Analysis of residual stress on tooth surface of spiral bevel gear with single abrasive grinding

CHANG Jibao; ZHANG Fengshou; LI Li; QU Yuanhao

doi:10.16579/j.issn.1001.9669.2026.01.010

Abstract：[Objective]To reveal the influence law of grinding parameters on the residual stress of spiral bevel gear tooth surfaces,solve the problem of insufficient research on the correlation mechanism between process parameters and residual stress in existing studies,and further optimize the grinding process to improve the load-carrying capacity and service life of gears.[Methods]Firstly,a finite element model of single abrasive grain grinding for spiral bevel gears was established based on Abaqus software,with the Johnson-Cook constitutive model and failure criterion adopted.Secondly,the influences of grinding speed,grinding depth and abrasive rake angle on residual stress were analyzed through single-factor simulation.Then,a residual stress prediction model was constructed by combining the response surface methodology,and the reliability of the model was verified by analysis of variance.Finally,multi-objective parameter optimization was conducted based on the reliable model,and comparative tests were carried out for verification.[Results]The results showed that the residual stress of the tooth surface distributed along the layer depth as"compressive stress-maximum compressive stress(subsurface)-tensile stress-approaching zero".The influence degree of each parameter on residual stress was ranked as abrasive rake angle>grinding depth>grinding speed.Under the optimal parameters(grinding speed 25 m/s,grinding depth 0.01 mm,abrasive rake angle-48°),the maximum residual compressive stress of the tooth surface reached 638.6 MPa,and the minimum residual tensile stress was 24.9 MPa.This result can provide a basis for the optimization of gear grinding processes.