Plunge Grinding of Gearbox Components
Plunge grinding of gearbox components is centered on dimensional accuracy, surface quality, and process stability. Hardened case-hardening and quenched-and-tempered steels require a tool with stable cutting ability and high thermal resilience.
Process
Ceramic-bonded CBN grinding wheels enable economical grinding of shaft shoulders, bearing and seal seats, and functional diameters with high reproducibility.
The defined pore structure produces a pronounced self-sharpening effect and consistent cutting conditions. CBN's high thermal conductivity reduces heat input into the surface layer – even at higher material removal rates.
What the process gains
Longer dressing intervals
Higher tool life and reduced machine downtime
Consistent profile and dimensional accuracy
Reproducible diameter and form accuracy
Reduced grinding forces
Lower spindle load, stable process conditions
Minimized heat input
Reduced risk of grinding burn and microstructural impact
Recommended tools
| Product types | Cylindrical and plunge grinding wheels |
|---|---|
| Bond | VEWN – EHWA ceramic bond |
| Grit size | B91 |
| Dimensions | Profile wheel Ø 350 mm |
Process example
Plunge grinding of hardened spur gears in series production
Goal: Increase tool life while maintaining consistent profile and surface quality
Reference: electroplated CBN profile wheel
| Material | 16MnCr5, case-hardened, 60–62 HRC |
|---|---|
| Module | m = 2.5 |
| Tooth width | 20 mm |
| Grinding wheel diameter | Ø 350 mm |
| Peripheral speed | 63 m/s |
| Infeed | radial plunge, total ap 0.18 mm |
| Feed rate | 0.2 – 0.35 mm/s |
Result
- Fewer dressing cycles, higher machine availability
- Consistent profile accuracy, gear quality up to Q6 without profile correction
Figures from an approved customer process. Tools are always engineered around the machine, workpiece, and process of the individual case – these figures are evidence, not a guarantee.