Theoretical Analysis of Conditions for Improving Gear Grinding Accuracy and Productivity

Abstract

The aim of this study is a theoretical substantiation of the possibilities for increasing accuracy and productivity in gear grinding and determining the optimal machining conditions based on the reduction of elastic displacements arising in the technological system. The expediency of gear grinding using the profile copy method is shown based on a theoretical analysis of the conditions for increasing the accuracy and productivity of gear grinding operations. Compared to the traditional milling, this method has more significant technological capabilities in terms of improving the accuracy and productivity of machining. This machining effect appears while implementing the dead-stop grinding, which provides a significant reduction in elastic displacements that occur in the technological system due to the uneven removed stock. In this case, the main part of stock removal is carried out in terms of high-performance deep grinding. For the implementation of gear grinding using the profile copy method, an analytical ratio has been obtained to determine the lateral feed elastic displacement that occurs after each wheel pass. Using this ratio allows achieving high machining productivity with the required accuracy. It has also been found out that it is possible to increase the machining accuracy and productivity during milling by increasing the refinement of the wheel pass by reducing the conditional cutting stress. This can be achieved by using high porosity grinding wheels, providing a decrease in the friction intensity in the cutting zone due to their high cutting ability.