Abstract
In grinding, interaction between the workpiece material and rotating abrasive tool generates high thermo-mechanical loads in the contact zone. If these loads reach critically high values, workpiece material properties deteriorate. To prevent the material deterioration, several models for thermomechanical analysis of grinding processes have been developed. In these models, the source of heat flux is usually considered as uniform in the temperature distribution calculation. However, it is known that heat flux in grinding is generated from frictional heating as well as plastic deformation during the interaction between workpiece material and each grain from the tool. To consider these factors in a future coupled thermomechanical model specifically for the process of gear generating grinding, an investigation of the mechanical load distribution during interaction between grain and workpiece material considering the process kinematics is first required. This work aims to investigate the influence of process parameters as well as grain shape on the distribution of the mechanical loads along a single-grain in gear generating grinding. For this investigation, an adaptation of a single-grain energy model considering the chip formation mechanisms is proposed. The grinding energy as well as normal force can be determined either supported by measurements or solely based on prediction models.
Highlights
Generating gear grinding is a hard finishing process mainly used to meet the high requirements for gears in terms of geometry and surface quality [1]
The understanding of each chip formation mechanism influence on the energy generated in grinding is important to better understand and control the part of the generated heat that flows into the workpiece
In order to better understand and control the part of the generated heat that flows In order to better understand and control the part of the generated heat that flows into the workpiece during grinding process, it is necessary to calculate the grinding energy into the workpiece during grinding process, it is necessary to calculate the grinding enconsidering the different phases of chip formation mechanisms
Summary
Generating gear grinding is a hard finishing process mainly used to meet the high requirements for gears in terms of geometry and surface quality [1]. Depending on the process condition, a fraction of 60–90% of the generated heat can flow into the workpiece [3]. In the work of Hahn it was established that the removal of material by each grain of the grinding tool during the process is performed during three different phases: Friction, plowing, and shearing [6,7]. Each of these phases contributes in a singular way to the partition of energy that goes to the workpiece [5,7]. From heat transfer considerations it was shown that almost all the energy generated in the friction phase was conducted as heat to the workpiece [5]
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