Numerical method for dynamic prediction of temperature field in aviation gear profile grinding

High-strength aviation gears are notably challenging to grind, primarily due to an increased risk of grinding burn. Consequently, the precise and efficient prediction of the three-dimensional temperature distribution throughout the grinding process of aviation gears is crucial. This study focuses on aviation gear in 12Cr2Ni4A material, devising a dynamic, time-variant triangular heat source model alongside a method for calculating the three-dimensional grinding temperature field for aviation gears. By proposing an accurate loading algorithm for the boundary conditions of the moving heat source load on the spatially curved surface in the grinding area and then directly solving the heat transfer differential equation constructed in a fully discrete form based on the principle of minimum potential and the Ritz method, a high-strength aviation gear grinding temperature field prediction model has been established. The accuracy of this proposed method was confirmed through experimental temperature measurements of gear grinding and by comparing these results with those obtained from standard finite element software. The results show that the maximum relative error between prediction values and experimental data is less than 5%. Moreover, when contrasted with the simulation results of standard finite element software, the present approach exhibits superior computational efficiency and accuracy. The developed numerical method reliably forecasts the temperature distribution throughout the gear grinding process and provides a significant reference for precise and efficient temperature field calculations.