Development of a cutting force model to optimize the process design for bevel gear grinding

 

Starting Situation

In industrial environments, the design of bevel gear grinding processes is generally based on experience. Suitable process parameters are determined for each workpiece geometry and grinding wheel specification in time- and cost-intensive empirical investigations. In addition, it is not known whether the derived process parameters are within the range of the productivity maximum. An effective design of productive bevel gear grinding processes can be based on the cutting force. Knowledge of the cutting force is necessary for predicting both the thermal influence of the component edge zone and the load and thus the wear of the grinding tools. In addition, the cutting force is decisive for the misalignment behavior of the tool in the process and is thus required for mapping the process-machine interaction. Knowledge of the cutting force therefore plays a decisive role in knowledge-based process design.

Research Objective

So far, no model exists to calculate the process force for bevel gear grinding. On the basis of a transfer of the findings from a DFG KL500/94-1 project on force calculation in gear grinding to bevel gear grinding, the existing knowledge deficit on hard fine machining of bevel gears in the marginal zones is to be addressed. The aim of the project is therefore to develop a model for predicting the cutting force during bevel gear grinding. Using the developed force model, the process design will be simplified and optimized for industrial users.