In‐process evaluation of continuous generating gear grinding for maintaining workpiece quality and acoustic behavior of gear wheels

Hard finishing of gearings such as continuous generating gear grinding is highly essential for manufacturers due to increasing demands on gearboxes regarding quality and economical aspects, especially in the growing field of electric mobility. Here, high requirements on the acoustic behavior and low production cost come into conflict in the last stage of manufacturing gearings in a particular way. Against this background, in‐process evaluation methods for manufacturing processes are developed in order to reduce scrap parts and to exploit the process limits by collecting and processing of sensor signal data and by adapting measures based on reasonable process models. This investigation shows how the condition of abrasive tools and workpiece quality are evaluated by means of process near acoustic emission sensor application and motor current of the grinding spindle in order to adapt shifting and feed movement in generating gear grinding process. A calculation method based on a simulation process model is introduced to characterize relevant vibration frequency bands and the resulting acoustically effective waviness on tooth flanks, depending on workpiece and process parameters. Appropriate adaption of the grinding process for increasing productivity while maintaining workpiece quality is based on the findings of an intelligent in‐process evaluation.