Tool wear in dry gear hobbing of 20MnCr5 case-hardening steel, 42CrMo4 tempered steel and EN-GJS-700-2 cast iron

Troß, Nico; Brimmers, Jens; Bergs, Thomas

doi:10.1016/j.wear.2021.203737

Cited by 22 publications

(10 citation statements)

References 13 publications

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“…8. The fly-cutting trial represents an established analogy process to gear hobbing, where a single hob tooth reproduces all the generating positions of the corresponding hob by means of a continuous shift process [28]. The trials were carried out on a Liebherr LC180 gear hobbing machine.…”

Section: Verification Of the Cutting Force Calculation In Machining Trialsmentioning

confidence: 99%

“…The workpiece material was a case-hardening steel 20MnCr5. A detailed characterization of the material can be found in a recent study of Troß et al, where the exact same material batch was used for tool wear investigations [28]. The material used for the trials does not fully correspond to the casehardened steel 18CrNiMo7-6 on which the simulations are based.…”

Section: Verification Of the Cutting Force Calculation In Machining Trialsmentioning

confidence: 99%

“…11 Comparison of model and FE simulation pearlitic material structure, cf. [18,28], and mechanical and thermal properties, cf. [30,31].…”

Section: Verification Of the Cutting Force Calculation In Machining Trialsmentioning

confidence: 99%

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Approach for multiscale modeling the thermomechanical tool load in gear hobbing

Troß

Brimmers

Bergs

2021

Forsch Ingenieurwes

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In this report, an approach is presented how a geometric penetration calculation can be combined with FE simulations to a multiscale model, which allows an efficient determination of the thermomechanical load in gear hobbing. FE simulations of the linear-orthogonal cut are used to derive approximate equations for calculating the cutting force and the rake face temperature. The hobbing process is then simulated with a geometric penetration calculation and uncut chip geometries are determined for each generating position. The uncut chip geometries serve as input variables for the derived equations, which are solved at each point of the cutting edge for each generating position. The cutting force is scaled according to the established procedure of discrete addition of the forces along the cutting edge over all individual cross-section elements. For the calculation of the temperature, an approach is presented how to consider a variable chip thickness profile. Based on this, the temperature distribution on the rake face is calculated. The model is verified on the one hand by cutting force measurements in machining trials and on the other hand by an FE simulation of a full engagement of a hob tooth.

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Section: Verification Of the Cutting Force Calculation In Machining Trialsmentioning

confidence: 99%

Section: Verification Of the Cutting Force Calculation In Machining Trialsmentioning

confidence: 99%

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Approach for multiscale modeling the thermomechanical tool load in gear hobbing

Troß

Brimmers

Bergs

2021

Forsch Ingenieurwes

Self Cite

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“…Grinding processes as an important method were employed to eliminate deformation after heat treatment and improve the accuracy of the workpiece. However, the unexpected grinding burn easily occurs due to the aggregation of high grinding force and heat on the workpiece surface, resulting in poor surface quality and high surface residual tensile stress [5][6][7]. In this case, a new machining technology is urgently needed to reduce the grinding force and heat.…”

Section: Introductionmentioning

confidence: 99%

Experimental study on ultrasonic vibration-assisted grinding of hardened steel using white corundum wheel

Qiang¹,

Zhao

Cao³

et al. 2022

Preprint

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Ultrasonic vibration assisted grinding (UVAG) combined with the ultrasonic vibrating method and CG process was proposed, aiming at improving the grindability of hardened steel in conventional grinding (CG) process. Comparative investigations on grinding force, temperature, and specific grinding energy for both grinding processes were studied in detail. In addition, the morphologies of wheel wear surface and ground surface were also conducted. Findings show that in comparison of CG processes, the grinding forces in UVAG are reduced greatly by 16.44% and 17.44%, for normal and tangential forces, respectively. The UVAG process attributes to a lower specific grinding energy by 8.30% owing to the increase of maximum undeformed chip thickness, and a smaller grinding temperature by 19.01% due to the improvement of coolant heat transfer capacity in the grinding arc zone. Meanwhile, the promising grain sharpness of wheels can be guaranteed, resulting from the enhanced cooling function on grinding arc zone and grains micro-fracture caused by ultrasonic impacting actions.

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“…In order to fully utilize the potential of this material, it is necessary to consciously shape the properties of its surface layer in both machining and abrasive machining. The authors of the work [16] point the need to ensure appropriate cutting conditions, giving special emphasis to the proper selection of cutting parameters and the type of tool material and their impact on the durability of the cutting tool during gear hobbing. In another study devoted to gear hobbing, the purposefulness of using the minimum GF flow rate supply by the MQL method, was demonstrated [17].…”

Section: Introductionmentioning

confidence: 99%

The Influence of the Depth of Grinding on the Condition of the Surface Layer of 20MnCr5 Steel Ground with the Minimum Quantity Lubrication (MQL) Method

et al. 2022

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This paper describes the research on abrasive machining conditions and their influence on microhardness and residual stresses distribution in the technological surface layer of 20MnCr5 steel. The roughness of ground samples was also measured. Samples underwent a vacuum carburizing process (LPC) followed by high-pressure gas quenching (HPGQ) in a 4D quenching chamber. Processes were realized with a single-piece flow method. Then, the flat surfaces of samples were ground with a Vortex type IPA60EH20VTX alumina grinding wheel using a flat-surface grinder. The samples were ground to three depths of grinding (ae = 0.01; 0.02; 0.03 mm) with grinding fluid supply using either flood method (WET) or minimum quantity lubrication (MQL) method. The condition of the technological surface layer was described using microhardness and residual stresses, as well as some selected parameters of surface roughness. The results obtained revealed that changes in microhardness as compared to microhardness of the material before grinding were lower in samples ground with grinding fluid supplied with MQL method. At the same time, the values of residual stresses were also better for samples ground using MQL method. Furthermore, the use of grinding fluid fed with MQL method produced lower values of surface roughness compared to the parameters obtained with WET method. It was concluded that for the tested scope of machining conditions, the MQL method can be a favourable alternative to the flood method of supplying grinding fluid into the grinding zone.

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Tool wear in dry gear hobbing of 20MnCr5 case-hardening steel, 42CrMo4 tempered steel and EN-GJS-700-2 cast iron

Cited by 22 publications

References 13 publications

Approach for multiscale modeling the thermomechanical tool load in gear hobbing

Approach for multiscale modeling the thermomechanical tool load in gear hobbing

Experimental study on ultrasonic vibration-assisted grinding of hardened steel using white corundum wheel

The Influence of the Depth of Grinding on the Condition of the Surface Layer of 20MnCr5 Steel Ground with the Minimum Quantity Lubrication (MQL) Method

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