Analysis of the influence of gear dimensions on cutting speed and contact conditions during the gear honing process

Abstract

In many cases, gear honing represents a costefficient process for gear manufacturers. Another advantage of gear honing is the generation of a surface structure on the tooth flank which improves the noise behavior of the gear. Previous research activities have resulted in reliable gear honing processes, particularly for automotive gears with a tip diameter of up to 150 mm. Problems occur, however, when honing larger gears with a tip diameter of more than 150 mm, thereby rendering a robust manufacturing process is difficult. In the course of this paper, an analysis will be carried out of the geometrical and kinematic conditions that will lead to a better understanding of the process. The aim of this report is to provide an overview of the current basic conditions of the gear honing process. Theoretical studies are conducted to identify differences in gear honing processes with various tip diameters. This analysis forms the basis for optimizing process design, with the aim of generating a cost-efficient gear honing operation for gears with a tip diameter of more than 150 mm.

Aspects of the Internal Gear Honing Process

“…Through X-ray diffraction, residual stresses up to -1400 MPa can be detected directly on the surface. At depths of just 20 μm, the value of the residual stresses drops considerably to values of about -200 MPa, which remain constant up to a depth of 90 μm [10]. These high compressive values of the residual stresses contribute to excellent lifetime performance and to the ability of loading the gear flanks at high values.…”

“…Subsequent research, combined with the growth of industrial applications and the development of machine tools and cutting tools, allows a depth of cut of 80 μm. The process has been called "gear honing" [10].…”

Dynamic transmission error measurements of a drive train

“…Furthermore, variations of the flank twist and the tip relief have been investigated [3]. Influences of surface roughness on the gear noise as shown in [4] and [5] have not been considered in the designing process. Focusing on two helical gear variants the results of the investigation will be presented.…”

Peridynamic Simulation to Fracture Mechanism of CBN Grain in the Honing Wheel Dressing Process

“…Gear honing is a cost-efficient process for the manufacturing of gears due to its low noise and beneficial wear characteristics [1]. Therefore, it is usually used in the precision machining of gears.…”