Data-driven bending fatigue life forecasting and optimization via grinding Top-Rem tool parameters for spiral bevel gears. (August 2022)

• Record Type: Journal Article
• Authors: Ding, Han; Zhang, Yuntai; Kong, Xiannian; Shi, Yingjie; Hu, Zehua; Zhou, Zhenyu; Lu, Rui
• Is Part Of: Advanced engineering informatics. Volume 53(2022)
• Publication Date: 2022-08
• Subjects: Spiral bevel gears -- Bending fatigue life forecasting and optimization -- Grinding Top-Rem tool parameters -- Root bending stress -- Simulated loaded tooth contact analysis (SLTCA); Computer-aided engineering -- Periodicals; Engineering -- Data processing -- Periodicals; 620.00285
• DOI: 10.1016/j.aei.2022.101724
• Languages: English
• ISSNs: 1474-0346

Abstract

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.