Modeling of tool load for optimization of tool life in diagonal generating grinding

Diagonal continuous generating grinding with ceramic bonded wheels is commonly used for hard finishing of automotive gears with topological modifications. In this process, areas of the grinding wheel have to be used repeatedly to machine multiple components, resulting in not achieving the same tool life as conventional generating grinding. This paper presents a detailed process model predicting loads on the wheel as a basis for an optimization of tool life. Based on a redistribution of the roughing and shifting areas of the grinding wheel, significantly lower wear could be demonstrated in tests.