Impact of gear finishing processes on micro geometry - simulation of defective production processes and resulting acoustic properties

The manufacturing process has substantial influence on the resulting surface topography of the gear. This topography varies not only with different production techniques, in addition to that technological properties as well as deviations have significant consequences. Regarding the deviations a distinction between kinematic and geometric deviations is useful. In this paper, a simulation-based investigation on two production techniques is presented. Gear skiving as a soft machining process and generation grinding as a common finishing process are chosen. For both processes the underlying kinematics are expounded as well as different cutting models for defined and undefined cutting edge. Following this, the influence of typical technological parameters on the resulting micro geometry is discussed as well as the effects of kinematic and geometric deviations. Furthermore the resulting micro geometry is analyzed regarding its acoustic behavior. It is shown that ripples which may cause so-called ""ghost frequencies"" can be induced by a wide field of vibrations or deviations. In some circumstances complex relationships to the resulting undulation due to the tool geometry and process kinematics exist.