Abstract: A three-dimensional FE (finite element) simulation model of the grinding temperature field was proposed by considering the coupling effects of three adjacent heat sources（tooth bottom heat source， transition arc heat source and tooth profile heat source）to calculate the grinding temperature in profile grinding of full tooth grooves. Then， the residual stresses caused by grinding were calculated by the FE method based on thermal structure coupling. The characteristics of the grinding temperature and residual stress fields were analyzed， as well as the influences of the size of the tooth root transition arcs on the grinding temperature and the residual stress distribution at the tooth root after grinding. The results show that the effects of the transition arc radius on the grinding temperature are relatively small， but the effects on the residual stress are relatively large. Compared with a tooth groove without transition arcs， the maximum residual stress after grinding is reduced by more than 20% when the radius of the transition arcs exceeds 2 mm. The measurement results are consistent with the FE simulation ones， which proves the correctness of the simulation results. 

Key words: profile grinding, gear, tooth root transition arc, grinding temperature, residual stress

摘要： 在齿轮全齿槽成形磨削过程中，考虑相邻三个热源（齿底热源、过渡圆弧热源、齿廓热源）的耦合效应，建立了磨削温度场的三维有限元仿真模型，计算了全齿槽成形磨削温度，并在此基础上，采用基于热-结构耦合的有限元方法计算了磨削引起的残余应力，分析了磨削温度场和残余应力场的分布特征，以及齿根过渡圆弧的大小对磨削温度和磨削后齿根处残余应力分布的影响。结果表明，过渡圆弧半径对磨削温度的影响相对较小，但对齿根处残余应力的影响较大；与没有过渡圆弧的齿槽相比，当过渡圆弧半径超过2 mm时，磨削后齿根最大残余应力降低20%以上。实验测量结果与有限元仿真结果一致，证明了模拟结果的正确性。

关键词: 成形磨削, 齿轮, 齿根过渡圆弧, 磨削温度, 残余应力