Analysis of Thermal Loads in Generating Gear Grinding for Residual Stress Prediction

• Applicant: Professor Dr.-Ing. Thomas Bergs
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 542796554

Motivated by the need of enhancing the gear’s lifetime, a predictive model is required in order to design a generating gear grinding process focused on the achievement of a beneficial state of residual stresses. For the development of the predictive model, a hybrid approach is considered a suitable solution based on the grinding process characteristics. Despite of its advantages, the hybrid approach requires a good description of thermal and mechanical loads with accurate spatial and time resolution in the contact zone. Existing analytical models for mechanical load considering micro-interaction characteristics were already verified. However, there is still a lack of validated models for the thermal loads in generating gear grinding process, due to the lack of local temperature measurements. Furthermore, the validated thermal and mechanical loads models can also be used in combination with data analysis models for the support not only in the prediction of residual stresses but also in set-up of the process. In order to improve the prediction of residual stresses and oriented control of generating gear grinding process, the application and positioning of a suitable sensor, the analysis of data, and development of a method for combination between the thermal models and data analysis are required.

• DFG Programme: Research Grants