The optimization of friction disc gear-shaping process aiming at residual stress and machining deformation

Friction disc is the key part of the frictional clutch. But there is a lack of in-depth studies on the effect of the cutting parameters on residual stress and machining deformation. In this study, the simulation model for friction disc gear shaping was established and the effect of the typical cutting parameters on surface residual stress and machining deformation was studied. Based on the study’s results, the optimization experiment of friction disc gear shaping was carried out and a method was proposed to reduce machining deformation and to improve the fatigue life. Applying the proposed method, the residual stress on the tooth bottom increased from −122.50 to −371.33 MPa, an increase of 203.13% that increases the fatigue life greatly. Meanwhile, the front and bottom face deformation of the outer ring as well as the deformation of the front and bottom tooth tip can be decreased effectively. This study can provide technical support for improving the comprehensive performance of the friction disc and transmission system.