Model of Surface Texture for Honed Gear Considering Motion Path and Geometrical Shape of Abrasive Particle

Abstract Gear power-honing is mainly applied to finish small and medium-sized automotive gears, especially in new energy vehicles. The distinctive curved surface texture greatly improves the noise emission and service life of honed gears. The surface texture for honed gear considering the motion path and geometrical shape of abrasive particles has not been investigated. In this paper, the kinematics of the gear honing process is analyzed, and the machining marks produced by the abrasive particles of honing wheel scratching abrasive particles against the workpiece gear are calculated. The tooth surface roughness is modeled considering abrasive particle shapes and material plastic pile-ups. This results in a mathematical model that characterizes the structure of the tooth surface and the orientation of the machining marks. Experiments were used to verify the model, with a maximum relative error of less than 10% when abrasive particles are spherical. Based on this model, the effects of process parameters on the speeds of discrete points on the tooth flank, orientations of machining marks and roughness are discussed. The results show that the shaft angle between the workpiece gear and the honing wheel and the speed of the honing wheel is the main process parameters affecting the surface texture. This research proposes a surface texture model for honed gear, which can provide a theoretical basis for optimizing process parameters for gear power-honing.