The temperature field study on the three-dimensional surface moving heat source model in involute gear form grinding

Form grinding is one of the most important finishing processes for obtaining high surface quality gears. Nevertheless, to avoid thermally induced burning and structural change poses a major challenge for this manufacturing technology. Based on the moving heat source model and the superposition principle of heat sources, a comprehensive analytical thermal model for analyzing the heat transfer mechanism of involute gear form grinding was derived. A three-dimensional distribution model of equivalent grinding heat source considering the non-linear distribution of tangential grinding force, grinding parameters, and heat partition ratio was proposed. The FEM (finite element method) simulation of the grinding temperature field was carried out to predict the grinding temperature field using a nested net heat flux equation. Research results have shown that the grinding temperature increases nonlinearly with the rolling angle increasing and the evident peak grinding zone temperature appearing near the tip of the tooth. Through the comparison with the previous experimental measurement results, it is found that the temperature distribution of analytical calculation and numerical simulation agrees well with the measured results.