Effect of Running-In (Load and Speed) on Surface Characteristics of Honed Gears

Mallipeddi, Dinesh; Norell, Mats; Sosa, Mario; Nyborg, Lars

doi:10.1080/10402004.2019.1565849

Cited by 14 publications

(6 citation statements)

References 15 publications

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“…2 It is therefore desirable to conduct detailed research to better understand and use this phenomenon to improve the working ability of the contact surfaces. The main research of the running-in process is oriented toward two major directions: research where particular machine elements are examined (cam mechanisms, 3 gear pairs, 4,5 plain bearings, 6 cylinder liners, 7 external gear pumps, 8 etc. ); and simplified testing on different types of tribometers (disc-on-disc, 9 pin-on-disc, 10 block-on-disc, 11 etc.).…”

Section: Introductionmentioning

confidence: 99%

Influence of the running-in process on the working ability of contact surfaces in lubricated sliding conditions

Dimić

Vencl

Ristivojević

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part J:

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The influence of the running-in process operating parameters on tribological properties of the block-on-disc samples in lubricated sliding conditions is analyzed and discussed in detail. Different running-in regimes are achieved by varying the normal load and sliding speed. After the running-in period, during which the operating parameters are varied, all samples are placed in a working regime under the same set of operating conditions. At the end of the running-in period, as well as at the end of the working period, an analysis of the changes in the surface roughness, microhardness, wear rate, and coefficient of friction is performed. Less desirable properties in terms of wear rate and steady-state coefficient of friction are noticed for the samples that were run-in with the operating conditions which were the same as the working regime operating conditions. In the defined test conditions, it is shown that the intensity of normal load applied during the running-in process has a dominant influence on the amount of wear and coefficient of friction value. It was also shown that the running-in process can significantly improve the roughness of the initially rough contact surfaces. The results of experimental testing indicate that the variation of the operating parameters during the running-in process can be used to improve the working ability of the sliding contact surfaces under the mixed lubrication regime.

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Section: Introductionmentioning

confidence: 99%

Influence of the running-in process on the working ability of contact surfaces in lubricated sliding conditions

Dimić

Vencl

Ristivojević

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part J:

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“…Precision hardened gears are widely used and in great demand in fields such as high-performance automobiles and high-end robots, which have high requirements for the lifespan, transmission efficiency, and load capacity of gears. Power gear honing is a new technology that offers an alternative to grinding for precision-hardened gears, which has the advantages of improving the geometric accuracy of tooth orientation and tooth shape, prolonging the working life of gears, reducing transmission noise and increasing the bearing capacity of tooth surfaces [ 1 , 2 , 3 , 4 ]. However, gear honing is a complex multi-grain micro-edge cutting process with a large number of irregularly distributed abrasive grains on the tooth surface of the honing wheel [ 5 ], removing the machining allowance [ 6 ] and generating the typical honing grooves [ 2 , 6 ] along the contact traces [ 7 ] in the contact area with a smaller honing force [ 8 ] and lower honing speed [ 9 ].…”

Section: Introductionmentioning

confidence: 99%

“…Power gear honing is a new technology that offers an alternative to grinding for precision-hardened gears, which has the advantages of improving the geometric accuracy of tooth orientation and tooth shape, prolonging the working life of gears, reducing transmission noise and increasing the bearing capacity of tooth surfaces [ 1 , 2 , 3 , 4 ]. However, gear honing is a complex multi-grain micro-edge cutting process with a large number of irregularly distributed abrasive grains on the tooth surface of the honing wheel [ 5 ], removing the machining allowance [ 6 ] and generating the typical honing grooves [ 2 , 6 ] along the contact traces [ 7 ] in the contact area with a smaller honing force [ 8 ] and lower honing speed [ 9 ]. Hence, it is much more complicated than ordinary turning, milling, grinding and other machining methods, restricting the wide application of honing technology.…”

Section: Introductionmentioning

confidence: 99%

Cutting Performance of Randomly Distributed Active Abrasive Grains in Gear Honing Process

et al. 2021

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In power gear honing, the random distribution of abrasive grains on the tooth surface of the honing wheel is the main factor that influences the machining performance of high-quality hardened gears. In order to investigate the micro-edge cutting performance of the active abrasive grains on the workpiece gear, the real honing process is simplified into a micro-edge cutting model with random distribution of active abrasive grains in the cells of the meshing area by obtaining the random distribution states such as the position, orientation and quantity of the honing wheel teeth. The results show that although the active abrasive grains are distributed at different locations, they all experience three types of material removal—slip rubbing, plowing and cutting—allowing the gear honing process to have the combined machining characteristics of grinding, lapping and polishing. The active abrasive grains in first contact produce high honing force, high material removal efficiency and poor surface roughness on the machined workpiece, while the latter ones have the opposite effects. The dislocation angle affects the chip shape and chip discharging direction, and the highest honing force and material removal efficiency is achieved with a dislocation angle of 135°. The higher the number of active abrasive grains in a given contact area, the higher the material removal efficiency.

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“…With the increasing requirements of gears for automotive dual clutch automatic transmissions (DCTs), robot joint cycloid reducers, etc., it has become essential to reduce gear noise and improve the accuracy, load capacity, and life span of hardened gears [1,2]. Therefore, the development of coated tools [3][4][5][6] and CNC machines and the advancement of machining technologies such as gear honing [7], gear grinding [8], gear shaving [9], gear turning [10], and gear milling (faced-milled gear) [11,12] have become an even more urgent task.…”

Section: Introductionmentioning

confidence: 99%

“…Compared with the corundum honing wheels made of polyester or ceramic bonds [14], CBN honing wheels can remove interfering workpiece material at higher cutting speeds (6-10 m/s) [15], larger honing forces (>400 N) [16], and more material removal (50-100 µm/flank) [17] without any grinding operation. Thus, it can substantially improve the material removal rate, machining accuracy, and surface quality of hardened gears [1,18]. The micromorphology of the honing wheel tooth surface, composed of the shape, number, size, and spacing of abrasive grains [19], determines the properties of the honing wheel and plays an important role in honing performance.…”

Section: Introductionmentioning

confidence: 99%

Simulation to Microtopography Formation of CBN Active Abrasives on a Honing Wheel Surface

et al. 2021

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The microtopography of a honing wheel surface composed of active abrasive grains is the key factor affecting the honing characteristics, and control of it is a sufficient condition to realize high-efficiency precision honing. Based on the magnetron sputtering method and phase field method, a theoretical model of cubic boron nitride (CBN) coating formation on a honing wheel surface is established. The physical vapor deposition (PVD) discrete phase field equation is solved by the finite difference method. A MATLAB program is compiled to simulate the formation process and micromorphology of the CBN coating on the honing wheel surface. A Taguchi method is designed to study the relationships of the sputtering time, substrate temperature, gas flow rate, and reaction space with the number of active abrasives and the length, width, height, and size of the abrasives. The simulation results are highly similar to the scanning electron microscopy (SEM) examinations, which shows that the model can accurately and effectively simulate the abrasive morphology of the wheel surface under different process conditions and provide a theoretical basis for the prediction and control of the CBN wear morphology on a honing wheel surface.

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Effect of Running-In (Load and Speed) on Surface Characteristics of Honed Gears

Cited by 14 publications

References 15 publications

Influence of the running-in process on the working ability of contact surfaces in lubricated sliding conditions

Influence of the running-in process on the working ability of contact surfaces in lubricated sliding conditions

Cutting Performance of Randomly Distributed Active Abrasive Grains in Gear Honing Process

Simulation to Microtopography Formation of CBN Active Abrasives on a Honing Wheel Surface

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