Calculation model for surface roughness of face gears by disc wheel grinding

Wang, Yanzhong; Liu, Yang; Chu, Xiaomeng; He, Yueming; Zhang, Wei

doi:10.1016/j.ijmachtools.2017.08.002

Cited by 50 publications

(8 citation statements)

References 9 publications

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“…Surface topography includes both surface roughness and waviness which could be accessed with contact (stylus/laser profilometers) [33,34] and non-contact (3D interferometry) measurements [35][36][37]. Due to the nature of the reinforcement in MMCs, it allows more applications for parts undergoing high friction and cycle loading conditions wherein the surface topography is of great concern.…”

Section: Surface Integrity After Machining Of Metal Matrix Compositesmentioning

confidence: 99%

State-of-the-art of surface integrity in machining of metal matrix composites

Liao

Abdelhafeez

et al. 2019

International Journal of Machine Tools and Manufacture

185

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Metal matrix composites (MMCs), as advanced substitutes of monolithic metallic materials, are currently getting an increasing trend of research focus as well as industrial applications for demanding applications such as aerospace, nuclear and automotive because of their enhanced mechanical properties and relative lightweight. Nevertheless, machining of MMC materials remains a challenging task as a result of their structural heterogeneity which leads to deterioration of the machined surface integrity and rapid tool wear. While prior review papers have concentrated on the other machining aspects (e.g. process modelling and tool wear) of MMCs, none of them has addressed the subject of reviewing workpiece surface integrity aspects in details. This paper presents a detailed literature survey on the conventional and nonconventional machining of metal matrix composites with the primary focus on the aspects related to workpiece surface integrity. The contribution of material mechanical and microstructural properties as well as the material removal mechanism upon the quality of workpiece surfaces/subsurface are discussed along with their influences on the fatigue performance of machined part.

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Section: Surface Integrity After Machining Of Metal Matrix Compositesmentioning

confidence: 99%

State-of-the-art of surface integrity in machining of metal matrix composites

Liao

Abdelhafeez

et al. 2019

International Journal of Machine Tools and Manufacture

185

View full text Add to dashboard Cite

show abstract

“…Haifeng [19] investigated the particle trajectory motion model according to the generating grinding process and determined the surface roughness of the involute gear pro le using the plane projection mapping method. By integrating the single particle grinding cross-sectional area model and based on the equivalent diameter of the grinding wheel, Wang [20] determined the surface roughness of the face gear tooth surface. Moreover, based on the plane formed by the meshing point and its normal direction, a calculation model for the grinding residual of the face gear was established for accurately modeling the surface topography of the face gear.…”

Section: Introductionmentioning

confidence: 99%

Face gear generating grinding residual model based on the normal cutting depth iterative method

Cai

Yao

et al. 2023

Int J Adv Manuf Technol

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The generating grinding method has the characteristics of high machining accuracy and high e ciency. Therefore, it is widely used in the nishing process of the face gear tooth surface. The physical performance of the grinding process is an important factor that in uences the machining accuracy of the face gear tooth surface. Therefore, to improve the manufacturing accuracy of the face gear, it is necessary to accurately simulate the grinding process of the face gear. Owing to the in uence of the complex spatial geometric characteristics of the face gear tooth surface and the grinding wheel, establishing a surface residual modeling method for the face gear is a key challenge in simulating the generating grinding process. To address the aforementioned issues, this study proposes a normal cutting depth iterative method to calculate the grinding residual in the face gear generating grinding process. First, the mathematical models of the grinding wheel pro le, grinding trajectory, and face gear tooth surface are established. Then, the initial conditions of algorithm iteration are established by calculating the parameter coordinates of the meshing point of the grinding wheel and the face gear at each moment. Subsequently, the tooth surface of the face gear is gridded, its node normal direction is determined, and the normal grinding residual matrix of the face gear tooth surface is obtained. Based on the cutting surface of the grinding wheel, the normal cutting depth of the grid node on the tooth surface at each moment is iteratively approximated. Furthermore, by taking the meshing point as the initial solution point and the face gear normal grinding residual matrix at the previous moment as the initial condition of iteration, grinding area on the face gear tooth surface at the current moment is calculated, and the face gear normal grinding residual matrix is updated. Finally, these steps are repeated until the grinding is completed, and the nal normal grinding residual matrix of the face gear is obtained. Thus, the generating grinding residual of the face gear is obtained. This algorithm considers the complex 3D spatial characteristics of the face gear tooth surface and establishes the spatial residual model of each grid node of the face gear in the process of generating grinding. Compared with other residual algorithms based on 2D truncation or Boolean operation of face gears, this algorithm has higher computational accuracy and e ciency. Thus, it lays the foundation for accurately establishing the complex spatial microscopic surface topography in the face gear generating grinding process.

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“…They revealed material removal mechanism of generating grinding and investigated the influence of tool swing angle on the topography of face gear, founding that tooth surface roughness and processing efficiency can be guaranteed when the swing angle is 0.5°. Wang et al 12 proposed a model for the roughness calculation in face gear generating grinding based on the meshing principle of gear pair. In this process, they investigated the generating mechanism of generating process and found that the swing of wheel directly affected the surface roughness of tooth surface.…”

Section: Introductionmentioning

confidence: 99%

Prediction and optimisation for surface roughness distribution in external spline shaping based on micro-element method

Yao

Liu

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Previous surface topography prediction models for external spline shaping do not consider the relationship between the tool and workpiece geometry and cutter edge wear. In this work, by considering the tool–workpiece geometry correlation, a model for the tooth surface topography of the external spline is established based on the micro-element method. Combined with adhere model, a gear shaper wear model is founded on the wear mechanism of cutter edge micro-element derived from the abrasive wear mechanism. The distribution characteristics of tooth topography are analysed through an external spline shaping experiment, which verifies the validity of the presented model. For the uneven distribution of tooth surface topography, a shaping process optimisation algorithm is proposed based on the advance-and-retreat method, which can obtain tooth surfaces with uniform surface topography distribution and reduce tool wear. This work can guide the optimisation of the external spline shaping process, improve the integrity of the tooth surface and prolong the serviceable life of gear shaper.

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Calculation model for surface roughness of face gears by disc wheel grinding

Cited by 50 publications

References 9 publications

State-of-the-art of surface integrity in machining of metal matrix composites

State-of-the-art of surface integrity in machining of metal matrix composites

Face gear generating grinding residual model based on the normal cutting depth iterative method

Prediction and optimisation for surface roughness distribution in external spline shaping based on micro-element method

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