Integrated novel modeling approaches for non-uniform heat source and temperature field in gear profile grinding

Temperature field prediction for the gear profile grinding process is an essential theoretical basis for preventing grinding burn and is significant to gear performance improvement. However, the existing models rely on the secondary development of finite element software, which has the disadvantages of prolonged time consumption and poor robustness and is limited to the guidance of the actual process. This study presents an efficient calculation model integrated with the heat source and temperature field of gear profile grinding, considering the non-uniform and complex boundary conditions on the local area of the gear tooth flank. Based on the proposed model, the relationship of grinding parameters and the tooth temperature field is established in detail. Besides, the risk assessment and prevention strategy of grinding burn for gear profile grinding are conducted to optimize the processing parameters. According to the gear profile grinding experiments, the maximum error of peak grinding temperature between the calculated and experimental values is less than 4.1%, which verifies the accuracy of the proposed model. This work offers an effective tool for improving gear profile grinding technology and could be applied to other mechanical components with complex surfaces.