Surface integrity aspects in gear manufacturing

Karpuschewski, Bernhard; Beutner, M.; Eckebrecht, J.; Heinzel, Jonas; Hüsemann, T.

doi:10.1016/j.procir.2020.05.112

Cited by 14 publications

(8 citation statements)

References 12 publications

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“…As shown in Figure 2, the wear resistance, fatigue resistance, and corrosion resistance of high-performance hard tooth surface gears largely depend on the quality of the machined tooth surface after honing. Usually, surface roughness, waviness, surface defects, and texture direction are used to represent the micro geometric morphology of the tooth surface, while residual stress [37], surface texture [38], and tooth surface hardness [39] are used to characterize the physical and mechanical properties of the tooth surface. Among them, the surface roughness affects the tooth surface wear resistance, fit stability, corrosion resistance, etc.…”

Section: Process Systemmentioning

confidence: 99%

Quality evaluation of effective abrasive micro-edge honing based on Tra-FAH and SPA

Yu,

Liang,

Liu

et al. 2023

Preprint

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CNC powerful gear honing can comprehensively improve the tooth surface performance and is widely used in the finishing process of high-performance gears in the transmission system of new energy vehicles. Accurate evaluation of gear honing processing quality has important engineering application value for popularizing the process of "honing instead of grinding". In this paper, 12 factors, such as abrasive particle size, are determined qualitatively by analyzing the factors affecting gear honing accuracy, tooth surface quality and machining efficiency. Based on trapezoidal fuzzy analytic hierarchy process (Tra-FAH) and set pair analysis method (SPA), a quantitative evaluation model of CBN abrasive micro edge honing quality is established. Through the influence factor weight and key factor sensitivity analysis, it is quantitatively determined that the honing process parameters and abrasive particle size, abrasive particle shedding, abrasive particle breakage and other factors are the key factors affecting the honing quality. Taking the particle size factor as an example, the machining experiment and analysis show that the model can correctly evaluate the honing quality of high quality hardened gears and can be used to study the mechanism of honing characteristics and improve the comprehensive quality of powerful gear honing.

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Section: Process Systemmentioning

confidence: 99%

Quality evaluation of effective abrasive micro-edge honing based on Tra-FAH and SPA

Yu,

Liang,

Liu

et al. 2023

Preprint

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“…During grinding, the variation in different grinding parameters can introduce different temperatures within the grinding zone and, if non-optimal grinding parameters are used, the heat input produced might be too high and cause grinding burns. For example, a locally increased material removal rate may lead to the risk of grinding burn [2]. As Malkin and Guo [3] have stated, most grinding damage is thermal in origin.…”

Section: Introductionmentioning

confidence: 99%

“…In a typical milder grinding burn, the surface stress may be compressive (but lower compared to the original) but it changes quickly into tensile stress below the surface. However, if the grinding parameters are chosen progressively, an even tensile stress can be formed at the surface [2]. Therefore, different grinding parameters have a great effect on the outcome of the grinding, such as the material removal rate (Q w ), which is the volume rate per unit of time at which the material is removed from a workpiece during grinding, and material removal (V w ), which is the volume of workpiece material removed during the grinding time.…”

Section: Introductionmentioning

confidence: 99%

Sub-Surface Analysis of Grinding Burns with Barkhausen Noise Measurements

et al. 2022

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Barkhausen noise (BN) measurements are commonly used for surface characterisation. However, often there is also a need to verify the sub-surface region because detrimental tensile stresses may be present after different manufacturing steps. Especially in a grinding burn, the surface stress may be compressive, but it changes quickly into tensile stress below the surface. The aim of this study was to find out whether regular surface-sensitive BN measurement is also sensitive to the stresses below the surface caused by grinding burns. More specifically, the aim was to study the relationship between BN features and sub-surface stresses and to identify a model that estimates sub-surface stresses. Real samples were collected from an actual process. The samples were cylindrical samples manufactured from commercial alloyed AISI/SAE L6 steel that was through-hardened prior to grinding. Barkhausen noise measurements were carried out for 42 grinding burn locations followed by X-ray diffraction-based residual stress surface measurements and residual stress depth profiles. Depth information was obtained through step-by-step electrolytic removal of thin layers. The stress profiles were pre-processed through interpolation and averaged stress was calculated as a function of depth below the surface. Correlation analysis was carried out to evaluate the relationships between BN features and stress at different depths and among BN features. The main outcome of the analysis was that BN measurement is dominated by the sub-surface tensile stresses rather than the compressive stress at the surface. It was also noticed that BN features form two groups, corresponding to average Barkhausen activity and magnetising field strength leading to maximum Barkhausen activity. Models for stress at different steps were identified systematically. The performance of the models for sub-surface stresses was reasonable with R2 values of around 0.85 and root mean squared error (RMSE) values of around 95 MPa. Based on the results, it is concluded that BN measurement provides information about sub-surface stresses and that stress can be evaluated through straightforward modelling, allowing fast detection of grinding burns.

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“…8,9 Therefore, gear teeth surface integrity plays a decisive role in the gear service performance, including such indicators as longer life and lower noise. 10 These two factors should be comprehensively considered for the gear designation. On the one hand, in order to enhance the gear bending and contact fatigue resistances, it is necessary to adopt non-damaging mechanical processing technology.…”

Section: Introductionmentioning

confidence: 99%

Ultrasonic assisted machining of gears with enhanced fatigue resistance: A comprehensive review

Bie

Zhao

et al. 2022

Advances in Mechanical Engineering

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In recent years, ultrasonic-assisted machining (UAM) has been widely implemented to improve the performance and element quality of machined products. This paper comprehensively reviews the ultrasonic vibration effects on such ultrasonic vibration-assisted (UVA) processes as hobbing (UVAH), lapping (UVAL), electrochemical gear machining (UVAEGM), honing (UVAH), and grinding (UVAG), respectively. Compared with the conventional machining, the UAM significantly reduced the surface roughness, improved the surface microstructure, and quality. Considering the UAM applications surface modification and surface strengthening, the available technologies of ultrasonic impact, ultrasonic shot peening, and ultrasonic deep rolling were analyzed for gears and similar components. It was concluded that the surface was strengthened under UAM through introducing the high-amplitude and large-depth residual compressive stresses, restraining crack propagation to a certain extent, and improving the gear fatigue resistance. Finally, the ultrasonic machining effect on gear fatigue resistance was theoretically substantiated from the ultrasonic vibration system and surface integrity standpoints. This review aims to optimize the application of ultrasonic-assisted machining, in order to produce gears with enhanced fatigue resistance and surface integrity.

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Surface integrity aspects in gear manufacturing

Cited by 14 publications

References 12 publications

Quality evaluation of effective abrasive micro-edge honing based on Tra-FAH and SPA

Quality evaluation of effective abrasive micro-edge honing based on Tra-FAH and SPA

Sub-Surface Analysis of Grinding Burns with Barkhausen Noise Measurements

Ultrasonic assisted machining of gears with enhanced fatigue resistance: A comprehensive review

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