Discontinuous Generating Gear Grinding Optimization

Gear grinding on the MAAG machines allows obtaining a high degree of accuracy of gears but is characterized by a considerable investment of time. In contrast to the copying method, with MAAG discontinuous generating gear grinding, the contact zone of a grinding wheel with a flank of a tooth has a small area. As a consequence, a large number of gear grinding strokes are required to remove the unevenly spaced gear grinding stock allowance. Any the operation is forcing increases the possibility of grinding burns. In this regard, there is a need to optimize the gear grinding parameters, i.e., to increase these parameters so that the resulting burn layer does not exceed the remaining stock allowance for gear grinding. An optimization model is created and studied for two successive stages of the life cycle of gear: at the pre-production stage (gear grinding operation designing) and at the stage of production itself, i.e., at the gear grinding with optimal parameters - both mode parameters (grinding depths) and gear grinding power ones. The primary attention is paid to the pre-production stage, where optimization is a method of operation design. The MAAG machine is equipped with an automatic gear grinding power control system at the production stage. As the input of this system, the specified gear grinding power setpoints were found at the pre-production stage. Automatic robust gear grinding power control allows “continuing optimization” at the production stage to consider random factors that cannot be considered at the pre-production stage. Therefore, such optimization continuing at the production stage is a control method.