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

Einfluss der hartfeinbearbeitung auf die Mikrogeometrie - Simulation fehlerbehafteter Fertigungsprozesse und resultierender akustischer Eigenschaften
: Kimme, Simon; Bauer, Ruben; Drossel, Welf-Guntram; Putz, Matthias

VDI-Wissensforum GmbH; VDI-Gesellschaft Produkt- und Prozessgestaltung -GPP-:
6th International Conference on Gears 2015. Vol.1 : International Conference on High Performance Plastic Gears 2015, International Conference on Gear Production 2015; Europe invites the world; time and venue; October 5th to 7th, 2015, Technische Universität München (TUM), Garching (near Munich), Germany
Düsseldorf: VDI-Verlag, 2015 (VDI-Berichte 2255)
ISBN: 978-3-18-092255-3
International Conference on Gears <6, 2015, Garching>
International Conference on High Performance Plastic Gears <2015, Garching>
International Conference on Gear Production <2015, Garching>
Fraunhofer IWU ()
process simulation; gear skiving; generation grinding; acoustics; flank surface topography; defective production; ripple; ghost frequencies; micro geometry

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.