1. Processing with Norton 3SG60 grinding wheel
(1) rough grinding: the 1st ~ 3rd cutters are in the form of double-sided grinding, and the upper limit of grinding overload current of the machine tool is set to 10% (when the current intensity generated by cutting force is greater than 10%, the grinding program of the machine tool will stop automatically to ensure that the cylindrical gear tooth surface grinding will not produce burns and cracks. It is available for operators and technicians to check, judge, adjust and modify the grinding program, etc.).
(2) semi finish grinding: single side grinding is adopted for tool 4 ~ 5, and the upper limit of grinding overload current intensity of the machine tool is set to 13%.
(3) fine grinding: the 6th cutter adopts single-sided grinding, and the upper strength limit of grinding overload current of the machine tool is set to 8%. After a period of processing and verification, the qualified rate of product quality is 100%.
2. German comet 3SG60 grinding wheel is used for processing
The original grinding process is the same as above and will not be repeated here. After a period of processing verification, the product quality is 100% qualified. After research and test, the German comet brand 3sg grinding wheel is used for gear grinding, and there is still potential for further improvement in technology. The optimized gear grinding process is as follows:
(1) rough grinding: the 1st ~ 2nd cutter adopts the form of double-sided grinding, and the cutting amount of cylindrical gear tooth surface increases by 100%; The up and down stroke speed increases by 40%, which not only greatly improves the gear grinding efficiency, but also reduces the frequency of diamond roller dressing the grinding wheel. The upper limit of grinding overload current of the machine tool is set to 18%.
(2) semi finish grinding: the 3rd ~ 4th cutter adopts single-sided grinding, in which the upper limit of grinding overload current of the 3rd cutter machine tool is set to 15%. The 4th knife can be increased by 20% on the original basis, and the upper limit of overload current is set to 18%.
(3) finish grinding: the 5th ~ 6th cutter adopts single-sided grinding, and the grinding parameters remain unchanged to ensure the roughness and accuracy of cylindrical gear tooth surface. The upper limit of grinding overload current of the machine tool is set to 15%.
After adopting the above optimized grinding process, through tracking inspection, the one-time processing qualification rate of the product is 100%.