Bending fatigue life oriented tooth flank dry-grinding tool modification for cleaner manufacturing of spiral bevel gear product

Abstract Gear tooth flank dry-cutting was beget with emergent and disruptive NC technology. This new technology is enabling ever-higher levels of production efficiency and sustainability. It also has the potential to dramatically influence sustainable development of spiral bevel gear product. Sufficient guidance, in this respect, is lacking in the scholarly or practitioner literature. In this work, focusing on spiral bevel gear production, we further examine dry-cutting technology in terms of application and sustainability implications. We introduce bending fatigue life design into gear dry-grinding by considering various economic, environmental and social attributes. We also develop bending fatigue life oriented tooth flank dry-grinding tool modification by incorporating a high life cycle assessment (LCA) and low life cycle cost (LCC). At first, data-driven tool modification design relating to dry-grinding tool parameters is developed. Then, finite element method (FEM) based root bending fatigue assessment is performed by using the multiaxial fatigue damage model. Here, with data-driven finite element modeling, simulated loaded tooth contact analysis (SLTCA) is employed to root bending stress determination. They were introduced into the multiaxial fatigue damage model based fatigue life assessment. Moreover, focusing on the minimum fatigue at dangerous point namely fatigue limit, bending fatigue life oriented dry-grinding tool modification model considering geometric accuracy is established. Then, data-driven adaptive feedback and optimization is performed by using tool modification. The final output tool modification parameters can be used to obtain the cleaner manufacturing of gear product both flank geometric accuracy and fatigue life. Finally, the numerical instance was given to verify the proposed method. By building a bridge between the tool parameters in early design and the fatigue life in actual transmission, the proposed method can get a significantly important access to cleaner manufacturing of spiral bevel gears product.