Gear Profile Grinding

Discontinuous gear profile grinding is commonly used in the manufacture of large-module gears. And because the batch sizes are typically small to medium, the process must be highly flexible. In order to achieve this flexibility, dressable—rather than CBN-plated—grinding wheels can be applied. But in using these tools, the process robustness can be compromised by local structural damage—such as grinding burn—to the external zone. In tooth-flank profile grinding, due to the variation of contact conditions along the profile between grinding wheel and tooth flank, process optimization is difficult. And in comparison with other grinding processes, these conditions clearly lead to varying grinding conditions along the profile. Examination of the complex geometrical and contact conditions requires fundamental technological investigations in an analogy process. In this way, the relationship between various material removal conditions can be investigated as functions of the machining parameters and grinding wheel specifications.