Abstract The non-uniform grinding conditions due to the tool and workpiece geometries lead to the complexities of the chip geometry and topography characteristic in gear profile grinding. As a result, the previous surface prediction models that have been extensively studied for surface grinding are not able to reveal the surface generation mechanism of gear profile grinding. In this work, a comprehensive model is presented to calculate the surface topography and the chip geometry considering the non-uniformity of geometric contact and grain-workpiece interaction along the tooth profile. In this process, the geometric conditions are characterized by the radius of local tool circumference and the included angle between the plane of grain rotation and the surface normal. Experimental results show reasonable consistency with numerical simulations that validate the proposed model. Based on the model, the effect of geometric conditions on the texture pattern and roughness distribution is studied to give an in-depth analysis of the process characteristics by comparing the simulated results under actual and ideal conditions. Besides, the optimization method is proposed to obtain a more uniform tooth surface. This work provides new insight into the fundamental understanding of profile grinding of gears and can be utilized to guide the machining process for higher tooth surface integrity.

中文翻译：

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齿形磨削表面生成机理及粗糙度分布研究

摘要 由于刀具和工件几何形状的不均匀磨削条件导致齿轮轮廓磨削中切屑几何形状和形貌特征的复杂性。因此，先前针对平面磨削进行了广泛研究的表面预测模型无法揭示齿轮轮廓磨削的表面生成机制。在这项工作中，考虑到沿齿廓几何接触和晶粒-工件相互作用的不均匀性，提出了一个综合模型来计算表面形貌和切屑几何形状。在这个过程中，几何条件用局部刀具圆周半径和晶粒旋转平面与表面法线之间的夹角来表征。实验结果表明与验证所提出模型的数值模拟具有合理的一致性。在该模型的基础上，研究了几何条件对纹理图案和粗糙度分布的影响，通过比较实际和理想条件下的模拟结果，对工艺特性进行深入分析。此外，提出了优化方法以获得更均匀的齿面。这项工作提供了对齿轮轮廓磨削的基本理解的新见解，并可用于指导加工过程以提高齿面完整性。研究几何条件对纹理图案和粗糙度分布的影响，通过比较实际和理想条件下的模拟结果，对工艺特性进行深入分析。此外，提出了优化方法以获得更均匀的齿面。这项工作提供了对齿轮轮廓磨削的基本理解的新见解，并可用于指导加工过程以提高齿面完整性。研究几何条件对纹理图案和粗糙度分布的影响，通过比较实际和理想条件下的模拟结果，对工艺特性进行深入分析。此外，提出了优化方法以获得更均匀的齿面。这项工作提供了对齿轮轮廓磨削的基本理解的新见解，并可用于指导加工过程以提高齿面完整性。