Optimization of the gear finishing process: Increase of the resource efficiency of boundary layers in the tooth flank contact

通过提高齿轮的使用寿命或减少其在摩擦学接触中的摩擦力，可以提高齿轮的资源利用率。边界层保护齿面不受固态接触，因此会影响摩擦和磨损。边界层特性在预处理(制造和磨合)过程中受到影响。研究项目BR 2905/44-1强调了适当的精加工工艺将试验部件的有限寿命疲劳提高30%和效率提高10%的潜力。到目前为止，这些研究还没有从双盘接触转移到齿面接触。因此，本课题的研究重点是齿轮接触问题。本课题的研究目标是为充分形成加工诱导边界层而制定的齿轮精加工准则。优化了齿轮精加工的工艺参数，提高了热能和机械能的输入。适当的精加工工艺可以通过减少摩擦和磨损来提高齿轮的资源效率。此外，在局部模拟模型中捕捉到效率增益和边界层的影响。为达到这一目的，进行了承载能力和效率的齿轮试验。对不同加工齿轮的多个变量进行了试验。展成磨削因其实用性而被用作精加工工艺。在目前的研究项目中，WZL正在开发描述展成磨削中的过程力和温度感应的方法。基于这些方法，可以对磨削过程中的能量输入进行分析，从而得出关于边界层形成的结论。寿命和效率的提高使齿轮的设计更具可持续性和经济性。满足了驱动系统中对更高资源效率的要求。

The resource efficiency of gears can be improved either by increasing their lifetime or by decreasing their friction in the tribological contact. Boundary layers protect tooth flanks from solid-state contacts and therefore influence friction and wear. The characteristics of boundary layers are influenced in the course of preconditioning (manufacturing and run-in). The research project BR 2905/44-1 highlights the potential of adequate finishing processes to improve the finite life fatigue of the test parts by 30% and their efficiency by 10%. Up to now, these investigations have not been transferred from twin disk contact to gear flank contact. Hence, the focus of the present project is on the gear contact.The aim of the research project is a gear finishing guideline for the adequate formation of manufac-turing induced boundary layers. The process parameters of gear finishing are optimized in order to improve the thermal and mechanical energy input into the workpiece. An adequate finishing process can improve the resource efficiency of gears by reducing friction and wear. Furthermore, the gain in efficiency and the influence of the boundary layer are captured in a local simulation model. Gear tests on load carrying capacity and efficiency are conducted to achieve the aim. Multiple vari-ants of differently finished gears are tested. Generating grinding is applied as finishing process because of its practical relevance. In current research projects the WZL is developing methods to describe the process forces and the temperature induction in generating grinding. Based on these methods the energy input during the grinding process can be analyzed in order to draw conclusions on the formation of boundary layers. The improvement of lifetime and efficiency allows a more sustainable and economical design of gears. The requirements for higher resource efficiency in drive systems are fulfilled.