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Spur gear surface endurance tests were conducted to investigate CBN ground AISI 9310 spur gears for use in aircraft applications, to determine their endurance characteristics and to compare the results with the endurance of standard vitreous ground AISI 9310 spur gears. Tests were conducted with VIM-VAR AISI 9210 carburized and hardened gears that were finish ground with either CBN or vitreous grinding methods. Test conditions were an inlet oil temperature of 320 K (116 degree F), an outlet oil temperature of 350 K (170 degree F), a maximum Hertz stress of 1.71 GPa (248 ksi), and a speed of 10,000 rpm. The CBN ground gears exhibited a surface fatigue life that was slightly better than the vitreous ground gears. The subsurface residual stress of the CBN ground gears was approximately the same as that for the standard vitreous ground gears for the CBN grinding method used.
Cubic boron nitride (CBN) finishing of carburized gearing has been shown to have certain economic and geometric advantages and, as a result, it has been applied to a wide variety of precision gears in many different applications. In critical applications such as aerospace drive systems, however, any new process must be carefully evaluated before it is used in a production application. Because of the advantages associated with this process, a test program was instituted to evaluate the load capacity of aerospace-quality gears finished by the CBN process as compared to geometrically identical gears finished by conventional grinding processes. This article presents a brief description of the CBN process, its advantages in an aerospace application, and the results of an extensive test program conducted by Boeing Helicopters (BH) aimed at an evaluation of the effects of this process on the scoring, surface durability, and bending fatigue properties of spur gears. In addition, the results of an x-ray diffraction study to determine the surface and subsurface residual stress distributions of both shot-peened and nonshot-peened CBN-ground gears as compared to similar conventionally ground gears are also presented.
The merits of CBN physical characteristics over conventional aluminum oxide abrasives in grinding performance are reviewed. Improved surface integrity and consistency in drive train products can be achieved by the high removal rate of the CBN grinding process. The influence of CBN wheel surface conditioning procedure on grinding performance is also discussed.
Because of the better thermal conductivity of CBN abrasives compared to that of conventional aluminum oxide wheels, CBN grinding process, which induces residual compressive stresses into the component, and possibly improves the subsequent stress behavior. This thesis is the subject of much discussion. In particular, recent Japanese publications claim great advantages for the process with regard to an increased component load capacity, but do not provide further details regarding the technology, test procedures or components investigated. This situation needs clarification, and for the this reason the effect of the CBN grinding material on the wear behavior and tooth face load capacity of continuously generated ground gears was further investigated.
Dressable vitrified bond CBN grinding tools combine the advantages of other common tool systems in generating gear grinding. Yet despite those technological advantages, there is only a small market distribution of these grinding tools due to high tool costs. Furthermore, scant literature exists regarding generating gear grinding with dressable CBN. This is especially true regarding the influence of the grinding tool system on manufacturing-related component properties. The research objective of this report is to determine the advantages of dressable CBN tools in generating gear grinding.
Modern manufacturing processes have become an ally of the product designer in producing higher quality, higher performing components in the transportation industry. This is particularly true in grinding systems where the physical properties of CBN abrasives have been applied to improving cycle times, dimensional consistency, surface integrity and overall costs. Of these four factors, surface integrity offers the greatest potential for influencing the actual design of highly stressed, hardened steel components.
A considerable improvement in the performance of the machining of hard to grind materials can be achieved by means of CBN wheels.
Borazon is a superabrasive material originally developed by General Electric in 1969. It is a high performance material for machining of high alloy ferrous and super alloy materials. Borazon CBN - Cubic Born Nitride - is manufactured with a high temperature, high pressure process similar to that utilized with man-made diamond. Borazon is, next to diamond, the hardest abrasive known; it is more than twice as hard as aluminum oxide. It has an extremely high thermal strength compared to diamond. It is also much less chemically reactive with iron, cobalt or nickel alloys.
For over 50 years, grinding has been an accepted method of choice for improving the quality of gears and other parts by correcting heat treat distortions. Gears with quality levels better than AGMA 10-11 or DIN 6-7 are hard finished, usually by grinding. Other applications for grinding include, but are not limited to, internal/external and spur/helical gear and spline forms, radius forms, threads and serrations, compressor rotors, gerotors, ball screw tracks, worms, linear ball tracks, rotary pistons, vane pump rotators, vane slots, and pump spindles.
Until recently, form gear grinding was conducted almost exclusively with dressable, conventional abrasive grinding wheels. In recent years, preformed, plated Cubic Boron Nitride (CBN) wheels have been introduced to this operation and a considerable amount of literature has been published that claim that conventional grinding wheels will be completely replaced in the future. The superior machining properties of the CBN wheel are not disputed in this paper.
The bevel gear grinding process, with conventional wheels, has been limited to applications where the highest level of quality is required.
It isn't for everyone, but... Within the installed base of modern CNC gear profile grinding machines (approximately 542 machines worldwide), grinding from the solid isn't frequent, but a growing number of gear profile grinder users are applying it successfully using CBN-plated wheels.
The higher load carrying capacities, compact dimensions and longer life of hardened gears is an accepted fact in industry today. However, the costs involved in case hardening and subsequent finishing operations to achieve these advantages are considerable. For example, in order to achieve desired running properties on larger gears, it has been necessary to grind the tooth flanks. This costly operation can now be replaced, in many cases, by a new Hard Cutting (HC) process which permits the cutting of hardened gears while maintaining extremely low tooling costs.
In the quest for ever more exacting and compact commercial gears, precision abrasives are playing a key production role - a role that can shorten cycle time, reduce machining costs and meet growing market demand for such requirements as light weights, high loads, high speed and quiet operation. Used in conjunction with high-quality grinding machines, abrasives can deliver a level of accuracy unmatched by other manufacturing techniques, cost-effectively meeting AGMA gear quality levels in the 12 to 15 range. Thanks to advances in grinding and abrasive technology, machining has become one of the most viable means to grind fast, strong and quiet gears.
In conventional gear grinders, grinding wheels with Alundum grains and a hardness of about 2000 HV have been used for finishing steel gears with hardnesses up to about 1000HV. In this case, the accuracy of the gears ground is greatly affected by wear of the grinding wheel because the difference in hardness is comparatively small when the gears are fully hardened.
Hard Gear Finishing (HGF), a relatively new technology, represents an advance in gear process engineering. The use of Computer Numerical Controlled (CNC) equipment ensures a high precision synchronous relationship between the tool spindle and the work spindle as well as other motions, thereby eliminating the need for gear trains. A hard gear finishing machine eliminates problems encountered in two conventional methods - gear shaving, which cannot completely correct gear errors in gear teeth, and gear rolling, which lacks the ability to remove stock and also drives the workpiece without a geared relationship to the master rolling gear. Such a machine provides greater accuracy, reducing the need for conventional gear crowning, which results in gears of greater face width than necessary.
News Items About CBN
1 Holroyd?s Plated CBN on High-Rigidity Edgetek Machines Reduces Process Times with Single Lift and Setup (February 14, 2007)
Holroyd's Edgetek machines are produced with high-power/high-speed spindles that optimize the use of plated CBN wheels at surface spe... Read News
2 Norton Paradigm and CBN Wheels Provide High Performance (May 23, 2012)
Saint-Gobain Abrasives has recently introduced Norton Paradigm Diamond and CBN Wheels which are positioned in the "Best" tier o... Read News
3 Sandvik Coromant CB7015 CBN Grade Delivers High Quality Finishing of Transmission Components (September 11, 2015)
Sandvik Coromant’s CB7015 is a CBN grade for a broad range of applications and designed to deliver optimal finish quality in the pr... Read News
4 Holroyd Precision Limited Zenith 400 Helical Profile Grinder Works with Aluminum Oxide, CBN and Vitrified CBN Technologies (April 15, 2016)
Precision Technologies Group company, Holroyd Precision Limited, is to supply one of its ultra-precise Zenith 400 helical profile grinder... Read News