Data-driven bending fatigue life forecasting and optimization via grinding Top-Rem tool parameters for spiral bevel gears |
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| Affiliation: | 1. State Key Laboratory of High Performance Complex Manufacturing, Central South University, Changsha 410083, China;2. School of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China;1. State Key Laboratory of High-performance Complex Manufacturing, Central South University, Changsha 410083, China;2. School of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China;1. State Key Laboratory of High Performance Complex Manufacturing, Central South University, Changsha, China;2. School of Mechanical and Electrical Engineering, Central South University, Changsha, China;1. State Key Laboratory of High Performance Complex Manufacturing, Central South University, Changsha 410083, China;2. School of Mechanical and Electrical Engineering, Central South University, Changsha 410083, China;3. Zhejiang Asia-Pacific Mechanical & Electronic Co., Ltd, Hangzhou 310007, China;4. AECC Hunan Aviation Powerplant Research Institute, Zhuzhou 412002, China |
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| Abstract: | To establish a bridge between grinding tool parameters and loaded tooth fatigue life, an innovative data-driven root flank bending fatigue life forecasting and optimization via Top-Rem tool parameters was proposed for grinding spiral bevel gears. The recent machine settings modification is extended into grinding Top-Rem tool parameters modification in case that geometric accuracy and root bending fatigue life are integrated into a collaborative optimization. The proposed Top-Rem modification includes three key steps: (I) arc-shaped blade, (II) top part, and (III) top fillet part. Then, while root bending stress is determined by using finite element method (FEM)-based simulated loaded tooth contact analysis (SLTCA), data-driven fatigue life forecasting is developed by correlating with the multiaxial fatigue damage model based assessment. Moreover, data-driven bending fatigue life optimization model is established by using Top-Rem tool parameters modification, where the important constraints in target flank determination includes: (i) root overcutting, (ii) geometric accuracy, and, (iii) fatigue life. For high accuracy and efficiency, two different strategies are proposed: (i) the different parameters modification types; and, (ii) sensitivity analysis of grinding Top-Rem tool parameters. Finally, proposed method can verify that bending fatigue life can be significantly improved by modifying the key Top-Rem tool parameters in early stage of the whole life product development for spiral bevel gears. |
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| Keywords: | Spiral bevel gears Bending fatigue life forecasting and optimization Grinding Top-Rem tool parameters Root bending stress Simulated loaded tooth contact analysis (SLTCA) |
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