Abstract
Profile gear grinding is characterized by a high level of achievable process performance and workpiece quality. However, the wide contact length between the workpiece and the grinding wheel is disadvantageous for the fluid supply to the contact zone and leads to the risk of locally burning the workpiece surface. For the reduction of both the thermal load and the risk of thermo-mechanical damage, the usage of a grinding fluid needs to be investigated and optimized. For this purpose, different kinds of grinding fluid nozzles were tested, which provide different grinding fluid jet characteristics. Through a specific design of the nozzles, it is possible to control the fluid flow inside the nozzle. It was found that this internal fluid flow directly influences the breakup of the coolant fluid jet. There are three groups of jet breakup (“droplet”, “wave & droplet”, and “atomization”). The first experimental results show that the influence of the jet breakup on the process performance is significant. The “wave & droplet” jet breakup can achieve a high process performance, in contrast to the “atomization” jet breakup. It can therefore be assumed that the wetting of the grinding wheel by the grinding fluid jet is significantly influenced by the jet breakup.
Highlights
Introduction and the State of theArtIn grinding processes in general, a high risk of thermo-mechanical damage exists due to the kinematics of the abrasive grain in the contact zone as well as the large contact area between the grinding wheel and the workpiece
The results show that grinding fluid nozzles have an impact on the widening of the jet as a function of jet velocity and flow rate, and affect the jet breakup, the distribution of the droplets, and the fluctuations in impact pressure
In the fluidic investigations conducted in this study, the grinding fluid jet and the jet breakup the fluidic investigations conducted in this study, the fluid jet and jet breakup wereIncharacterized by means of high-speed photography
Summary
In grinding processes in general, a high risk of thermo-mechanical damage exists due to the kinematics of the abrasive grain in the contact zone as well as the large contact area between the grinding wheel and the workpiece. This can lead to residual tensile stresses and changes in hardness, which can have a negative effect on the lifetime of the component [1,2]. In profile gear grinding processes, the large contact area between grinding wheel and workpiece makes it difficult to supply the grinding fluid to the contact zone. A high performance grinding fluid supply becomes important
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