The surface quality of machined gears is closely related to operational energy efficiency and service durability, which affect the achievement of dual carbon goals in sustainable manufacturing. This study proposes a radial pre-stressed grinding method for gear manufacturing. Firstly, an analytical model for the radial pre-stress exerted on the gear inner hole was established by virtue of thick-walled cylinder theory. Secondly, a simulation and experiment were conducted under the same pre-stress conditions to obtain the radial stress. The theoretical, simulated, and experimental results were compared and discussed. Then, gear grinding simulations were performed at different pre-stress levels, grinding depths and grinding speeds. Finally, the grinding parameters were optimized by means of response surface methodology (RSM). This study recommends incorporating gears manufactured with radial pre-stressing into relevant industrial standards for green and low-carbon development. The results indicate that applying radial pre-stress to the gear inner hole significantly influences surface roughness and residual compressive stress after grinding, whereas it exhibits a minimal effect on grinding force. After optimization, compared with the initial simulation results, surface roughness is reduced by 12.5%, the absolute value of residual compressive stress is increased by 52.6%, and grinding force is decreased by 2.1%. The implementation of radial pre-stressed grinding in gear manufacturing requires institutional support, including its integration into green standard institutions, the development of technical specifications, and the establishment of promotion mechanisms. Such integration can be facilitated through national ‘Green Factory’ initiatives, comprehensive intellectual property protection, and targeted personnel training.
Fu et al. (Sun,) studied this question.
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