Design of Targeted Micro Geometry Scattering in the Generating Grinding Process to Optimize the Acoustic Operational Behavior of Cylindrical Gears under Consideration of Manufacturability

• Applicant: Professor Dr.-Ing. Christian Brecher
• Subject Area: Engineering Design, Machine Elements, Product Development
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 563786984

The increasing relevance of noise emissions in the automotive sector, rising customer demands and reduced masking noise due to drivetrain electrification are resulting in the steadily growing importance of gearbox acoustics. In order to counteract these tonal noise components, this effect can be addressed in the design of gears with targeted micro geometry scattering. Micro geometry scatterings can be understood as a variation of conventional standard tooth flank modifications, which are specifically distributed on the teeth of the gearwheel over the gear's circumference. Current research work proves the positive influence of a targeted micro geometry scattering on the acoustic operational behavior with the use of experimental studies. However, manufacturability has not yet been taken into account in the design of targeted micro geometry scattering. The continuous generating grinding process offers the possibility of producing tooth flank geometries with high process reliability and is used in particular in the automotive industry due to its high productivity. Up to now, it has not been possible to produce targeted micro geometry scattering in this type of process. The productivity advantages of the continuous generating grinding process must therefore be combined with the acoustic strengths of targeted micro-geometry scattering. The objective of this project is to develop a validated design method for optimizing the acoustic operational behavior of cylindrical gears through targeted micro geometry scattering, taking into account the manufacturability in the generating grinding process. By taking real machine kinematics and tool geometry into account, the method allows conclusions to be drawn about the manufacturability of required target geometries. In addition, the method enables micro geometric optimization to improve the acoustic operational behavior of various macro geometries in cylindrical gear pairs and thus offers the flexibility to consider different gear systems. By increasing the production rate, the manufacturing of targeted micro geometry scattering in large-scale production is gaining relevance. Extensive calculation studies can also reduce the number of rejected parts, as the manufacturability of the corresponding tooth flank modifications is ensured in advance.

• DFG Programme: Research Grants