Modeling of Specific Energy in the Gear Honing Process

Abstract

Gear honing is a cost-efficient method for the finishing of hardened gears in which material removal is realized through honing wheel and workpiece gear interactions. There are a number of indicators used for evaluating the degrees of these interactions, among which specific energy is a more appropriate one than the others since it is capable of quantifying the amount of energy consumption during the material removal process. Nevertheless, models for the prediction of specific energy in gear honing have not been thoroughly investigated. This work presents a theoretical model of specific energy to quantitatively evaluate the material removal efficiency in the external gear honing process. To develop the model, an analytical material removal rate and a honing force model are proposed, and the feasibility of the proposed model is validated against external gear honing experiments. The correlations of specific energy with processing parameters are investigated and the material removal efficiency scores of external gear honing and grinding are compared and discussed. The present approach enables an in-depth understanding of the abrasive–material interactions in the gear honing process and the effects of processing parameters on material removal efficiency.

Optimization Experimental Study of Machining Energy Consumption of Zig-Zag Milling Cutting Path Using Rsm.

“…On the other hand, Wang et al [11] conducted research on the energy consumption and material removal rate during gear horning process. They proposed the theoretical model of energy usage and material removal efficiency and it was validated by the physical gear horning experiment.…”