Process-Machine Interaction during Gear Honing

 

When honing spur gears, the performance of modern gear honing machines can often not be used to the full because vibrations occur and the desired gear quality cannot be achieved. The aim of the research project is to predict the excitation causes and the vibration behaviour of the gear honing process and to map possible self-excited vibrations. For this purpose, a process model and a machine model will be built.

Depending on the cause and form of the critical vibrations, a model of the entire machine or a partial model is coupled with the process model. As a basis for the process model and the excitation, the contact conditions of gear honing are transferred to an analogous process. For each gear flank in contact, an analog process is carried out to determine the process forces. Based on this data, the honing process can be analyzed over the tooth flank with spatial and temporal resolution. The process model is validated by superposition of the local cutting forces and comparison with honing tests. The machine model (if necessary partial model) is either represented by an approximation of the frequency response by coupled single mass oscillators or by an FE model. The structure of an overall model is based on the control engineering basic model of the interaction between machine and process. The calculation of the dynamic behaviour of the overall system is performed for discrete time steps. The cutting forces are calculated using the presented process model and coupled with the machine model. The occurring displacements are fed back into the process model and the control loop is closed. The model will allow to predict the process forces and the excitation behavior during gear honing.