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@PHDTHESIS{Lhrer:1022437,
      author       = {Löhrer, Patricia Helena de Oliveira},
      othercontributors = {Bergs, Thomas and Rego, Ronnie Rodrigo},
      title        = {{I}nfluence of material removal mechanisms on
                      thermo-mechanical loads in continuous generating gear
                      grinding; 1. {A}uflage},
      volume       = {2025,19},
      school       = {Rheinisch-Westfälische Technische Hochschule Aachen},
      type         = {Dissertation},
      address      = {Aachen},
      publisher    = {Apprimus Verlag},
      reportid     = {RWTH-2025-10024},
      isbn         = {978-3-9855530-9-9},
      series       = {Ergebnisse aus der Produktionstechnik},
      pages        = {1 Online-Ressource : Illustrationen},
      year         = {2025},
      note         = {Druckausgabe: 2025. - Auch veröffentlicht auf dem
                      Publikationsserver der RWTH Aachen University. - Weitere
                      Reihe: Technologie der Fertigungsverfahren. - Weitere Reihe:
                      Edition Wissenschaft Apprimus; Dissertation,
                      Rheinisch-Westfälische Technische Hochschule Aachen, 2025},
      abstract     = {Continuous generating grinding is a precision finishing
                      process used at the final stage of gear manufacturing to
                      meet stringent requirements for dimensional accuracy and
                      surface integrity. To prevent undesirable alterations in
                      surface integrity caused by thermal effects during grinding,
                      it is essential to understand and control the heat flux
                      entering the workpiece. Predictive models can aid in this by
                      providing insights into heat flux behavior during the
                      grinding process. However, most existing models only
                      partially account for the characteristics of the grinding
                      worm and other factors that influence grain engagement. When
                      these factors are considered, it is often done in a highly
                      empirical way. This work presents a methodology for
                      calculating thermo-mechanical loads in generating gear
                      grinding, taking into account the specific characteristics
                      of the grinding worm and the factors affecting grain
                      engagement. The methodology begins with a grain grinding
                      energy model that considers the chip formation mechanisms
                      according to the kinematics of the generating gear grinding
                      process. Understanding the energy generated by individual
                      grains during material removal formed the foundation for
                      subsequent calculations of thermo-mechanical loads in the
                      generating gear grinding process. The next step involved
                      adapting the single-grain grinding energy model to account
                      for multiple-grain engagements in the generating gear
                      grinding process. This adaptation required calculating the
                      micro-interaction characteristics based on the kinematics
                      and specific conditions of generating gear grinding through
                      process simulation. Grinding energy was then calculated and
                      verified through analogy trials, which were designed to
                      simplify force measurements at specific contact points
                      during the process. Using the validated grinding energy
                      model, thermal loads were calculated based on multiple-grain
                      engagement, incorporating a new method for defining the heat
                      partition coefficient, εf, based on the previously
                      calculated grinding energy. This heat flux calculation was
                      subsequently applied to predict the maximum temperature in
                      the grinding contact zone. The maximum temperature
                      calculation utilized the model of Demetriou and Lavine
                      (DEME00). Temperature measurements from analogy trials were
                      used to validate the heat flux and temperature calculation
                      models. In conclusion, the thermo-mechanical load models
                      developed in this work, which are based on the
                      micro-interaction characteristics of generating gear
                      grinding, were successfully tested and verified. The model
                      effectively identified critical levels of thermal energy
                      under varying process parameters, offering a reliable tool
                      that con-siders characteristics of the grinding worm as well
                      as factors influencing grain engagement in a non-empirical
                      manner.},
      cin          = {417410 / 417400},
      ddc          = {620},
      cid          = {$I:(DE-82)417410_20140620$ / $I:(DE-82)417400_20240301$},
      pnm          = {WS-B1.III-neu - Drive Chain (X080067-WS-B1.III-neu) / EXC
                      2023: Internet of Production (IoP)},
      pid          = {G:(DE-82)X080067-WS-B1.III-neu / G:(GEPRIS)390621612},
      typ          = {PUB:(DE-HGF)11 / PUB:(DE-HGF)3},
      doi          = {10.18154/RWTH-2025-10024},
      url          = {https://publications.rwth-aachen.de/record/1022437},
}