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

对圆柱齿轮的仿形磨削和展成磨削的科学研究表明，切削力的计算对于预测对工件的热影响是非常重要的。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，目前尚无计算圆锥齿轮磨削切削力的模型。因此，应结合现有技术的结果并使其适应制造过程的特性，以获得全面的过程模型。这将基于将前面DFG项目的结果转移到锥齿轮磨削上。通过所开发的力模型，将提高对工艺的理解，并简化和优化应用伙伴的工艺设计。本课题的目的是建立锥齿轮磨削工艺优化设计的力模型，在切削力预测方面，建立可用于计算砂轮与工件接触体积的过程运动学模型。通过采用先前项目的结果，可以对落锤式锥齿轮磨削过程的运动学进行建模。用Werner方法将切削力从接触体积中近似出来。根据锥齿轮磨齿的接触条件，推导出不同工艺变量的类比试验。对于这些类比试验，接触体积和过程力将是近似的。在进行类比试验的过程中，将测量过程力以实现力模型的参数化。此外，还将对研磨后的工件进行分析，以确定对工件的热影响和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，将确保前述DFG项目的结果和锥齿轮磨削的模拟试验的结果的可转移性。在磨削力模型的基础上，提出了优化工艺设计的指导思想。切削力的极限值将被确定，由此可以预期临界热影响。通过将其转化为工业环境，其科学成果将直接适用于圆锥齿轮磨齿技术的用户。

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.