Extending a cutting force model for generating gear grinding while regarding micro-geometrical influences
Final Report Abstract
In this project, the influence of the grains on the material removal behavior and its application on the generating gear grinding force model was investigated. For this investigation, the behavior of the specific energy k was analyzed. It was verified that the increase in the cutting speed led to higher values of specific energy k. It was also verified that the shape of the grains in terms of the grain angles is also relevant for the specific energy k determination. Larger angles generated higher grain crosssection areas that ultimately led to a smaller specific energy. The specific energy was also investigated along the contact length. In the single-grain scratch tests it was shown that the k required for each point along the contact length was different. The findings of the single grain scratch trials were further applied in the segment trials by means of an alternative method for the specific energy k calculation. In addition, a standard method for the specific energy calculation was used. The standard method is essentially empirical, depending mainly on the force measurements during the process. Due to this, it is not only time consuming, but also not reproducible, since for each alteration in the process parameters or in the tool characteristic, tests must be performed. Therefore, the alternative method of specific energy calculation based on the findings of the single grain scratch gives the opportunity for a reproducible determination of the specific energy, avoiding the need of force measurements for each process conditions. Next, the maximum normal force was calculated for the segment trials, using the alternative method for the specific energy calculation. The comparison between the calculated and the real normal forces showed a very good correlation. The implementation of the findings of the single grain trials and segment trials on the generating gear grinding was partially performed, due to the limitations of the contact conditions discretization available. However, the results of the simulation showed an accurate calculation of the normal force for the case of generating gear grinding, although an average specific energy was used for the force calculation. The result of the investigation showed that it was possible to implement successfully the material removal behavior on the generating gear grinding force model. In addition, the research also determined the influence of particular process conditions, such as cutting speed, grain size and especially contact length on the specific energy k. Due to this, the behavior of the specific energy k has a direct correlation to the material removal mechanism during the grinding process. Ultimately, the investigation of a variable k also highlighted that the appropriate characterization of the specific energy for the generating gear grinding is an important tool for a more accurate understanding of the correlation between the process parameters and the surface integrity state.
Publications
- Analysis of abrasive grit cutting for generating gear grinding. In 10th CIRP Conference on Intelligent Computation in Manufacturing Engineering – CIRP ICME 16. 2016
Brecher, C.; Klocke, F.; Löpenhaus, C.; Hübner, F.
(See online at https://doi.org/10.1016/j.procir.2016.06.042) - Extended Calculation Model for Generating Gear Grinding Processes. In: Advanced Materials Research, Vol. 1140, pp 141-148. 2016
Hübner, F.; Löpenhaus, C.; Klocke, F.; Brecher, C.
(See online at https://doi.org/10.4028/www.scientific.net/AMR.1140.141) - Force Modelling of Generating Gear Grinding. 6th WZL Gear Conference in the USA 2016: June 28, 2016 (Ann Arbor, Michigan)
Ophey, M.; Hübner, F.; Löpenhaus, C.; Klocke, F.
- Analysis of abrasive grit cutting for generating gear grinding. In Procedia CIRP Volume 62, Pages 299-304 2017
Brecher, C.; Klocke, F.; Löpenhaus. C; Hübner, F.
(See online at https://doi.org/10.1016/j.procir.2016.06.042) - A Multi-grain approach for micromechanical contact in grinding. In 8. WGP-Jahreskongress, Aachen, 19.-20. November 2018
Teixeira, O.P.; Löpenhaus, C.; Brecher, C.
(See online at https://doi.org/10.1007/978-3-030-03451-1_37) - Modelling and simulation of dry generating grinding process for automotive gears production. Diss., Università di Bologna, 2018
Guerrini, G.
(See online at https://doi.org/10.6092/unibo/amsdottorato/8335)
