Surface structuring using kinematic modulation in grinding

A sustainable use of resources is rising to the top of the scientific agenda for industry and research institutes. Issues like raising power density, functional safety and reliability of machine components as well as the reduction of energy consumption during manufacturing and operation can lead to a sustainable use of resources. Offshore wind power stations for example can make a major contribution to resource conservation. The economic and ecological success of these plants is decisively dependent on the reliability of the gears, as the costs for maintenance and repairs especially offshore are very high. To meet high demands in terms of accurate dimensions and shape, as well as high surface qualities, innovative approaches for the manufacturing process of functional surfaces are pursued. The development of a kinematic modulated grinding process can lead to specific surface structures of functional surfaces. A reduction of surface roughness combined with tailored surface structuring offers a longer service life and higher power density of rolling contact partners, by influencing the distribution of the lubricant film positively. As a result, the squeezing of the lubricant film is more difficult. The basis for the technological investigation is a mathematical modeling of producible surface structures by using an additional movement. Based on the results given by the simulation, appropriate surface structures for rolling contacts can be identified and evaluated.