Extending a cutting force model for generating gear grinding while regarding micro-geometrical influences

优化齿轮承载能力和静音的最新技术是对表面硬化的齿轮进行热处理后的精细加工。精加工的一种选择是展成齿轮磨削工艺，由于其高生产率，这是一种广泛的工业应用。尽管该工艺在工业上得到了广泛的应用，但科学研究却很少。一个可能的原因是磨削过程中刀具与齿面的接触条件复杂，不同的刀具后刀面与不同的齿面啮合。这使从其他研磨过程中获得的知识的转移变得复杂。接触条件的变化会导致明显的动态激励，这给机械和控制工程的发展带来了挑战。对预期切削力及其特性的了解对于描述动力学和优化工艺是必要的。实际研究项目外齿轮展成磨齿切削力模型的建立提供了第一种根据Werner和Kassen计算切削力的方法。但该模型简化了蜗杆磨削加工。虽然已有文献估计了必要的切削力参数，但该模型与展成磨齿的切削力测量结果具有很好的定性相关性。应用研究项目的目的是扩展开发的切削力模型，用于计算所有活动刀具和齿轮展成磨齿的局部切削力。扩展模型通过确定合适的切削力参数，既考虑了加工过程的宏观几何参数，又考虑了单个磨削网格的微观几何加工。通过刚玉栅和表面淬火钢的单、多栅格划痕试验，确定了相应的工艺参数。到目前为止，对于齿轮制造过程中的这些典型材料，只实现了很少的划痕试验。在上述材料的参数定义和关于Werner和Kassen的模型扩展后，知识将转移到展成齿轮磨削。模型的结果将通过磨削试验中的测力进行优化，并最终通过磨削基准齿轮和测量切削力进行验证。

State of the art for optimizing the load carrying capacity and quietness of gears is the fine finishing of case hardened gears after heat treatment. One option for fine finishing is the generating gear grinding process, which is a wide spread industrial application due to its high productivity. Despite the wide industrial application of the process, only few scientific investigations exist. One possible reason for this is that the contact conditions between tool and gear flank are complex During the grinding process, various tool flanks mesh with various gear flanks. This complicates the transfer of knowledge acquired form other grinding processes. The variation of the contact conditions can lead to a distinct dynamic excitation, which makes the development of the machine and the control engineering a challenge. Knowledge of the expecting cutting forces and their characteristics is necessary for describing the dynamics and optimizing the processes. The actual research project Development of a cutting force model for generating gear grinding of external gears gives a first approach for calculating the forces according Werner and Kassen. However this model simplifies the cutting by the grinding worm. Though necessary cutting force parameters were estimated by literature, the model gives a good qualitatively correlation to force measurements for generating gear grinding. Aim of the applied research project is the extension of the developed cutting force model for the calculation of the local cutting forces for all active tool and gear flanks for generating gear grinding. The extended model considers macro-geometrical parameters of the process as well as the micro-geometrical cutting of single grinding grids by determining appropriate cutting force parameters. With the help of single an multi grid scratch tests of corundum grids and case hardened steel the parameters are defined. Only few scratch tests were realized for these typical materials for the manufacturing process of gears so far. After the definition of the parameters and the model regarding to Werner and Kassen has been expanded for the mentioned materials, the knowledge will be transferred to generating gear grinding. The results of the model will be optimized by force measurements in grinding trials and finally verified by grinding a reference gear and measure the cutting forces.