Stirnradbearbeitung im Tauchgleitschleifen/Stream finishing of spur gears

Das Tauchgleitschleifen als eines der produktivsten Gleitschleifverfahren hat sich bei der Endbearbeitung komplexer Bauteile am Markt etabliert und eröffnet zunehmend neue Möglichkeiten in der Auslegung von Fertigungsketten und der Substitution bisheriger Endbearbeitungsprozesse in der Verzahnungsherstellung. Dieser Beitrag behandelt die Optimierung der Oberflächenrauheit und -textur von geradverzahnten Stirnrädern durch Untersuchungen mittels im Zahnrad integrierter Metallstreifen.   Stream finishing, as one of the most productive mass finishing processes, has been established on the market for finishing complex components, providing new options in the design of production chains and in the substitution of existing finishing processes in gear manufacturing. This paper focuses on the optimization of surface roughness and texture of spur gears by means of investigating metal strips integrated in the gear.

Minimum surface roughness using rule-based modeling of the vibratory finishing process in a high-frequency bowl system

Previous work on vibratory finishing has led to a better understanding and establishment of the mass finishing processes. Despite the sustained efforts made to date, vibratory finishing remains a field where the findings made have been based largely on empirical evidence. Through force sensor analyses and scanning electron microscopy imaging, in this work a successful attempt has been made in uncovering the underlying science—through first principles of Newtonian physics—behind vibratory finishing, providing explanations for the observations made. Trials were carried out in a high-frequency vibratory bowl, the first of its kind in the vibratory finishing industry. Through these trials, mathematical formulations have been derived, essentially providing a reliable way for the industry to estimate the process cycle time.

The Effect of Selected Parameters of Vibro-Abrasive Processing on the Surface Quality of Products Made of 6082 Aluminium Alloy

Vibro-abrasive processing is the basic method for the mass finishing of parts and components in various industries. Continuous progress in the development of processing media and machine design solutions means that every research effort into vibro-abrasive processing broadens the scope of knowledge in the selection of media, parameters, and applications in various industry fields. In this paper, an attempt is made to parametrize the vibratory grinding process, which is one of the three stages of high gloss finishing. Samples of the 6082 aluminium alloy intended for use in loaded machine parts and forged car wheel rims were subject to a research analysis. The samples were processed in a rotary vibrator equipped with a sample fixing system, using resin media and auxiliary com-pounds. On the basis of the analysis, the processing capacities were determined for the selected conditions and abrasive media. The influence of time and applied processing media on the change in samples’ roughness was determined. The effects of processing were examined with the use of laser devices measuring surface roughness in the areas of 3D and 2D analysis. The analysis of the test results showed that the use of S12TZ type resin media in a 12-hour finishing process of the 6082 aluminium alloy allowed for a 75.5% reduction in surface roughness, which corresponds to approximately 6.3% per hour of processing.

Multiscale 3D Curvature Analysis of Processed Surface Textures of Aluminum Alloy 6061 T6

The objectives of this paper are to demonstrate the viability, and to validate, in part, a multiscale method for calculating curvature tensors on measured surface topographies with two different methods of specifying the scale. The curvature tensors are calculated as functions of scale, i.e., size, and position from a regular, orthogonal array of measured heights. Multiscale characterization of curvature is important because, like slope and area, it changes with the scale of observation, or calculation, on irregular surfaces. Curvatures can be indicative of the topographically dependent behavior of a surface and, in turn, curvatures are influenced by the processing and use of the surface. Curvatures of surface topographies have not been well- characterized yet. Curvature has been used for calculations in contact mechanics and for the evaluation of cutting edges. Manufactured surfaces are studied for further validation of the calculation method because they provide certain expectations for curvatures, which depend on scale and the degree of curvature. To study a range of curvatures on manufactured surfaces, square edges are machined and honed, then rounded progressively by mass finishing; additionally, a set of surfaces was made by turning with different feeds. Topographic measurements are made with a scanning laser confocal microscope. The calculations use vectors, normal to the measured surface, which are calculated first, then the eigenvalue problem is solved for the curvature tensor. Plots of principal curvatures as a function of position and scale are presented. Statistical analyses show expected interactions between curvature and these manufacturing processes.