Generating gear grinding is one of the most important finishing processes for small and medium-sized gears, its process design often determined by practical knowledge.
Therefore a manufacturing simulation with the capability to calculate key values for the process — such as the specific material removal rate — is developed here. Indeed, this
paper presents first results of a model for a local analysis of the value. Additionally, an empirical formula — based on a multiple regression model for a global value describing the process — is provided.
Cracks initiated at the surface of case-hardened gears may lead to typical life-limiting fatigue failure
modes such as pitting and tooth root breakage. Furthermore, the contact load on the flank surface
induces stresses in greater material depth that may lead to crack initiation below the surface if the
local material strength is exceeded. Over time the sub-surface crack propagation may lead to gear
failure referred to as “tooth flank fracture” (also referred to as “tooth flank breakage”). This paper explains the mechanism of this subsurface fatigue failure mode and its decisive influence factors, and presents an overview of a newly developed calculation model.