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

扩展切削力模型以生成齿轮磨削，同时考虑微观几何影响

基本信息

批准号：
269650351
负责人：
Professor Dr.-Ing. Fritz Klocke
金额：
--
依托单位：
Werkzeugmaschinenlabor - WZL
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2015
资助国家：
德国
起止时间：
2014-12-31 至 2019-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/269650351?language=en
关键词：
Extending cutting force model generating

项目摘要

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.

优化齿轮承载能力和安静性的最先进技术是对热处理后的表面硬化齿轮进行精加工。精加工的一种选择是展成齿轮磨削工艺，该工艺由于其高生产率而在工业中得到广泛应用。尽管该过程在工业上得到广泛应用，但科学研究却很少。造成这种情况的一个可能原因是刀具与齿轮齿面之间的接触条件复杂。在磨削过程中，各种刀具齿面与各种齿轮齿面啮合。这使得从其他磨削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，这给机器和控制工程的开发带来了挑战。了解预期切削力及其特性对于描述动力学和优化工艺是必要的。实际研究项目“开发用于生成外齿轮磨削的切削力模型”给出了根据 Werner 和 Kassen 计算力的第一种方法。然而，该模型简化了蜗杆砂轮的切削。尽管必要的切削力参数是通过文献估计的，但该模型与齿轮磨削的力测量给出了良好的定性相关性。该应用研究项目的目的是扩展已开发的切削力模型，用于计算所有主动刀具和齿轮侧面的局部切削力，以产生齿轮磨削。扩展模型通过确定适当的切削力参数，考虑了工艺的宏观几何参数以及单个磨削网格的微观几何切削。借助刚玉网格和表面硬化钢的单网格和多网格划痕测试，定义了参数。迄今为止，仅对这些用于齿轮制造过程的典型材料进行了很少的划痕测试。在针对上述材料扩展 Werner 和 Kassen 的参数和模型的定义后，知识将被转移到生成齿轮磨削中。模型的结果将通过磨削试验中的力测量进行优化，并最终通过磨削参考齿轮并测量切削力进行验证。