Modelling of grinding worm profile wear at generating gear grinding

• Applicant: Professor Dr.-Ing. Thomas Bergs, since 7/2019
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: from 2016 to 2020
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 295379545

During generating gear grinding in addition to the processing parameters, the tool specification and the wear of the tool have a significant impact on the process productivity, part quality and the wear of the tool. Therefore, it is necessary to know how interactions of tool specification and processing parameters influence the tool waer. Furthermore, the influence on the workpiece with regard to quality and surface zone has to be determined. However, basic experimental studies that focus on the tool wear during generating gear grinding are still missing. The submitted research project comes in at this point. With an analogy trial, which has to be developed in this research project, the conditions of generating gear grinding are mapped and the load of the grinding worm is transferred to a grinding wheel with rack profile. Due to the free accessibility of the flanks of the grinding wheel the tool wear can be detected with no need to destroy the tool. The surface topography of the grinding wheel is measured with a 3D laser scanning microscope. Furthermore, the grinding wheel can be measured at different times and then used again for machining due to the new designed mandrel. By this method, not only the wear but also the progress of wear can be documented over time and machined volume. Using a penetration calculation characteristic values such as undeformed chip thickness can be determined for each trial. With the empirical data and the characteristic values a model to predict the wear of the tool profile of a grinding worm will be developed. For this, existing models are extended by the kinematic and geometric conditions of generating gear grinding. Subsequently, the models are trained with the empirical data from analogy trails. To verify the model generating gear grinding trails are performed and the wear of the rack profile of the grinding worm is determined for different cutting volumes. Subsequently, the findings and the model are tested with a second gear geometry to ensure the transferability onto other gear geometries.

• DFG Programme: Research Grants
• Ehemaliger Antragsteller: Professor Dr.-Ing. Fritz Klocke, until 6/2019