Grinding force model for gear profile grinding based on material removal mechanism

Traditional force models fail to predict the grinding force for gear profile grinding accurately owing to the specific grinding geometry and kinematics. On the other hand, few researchers about gear profile grinding concern the grinding force. To address this issue, a model to predict the grinding force for gear profile grinding is proposed. This comprehensive study consists of three aspects, namely, the wheel model, the kinematics model, and the force model. Unlike other wheel models for the grinding process, the cumulative number of grinding points in this wheel model is a variable depending on the radius infeed depth. A specific model for grinding geometry and kinematics of gear profile grinding are established based on the processing principle and grain-workpiece contact. Then, the force model is proposed considering the effect of grinding stages and the transformation matrix of the local coordinate system for abrasive grain. To verify the proposed model, experiments are conducted based on specific operations to overcome measurement restrictions, and the effects of grinding parameters on force components are investigated. The proposed models not only predict the grinding force but also reveal the differences between the material removal mechanism for gear profile grinding and that for surface grinding.