旨在预测工具-工件系统的机械变形。预期的知识增益在于改进的专业知识和计算工具-工件系统发生的变形以及在齿轮珩磨过程中对齿轮几何形状产生的影响，特别是使用新的弹性粘合齿轮珩磨工具。

The continuously increasing performance requirements for gears make hard fine machining of gears indispensable in many cases in order to correct deviations from rough machining and heat treatment. Gear honing is a highly productive process in the field of hard fine machining, especially of small and medium sized gears. Due to increasingly lower surface roughness required on tooth flanks, the application of existing gear polish grinding processes with elastic bonded grinding tools to the gear honing process is an important step. For gear honing, the potential for producing superfine surfaces using elastic bonded gear honing tools has not yet been investigated. Elastic bonded honing rings can deform during the process. This elastic deformation can lead to geometric deviations of the gears. These deviations must be corrected during the dressing process of the elastic bonded honing ring. Since dressing tools for gear honing are inflexible with regard to the geometry to be produced, the geometric corrections of the gears must already be provided in the dressing tool. Therefore, the objective of the research project is to model the cutting force during dressing of elastically bonded honing rings to predict the honing ring deformation and the resulting effect on the gear geometry achieved during the gear honing process afterwards. The uniqueness of the research project lies in the development of a method for prediction of the gear geometry based on an elastic dressing force model and an elastic gear honing force model. For the first time it will be possible to predict the gear geometry in the gear honing process as a function of the dressing tool geometry and the honing ring geometry and elasticity. The scientific challenge lies on the one hand in the transfer of an existing honing force model to the dressing process taking into account its kinematic characteristics. On the other hand, the extension by the elasticity is intended to predict the mechanical deformation of the tool-workpiece system. The expected gain of knowledge lies in the improved expertise and the calculation of the occurring deformation of the tool-workpiece system and the resulting influence on the gear geometry during gear honing, especially with new elastically bonded gear honing tools.