A parametric evaluation model of abrasive interaction for predicting tooth rough surface in spiral bevel gear grinding

The grinding of complex surface parts, such as spiral bevel gears (SBGs), involves intricate machine-tool settings and localized machining conditions. These factors contribute to the nonuniformity of the macro envelope and the complex cumulative behavior of grits, thereby increasing the challenge of predicting surface roughness. This paper proposes a novel parametric model that directly relates local envelope parameters influenced by machine-tool settings to abrasive interaction features. Four inclination angles are defined to describe the irregular abrasive posture and the coupled kinematics of generating grinding. Additionally, the calculation strategy of undeformed chip thickness with discrete grinding groove overlap is introduced. Based on the parametric model and the macro wheel-tooth geometry, we further simulate the micro-tooth surface and validate the simulation through experiments. The results indicate that the roughness of the convex surface of the pinion is lower compared to the concave surface. This discrepancy arises from variations in the equivalent contact radius and the inclined abrasive posture. Increasing the speed ratio between the tool rotation and the generating effectively reduces the roughness distribution discrepancy. This work provides a valuable guidance for the manufacturing of high-performance SBGs and quantifies the micro-topography evolution for any abrasive geometry, kinematics, and posture.