Experiment on grinding surface morphology of spiral bevel gear

Spiral bevel gear is widely used in the transmission system of heavy vehicles with the advantages of high transmission ratio, low noise and large transmission torque. “Gear milling – heat treatment – gear grinding” is a widely used production process in gear machining. Grinding is the last step in gear manufacturing. The integrity of grinding surface has a great impact on the service life of gears. Grinding surface morphology is one of the important indexes of surface integrity, which plays a key role in the wear resistance, fatigue strength and contact stress of gears.

By studying the geometric interaction between grinding wheel particles and spiral bevel gear surface, a three-dimensional morphology simulation model of grinding surface is established, which can predict and analyze the surface morphology characteristics of spiral bevel gear under different grinding process parameters. Many researchers have carried out in-depth research on it and achieved some remarkable results. Malkin describes in detail the motion trajectory of grinding wheel abrasive particles, the interaction between abrasive particles and machined spiral bevel gear and the generation mechanism of chips in the grinding process, and gives the influence law of grinding parameters on cutting thickness. Chen et al. Studied the generation method of grinding surface morphology, simulated and analyzed the grinding force in the grinding process, and verified the correctness of the proposed theoretical model through experiments. Butler et al. Used three-dimensional measurement technology to test the grinding wheel morphology, studied the characteristics of the surface morphology of worn and non worn grinding wheels, and the relationship between the grinding of spiral bevel gears with different grinding wheels and the grinding wheel morphology. Zhu et al. Pointed out that the abrasive particle height on the surface of the grinding wheel is in a random Gaussian distribution state according to the different shape, size and distribution density of the abrasive particles on the actual grinding wheel surface. Nguyen et al. [6] gave the cutting trajectory of each abrasive particle on the surface of the grinding wheel, mapped it to the surface coordinate system of the spiral bevel gear, and took the minimum value of all abrasive particle trajectories at each point on the surface of the spiral bevel gear, that is, the three-dimensional morphology of the surface of the spiral bevel gear after grinding. Chen Dongxiang and others generated grinding wheel morphologies with different statistical characteristics based on Johnson transform and linear filtering technology. According to the grinding kinematics, a simulation model of ultra precision grinding of spiral bevel gear surface is proposed. Gong Yadong et al. [8] considered the included angle between grinding wheel and spiral bevel gear axis α Based on the distribution of abrasive particles on the surface of grinding wheel and the kinematic characteristics of abrasive particles, the generation model of three-dimensional surface morphology of point grinding spiral bevel gear is given. LV Changfei and others used Johnson transform and Gabor wavelet transform to simulate the grinding wheel morphology in the random domain, and gave the cylindrical grinding simulation model to realize the simulation of machining spiral bevel gear morphology and roughness prediction.

To sum up, although many scholars have carried out simulation research on the surface morphology of grinding spiral bevel gear, most of them focus on surface grinding, cylindrical grinding, point grinding and other constant curvature trajectory grinding. During the grinding of spiral bevel gear, the spiral bevel gear moves based on the set spatial trajectory, and the curvature of its trajectory changes significantly, which affects the cutting interference trajectory of grinding wheel abrasive particles on the surface of spiral bevel gear. Therefore, in order to predict the grinding surface morphology of spiral bevel gear, firstly analyze the grinding particle kinematics of spiral bevel gear, then establish the grinding wheel surface morphology feature model, finally verify the proposed model by grinding test, and compare and analyze the influence law of grinding parameters on the grinding surface morphology of spiral bevel gear.

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