Temperature field modelling in the form grinding of involute gear based on high-order function moving heat source

Abstract

Grinding is one of the primary methods to enhance the tooth surface quality. For gear form grinding, due to the complexity of grinding movement and nonuniform grinding conditions of the tool and workpiece geometry, the accurate prediction for gear grinding temperature is difficult to achieve by using a single specific heat source shape. Therefore, a new temperature model based on high-order function curve moving heat source distribution in the grinding zone was established. Compared with the traditional models, using the new model can avoid assuming the heat source distribution shape in advance and greatly reduce the disadvantages caused by improper heat source shape assumptions under the nonuniform grinding conditions along the tooth profile. In this model, the analysis of geometry model of gear form grinding, characteristic parameters of abrasive grains and moving point heat source theory were comprehensively considered. Additionally, the finite element numerical simulation and gear grinding experiments were outperformed to analyze the gear grinding temperature. Comparison results show the highest temperature based on high-order function curve heat source appears earlier and closer to the front of the grinding contact arc compared with triangular and rectangular heat source distribution shapes. Furthermore, the tooth surface temperature in the grinding zone obtained by new model has better consistency with the experimental measurement results. The relative errors of the analytical and numerical simulation results of the maximum temperature are within 5.2 % and 6.4 %, respectively. These findings prove the accuracy and superiority of the temperature prediction model based on high-order function moving heat source distribution for gear form grinding, and it has a guiding role in the optimization of the workpieces with complex profiles in form grinding.