Gear Grinding Machines – Diamond and CBN Toolskadkraft.com/wp-content/uploads/2015/12/PRESENTATION-Reishauer... · Reishauer Process Development Tooling The Reishauer-Superfinishing

Gear Grinding Machines – Diamond and CBN Tools

Reishauer Generating Gear Grinding

© Reishauer AG Industriestrasse 36, 8304 Wallisellen, Switzerland +41 44 832 22 11 [email protected] www.reishauer.com

Gear Grinding

Generating Grinding Form Grinding

Di C ti C ti


Di C ti C tiDis-Continuous Continuous Dis-Continuous Continuous

© Reishauer AGNovember 2015

Page 2Gear Grinding

Gear Grinding


Di C ti C ti


Di C ti C tiDis-Continuous Continuous Dis-Continuous Continuous


Page 3Gear Grinding

RZ 410, 2010Flexible


RZ 60 / 160 / 260 / 360from 2012 – Automotive, Truck

RZ 60 / 160 / 260 / 360from 2012 – Automotive, Trucko 0 uto ot e, uco 0 uto ot e, uc

RZ 630, 2007Industrial Transm.

RZ 630, 2007Industrial Transm.

RZ 800, 2007Printing Machines

RZ 800, 2007Printing Machines

RZ 1000, 2007Wind Power

RZ 1000, 2007Wind Power




Page 4Reishauer Gear Grinding

Industrial Transm.Industrial Transm. Printing MachinesPrinting Machines Wind PowerWind PowerFlexibleFlexible

Setup

quick-change of OperatorAutomatic setting of all axis positionsand automatic positioning of the

diamond toolOperator and automatic positioning of thediamond tool, the grinding wheel andthe workpiece.

First automatic dressing of thegrinding wheel and grinding of thefirst workpiece.


Page 5Productivity


Page 6Productivity

Noise ReductionMinimized waivinessin profile direction

Minimized vibration and frequencyin drive system

Specific profile-and lead modification

LNS(Low Noise Shifting)


Page 7Functionality

Noise Reduction

LNSLNS (Low Noise Shifting)


Page 8Functionality

Statistically shortened waviness in axial direction (Low NoiseLow Noise Shifting LNS direction (Low Noise Shifting)

Yesterday: Today:generating grinding without LNS

ial d

irect

ion

Yesterday:

ial d

irect

ion generating grinding with LNS

Yesterday:

Ax

Profile direction

Ax

Profile direction

Today:

and or

generating grinding without LNS Honing generating grinding with LNSHoningHoning


Page 9

9ge e at g g d g t out S Honing generating grinding with LNSHoningHoning

Functionality

Mi i i d ib tiNoise Reduction

Minimized waivinessin profile direction




Page 10Functionality

Waiviness and Ghost Frequency

“Macro-waviness” “Ghost frequencies”_f_BCZ_Ordnung_ schwe

2.0Winkel_Sekunde P_P

past today

pastLimit

0.8

1.0

1.2

1.4

1.6

1.8

y = 0.8233 Winkel_Sekunde P_Px = 161.590 Ordnung (Bezugsfrequenz)

0.0

0.2

0.4

0.6

y = 0.2107 Winkel_Sekunde P_Px = 125.872 Ordnung (Bezugsfrequenz)

80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200Ordnung (Bezugsfrequenz)

10.08.00 14:35:45 Abt. 0672, Masch-Messung, Masch: 73996m Mess-Nr: 00002, n= 1881.5 1/min, Schlichthub,

today

Limit

Improved by:- Fine balancing- Defined number of grinding wheel starts- Increased Machine stiffness


Page 11

11- Increased Machine stiffness

Functionality

Noise ReductionMinimized waivinessin profile direction


Specific profile-and lead modification




Profile modification

Profile with tip relief


Page 13

13Functionality

Option:Line Dressing


Page 14Line Dressing

Topological Dressing of Profile

crowning tip and root reliefprofile angle


Page 15Line Dressing

Diamond ToolsDiamond ToolsDiamond Roll Set 1-start Diamond Profile Roll

Di d F ll P fil R ll Di d D bl T Di k

Module 1.5 - 5 Module 1.0 – 5 (10)

Diamond Full Profile Roll Diamond Double Taper Disk

Diamond Radius Form RollDiamond Dressing Tools

O t di t 123

Module 0.5 – 1.5 Module 1.0 – 5 (10)

Outer diameter 123 mmOuter diameter 160 mmBore diameter 52 mm


Page 16Dressing

Change of pressure angle modifications and corrections separate for:

left flank rigth flank


Page 17

17Dressing

Lead modification


Page 18

18Functionality

Constant Contact Pattern



Lead modification



Past:

Lead modification

Today on all Reishauer machines possible,tomorrow requested from R&D



Root and Lead Load Capacity

CompressiveConstant contact Modifications — Compressive residual stress

Constant contact pattern due to accuracy of profile, lead and pitch

Modifications specific to load conditions

lead and pitch

Root load capacityFlank load capacity Root load capacityFlank load capacity



Defined Root Grinding

Not allowed because of Protuberance requires Defined root radius Full form grinding

ae = Stock allowance per flanc St k ll i th t

grinding step excellent pre machining


Page 23

ae = Stock allowance in the root

Functionality

Compressive Residual Stress

Compressive residual stress in tooth flank

Flank

stress in tooth flank

Flank

Compressive residual30 30

Root

Compressive residual stress in tooth root

Root



Compressive Residual Stress

-400

-200

0

s ES

/MPa

-1000

-800

-600

-400

Res

idua

l stre

ss

-400

-300

-200

-100

0

al s

tress

ES

/MPa

10000 0.02 0.04 0.06 0.08 0.1

Distance from surface [mm]

-700

-600

-500

0 0.02 0.04 0.06 0.08 0.1


Res

idua

0a

-500

-400

-300

-200

-100

sidu

al s

tress

ES

/MPa

-600

500

0 0.02 0.04 0.06 0.08 0.1


Res




Page 26Standard and Polish Ground Gear

ToolingReishauer Process Development ToolingThe Reishauer-Superfinishing use one grinding worm for the total grinding operation as grinding tool . The grinding wheel is divided in two zones with different specifications.

Reishauer Process Development

The geometry of the grinding wheel isThe geometry of the grinding wheel is done with standard Reishauerdressing tools and the same dressing technology used for generating grinding


Page 27Reishauer-Superfinishing


Page 28Polish Grinding Prinziple

ResultsReishauer Process DevelopmentStandard-generating grinding

Material fraction left flank

ResultsReishauer Process Development

Reishauer-Superfinishing

0.81 µm

1.08 µm

Material fraction right flank

µ

With removal of the material peak the material fraction of the superfinished surface increase.


Page 29

p

Reishauer Polish Grinding

Gear load bearing capacity

Gear wear behaviour


Page 30Abbott Material Ratio Curve

Special Profile



fully shapedtooth tip

fully shapedfully shapedroot

involutes



Inspection offull shape

Inspection ofinvolute area



Special Application

Without negative crowning bad pattern


Page 34Special Application

Profile Grinding



Profile Grinding Dressing Condition



Hardness

Maximum Hardness 62 HRc (740 Hv)Maximum Hardness 62 HRc (740 Hv)

Hardness over HRc 62:

-Difficult / impossible to grindHigh risk for cracks-High risk for cracks

-High risk for burning


Page 37Pre – Work Condition

Quality

P k lit b tt th DIN 10Pre-work quality better then DIN 10

R t d A l t d Pit h E b tt th DIN 9Runout and Accumulated Pitch Error better the DIN 9Fp and Fr less then 100 µm


Page 38Pre – Work Condition


Page 39REISHAUER GENERATING GRINDING

Documents

Gear Grinding Machines – Diamond and CBN Toolskadkraft.com/wp-content/uploads/2015/12/PRESENTATION-Reishauer... · Reishauer Process Development Tooling The Reishauer-Superfinishing