Modeling of the behavior of elastically bonded tools in gear honing

对齿轮的性能要求不断提高，在许多情况下，为了纠正粗加工和热处理的偏差，必须对齿轮进行硬精加工。齿轮珩磨是硬精细加工领域，特别是中小齿轮加工领域的一项高产工艺。由于对齿侧表面粗糙度的要求越来越低，将现有的弹性结合剂磨齿工艺应用于齿轮珩磨工艺是重要的一步。对于齿轮珩磨，使用弹性键合齿轮珩磨工具产生超精细表面的潜力尚未进行研究。弹性粘结珩磨环在加工过程中会发生变形。这种弹性变形会导致齿轮的几何偏差。这些偏差必须在弹性粘接珩磨环修整过程中加以纠正。由于齿轮珩磨修整工具对于要生产的几何形状是不灵活的，因此齿轮的几何校正必须已经在修整工具中提供。因此，本研究项目的目的是建立弹性粘接珩磨环修整过程中的切削力模型，以预测珩磨环变形及其对后续珩磨过程中齿轮几何形状的影响。本课题的独特之处在于开发了一种基于弹性修整力模型和弹性齿轮珩磨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珩磨过程中的齿轮几何形状作为修整刀具几何形状和珩磨环几何形状和弹性的函数。科学挑战一方面在于将现有的珩磨力模型转移到考虑其运动学特性的修整过程中。另一方面，弹性扩展是用来预测工具-工件系统的机械变形。期望获得的知识在于提高专业知识和计算工具-工件系统在珩磨过程中发生的变形及其对齿轮几何形状的影响，特别是使用新的弹性键合齿轮珩磨工具。

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.