One possible process for the hard finishing of gears is the continuous generating gear grinding, which has
replaced other grinding processes in batch production of small to medium sized gears due to its high process
efficiency.
Despite the wide industrial application of this process only a few published scientific analyses exist. The
science-based analysis of generating gear grinding needs a high amount of time and effort. This is due to the
complex contact conditions between tool and gear flank, which change continuously during the grinding
process. These complicate the application of the existing knowledge of other grinding processes onto
generating gear grinding.
The aim ofthis report is to determine the existing cutting forces for a sample gear in trials for the first time and to
analyse their connection to process parameters and the appearance of profile form deviations.
Simultaneously for a sample gear the same process design will be analyzed using a manufacturing
simulation. The results of trials and simulation will be compared. This report will present new possibilities in
process analysis and will give the process user ideas for future process improvements.

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