Comparison of measured surface layer quality parameters with simulated results

Abstract

The grinding temperature is one of the factors limiting the throughput performance of the profile gear grinding
operation. There are two main methods for determining the grinding temperature: an analytical method with the aid of analytical
models and a simulation one based on both the analytical and geometrical models. In the paper, at the first stage the profile gear
grinding temperature field is investigated with the aid of finite element method (FEM) simulation as an example of information technology which helps to predict the surface layer quality physical parameters. The results obtained are compared with similar calculations for the analytical models and the tooth surface area is found to determine the temperature according with the analytical models. At the second stage, a series of experimental studies on the CNC machine Höfler Rapid 1250 is carried out on a real gear by
means of a successive increase in the depth of profile gear grinding. From the gear machined the special samples were cut out on the
electro-erosive machine mod. MV 2400S ADVANCE Type 2 (MITSUBISHI ELECTRIC Company) for additional investigation of
these samples. The teeth surface layer quality experimental study and the structural-phase state of the surface layer metallographic
analysis have been performed using modern measuring equipment and instruments, e.g. microscope Altami MET-5. It is established
that, in other equal conditions, the highest grinding temperature occurs in the upper part of the tooth which is grinding. It is identified areas of the tooth profile, on which the grinding temperature can be calculated by the famous analytical dependencies. It is established that as the parameters characterizing the grinding intensity and the volume of material removal per unit of the grinding
wheel width increase, the grinding burn arises and its thickness increases. The regularity of the change in the thickness of the burn
along the height of the tooth is established, which makes it possible to evaluate the reliability of the corresponding theoretical studies