Acoustic Optimization of Cylindrical Gears using Targeted Micro Geometry Scattering: Challenges and Potentials of Continuous Generating Grinding
Alexander Mann
Value for the audience
Die Teilnehmenden erfahren über Potenziale des Wälzschleifverfahrens zur Herstellung anregungsreduzierter Stirnradverzahnungen durch Mikrogeometriestreuungen mithilfe von eher unkonventionellen Ansätzen. Hierbei werden die guten Produktivitätseigenschaften aus dem Wälzschleifprozess mit den akustischen Vorteilen gezielter Mikrogeometriestreuungen vereint. Insbesondere Maschinenhersteller könnten aus dem Vortrag Ideen und Ansätze entwickeln.
Summary
The increasing relevance of noise emissions in the automotive sector due to drivetrain electrification are leading to the steadily growing importance of gearbox acoustics. Tonal components in the noise spectrum in particular can be perceived as unpleasant. Targeted micro geometry scatterings can counteract this effect. A micro geometry scattering can be understood as a variation of conventional standard tooth flank modifications, which are selectively distributed on the teeth over the gear circumference. Until now, this approach could only be realized in the discontinuous profile grinding process. In contrast, continuous generating grinding offers more productive series production, but is restricted by process-related manufacturing limitations. It was not previously possible to produce targeted micro geometry scatterings in this process.
Manufacturing simulations can be used to model the process at an early stage of development in order to investigate manufacturability. This paper therefore presents a method for the geometry calculation of cylindrical gears with multi-start grinding worms with differently dressed starts. An elementary component of this method is the positionally correct rolling simulation and the pre-calculation of the meshing conditions between tool and workpiece. It is also possible to specify variable grinding worm start geometries. The effects of different design strategies for the individual grinding worm starts are investigated using common-divisor- and relatively-prime grinding in order to analyze the manufacturability of targeted micro geometry scattering in this process in more detail. The implemented functions of the method are verified by applying them to an example gear geometry. The manufacturing simulation thus forms the basis for the computational generation of targeted micro geometry scattering in the generating grinding process and can provide future support in the investigation of manufacturability.