Influence of the turning process on the distortion of disks for gear manufactureReport as inadecuate

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Production Engineering

, Volume 5, Issue 6, pp 613–620

First Online: 30 July 2011Received: 31 May 2011Accepted: 14 July 2011


This study presents investigations on the fundamental mechanisms of part distortion during the machining of disks cylindrical gear base bodies. The work focuses on the effects of machining induced residual stresses and inhomogeneous material removal. In this context the workpiece clamping was investigated as a major impact factor on the distortion. In order to analyze and describe the complex shape deviations, an appropriate distortion characterization method was developed. Since the distortion of disks directly affects the gear wheel quality, the results will help to understand the formation of gear distortion as well as to reduce and compensate it.

KeywordsDistortion Manufacturing Disk Gear Clamping Residual stress List of symbolsak mmAmplitude

ap mmDepth of cut


d mmDistance from centerline

da, di mmOuter, inner diameter

f mmFeed rate

Fc,cj NCentrifugal force, acting on clamping jaws

Fcl NClamping force

Fcld NDynamic clamping force

Fcls NStatic clamping force

h mmHeight

L mmLength

mcj kgMass of clamping jaws

r mmRadius

rcj, rt mmRadial position of clamping jaw, tool

RCoefficient of determination

U μmMeasurement uncertainty

vc m-minCutting speed

σt N-mm²Tangential surface stress

φ °Circumference angle

RSResidual stress

SRAStress relief annealing

SJSegment jaw

GM1Geometry measurement before final cut

GM2Geometry measurement after final cut

GM3Geometry measurement after final SRA

FFTFast Fourier transform

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Author: Tim Kohlhoff - Jens Sölter - Ekkard Brinksmeier


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