Exploitable results High precision shave-grinding system for single step hard finishing operation of gears The research and development activities of the project will provide the basic technological parameters for grinding at low speed with a main emphasis on gears. The results lead to a new precision machining technology for the shave-grinding process of gears (including tools and process strategy). Additionally an optoelectronic system, which contains a charge coupled device (CCD)-camera, structured light and specific hardware/software will be connected to the machine to solve in process detection of surface defects. The work package will be done in a generic way so that a transferability to other products and branches is ensured. Shave grinding for hard finishing of gears Shave grinding (power honing) is a new technology for the hard finishing of gears. The technology is a new approach with high potential because it is free from thermal influence on the subsurface and produces a favourable surface texture. The research work included modelling the shave-grinding process allowing design of a suitable test bench. For the visualization of the shave grinding process the software VIRTUAL-NC from DENEB ROBOTICS has been used. The visualization could be enhanced easily to include the machine attachments. The following achievements resulted from the work: constraint model of parameters for shave-grinding process; test bench for new shave-grinding ring specifications; recommendations on shave-grinding tool performance for commonly used tool specifications; improvement of existing shave-grinding tool specification and development of new specification; graphic visualization of shave-grinding process; laboratory set up for visual inspection of helical gear wheels. As consequence of the improvements the shave-grinding process can be conducted in a more stable way. This leads to shorter cycle times and tool cost. The economic advantage can be estimated to 20-30% of the cost of the operation. Gears machined under above mentioned conditions do have a very favourable noise behaviour compared to gears machined with any other known finishing method. This shows that shave grinding today can be considered as a technology which gives, as far as gear noise is considered, results at a very reasonable cost level that can not be achieved with any other process. New environmental laws require a new generation of engines, especially in the truck industry, with a considerably reduced noise level. Searching for OpenAIRE data... There was an error trying to search data from OpenAIRE No results available
