Generating gear grinding is a method used for hard machining of gearbox gears. It facilitates a productive gear manufacturing with tight tolerances regarding surface roughness and geometrical accuracy. However, if the grinding is done with incorrect parameters, so called grinding burns can arise with consequences such as changes in surface hardness, changes in residual stress levels, surface embrittlement and compromised fatigue strength. This thesis investigates the gear tooth quality resulting from grinding parameters contributing to an improved grinding time. A literature study will cover gear geometries and material, grinding wheel properties, influences by grinding parameters and several verification methods. An experimental test will then be used to put four different grinding parameters to the test. The results showed that an increased cutting speed indicated finer surface roughness andincreased Barkhausen noise but showed no influence on gear geometry. Increasing both rough and fine feed rates resulted in a minor increase in geometry deviation but no significant difference in surface roughness. Large variations within the different verification method results related to grinding burns madeit difficult to draw conclusions regarding the experimental factors chosen. However, several factors apart from the experimental ones varied in the testing were believed to have significant influence, such as the flow of the cooling fluidand the amount of retained austenite from the carburizing process. In fact, the trends which seemed to be connected to these factors could be seen in both Barkhausen noise analysis, hardness measurementsand microstructure.

In der vorliegenden Arbeit wird ein Simulationsmodell entwickelt und validiert, welches die Hartfeinbearbeitung von Zahnrädern durch kontinuierliches Wälzschleifen abbildet. Dabei liegt ein besonderer Schwerpunkt auf der in fehlerbehafteten Prozessen erzeugten Flankentopografie und deren Bewertung hinsichtlich periodischer Strukturierung und des daraus resultierenden Einflusses auf den Drehfehler. Bei der Betrachtung verschiedener Prozessabweichungen zeigt sich eine starke Abhängigkeit der erzeugten Flankentopografien von verschiedenen Prozessparametern. Die simulativ erzeugten Flanken werden bezüglich periodischer Anteile der Strukturierung mit neuen Methoden analysiert und unter Berücksichtigung aller Zähne in einer Drehfehlersimulation hinsichtlich des Einflusses auf den Drehfehler bewertet. Zur Validierung des Simulationsmodells wird die Fertigung mit gezielter Schwingungsüberlagerung genutzt und Vergleiche sowohl bezüglich der erzeugten Flankentopografie als auch des Drehfehlers gezogen.:1 Einleitung 2 Stand der Wissenschaft und Technik 3 Ziel und Struktur der Arbeit 4 Analyse von periodisch strukturierten Zahnflankentopografien 5 Simulationsmodell 6 Simulationsergebnisse 7 Validierung anhand von Versuchen 8 Zusammenfassung und Ausblick / In this thesis a simulation model representing the hard fine machining of gears by continuous gear grinding is developed and validated. Special emphasis is put on the flank topography generated in faulty processes and its evaluation with respect to periodic structuring and the resulting influence on the transmission error in gear mesh. When considering different process deviations, a strong dependence of the generated flank topographies on different process parameters becomes apparent. The simulated flanks are analysed with new methods regarding periodic parts of the structuring and are evaluated in a gear mesh simulation regarding the influence on the transmission error, taking all teeth into account. For the validation of the simulation model, the manufacturing with targeted vibration superposition is used and comparisons are made with regard to the generated flank topography as well as the transmission error.:1 Einleitung 2 Stand der Wissenschaft und Technik 3 Ziel und Struktur der Arbeit 4 Analyse von periodisch strukturierten Zahnflankentopografien 5 Simulationsmodell 6 Simulationsergebnisse 7 Validierung anhand von Versuchen 8 Zusammenfassung und Ausblick

The diploma thesis deals with the technology of continuous generating gear grinding. With reference to this technology, used grinding wheels and grinding machines are described. A detailed analysis is devoted to the technological parameters of the grinding process and their influence on the resultant tooth flank surface integrity. In order to verify described rules, the diploma thesis contains results of practical experiments as well.