One possible process for hard finishing gears is generating gear grinding. Due to high process efficiency,
generating gear grinding has replaced other grinding processes like profile grinding in batch production of
small and middle sized gears.
Despite the wide industrial application of generating gear grinding, the process design is based on
experience and time and cost intensive trials. The science-based analysis of generating gear grinding
needs a high amount of time and effort and only a few published scientific analyses exist. In addition, the
transfer of existing knowledge from other grinding processes onto generating gear grinding is complicated
due to the contact conditions be-tween tool and gear flank, which change continuously during the grinding
process.
One research objective for generating gear grinding is to increase economic efficiency and productivity of
the process. At the same time gear quality must be equal or higher and the external zone must not be
damaged. However, especially the influence of the grinding process on the external zone in generating
gear grinding is unknown. In case of an inappropriate process design in combination with stock
deviations an unwanted process result or even a thermal damage of the external zone can occur. In this
report a thermo-mechanical process model, which describes influences on the surface zone in generating
gear grinding, is introduced.