Analytical modeling of grinding force and experimental study on ultrasonic-assisted forming grinding gear

This study aimed to propose an ultrasonic-assisted forming grinding (UAFG) gear processing method that would enhance the processing efficiency of traditional forming grinding (TFG) gears and reduce the surface damage of gears caused by excessive grinding force. The actual cutting arc length of the grain was deduced by analyzing the separation time of the adjacent grain of the forming wheel. This was combined with the actual cutting depth of the grain to establish the grinding force in the UAFG method. The established theoretical model could predict the grinding force. The results indicated that the grinding force of TFG was larger than that of UAFG under the same condition. In this process, the effect of each processing parameter on the grinding force was in the following sequence: ultrasonic amplitude, grinding wheel speed, grinding depth, and feed speed. The influence of the grinding force on the surface quality was examined based on the grinding force model. The results showed that UAFG helped remove the gear tooth surface material and improve grinding surface quality. The study provided a new research method to improve the machining efficiency and surface quality of the forming grinding gear.