Tooth surface roughness model based on kinematics of continuous generating grinding

The requirements for tooth surface roughness in high-end equipment are becoming increasingly strict, which is associated with load-bearing capacity and reliability of gears in the transmission system. To address this issue, tooth surface roughness model based on kinematics of continuous generating grinding is proposed. The roughness model considers the influence of material removal mechanism, discrete generating motion, and equivalent cutting model on tooth surface roughness. Among them, the equivalent cutting model is introduced to conduct contact analogy for continuous generating grinding, in order to establish the relationship between cutting depth and tooth surface roughness. On this basis, based on the kinematics of continuous generating grinding, the velocity vector of the gear, the velocity vector of the grinding wheel, and the relative velocity vector between the gear and grinding wheel are obtained, thereby calculating the tooth surface roughness. According to the obtained tooth surface roughness, the reasons for the uneven distribution of roughness are analyzed, and the effect of grinding process parameters on roughness is explored. Finally, the proposed roughness model is verified through experiments. The experimental results show that the relative error between theoretical and actual roughness does not exceed 7.88 %, indicating that the roughness model can provide new insights for optimizing process parameters in continuous generating grinding processes to achieve higher tooth surface quality.