Optimum on grinding parameter for 16Cr3NiWMoVNbE aircraft gear by grey correlation analysis of surface integrity

To address the fatigue resistance and wear resistance requirements of aviation gears, this study investigates the surface integrity of grinding processes. Focusing on a representative difficult-to-machine material 16Cr3NiWMoVNbE carburized aviation gears, orthogonal grinding experiments were designed to analyze key parameters affecting surface roughness and residual stress. Multi-objective process optimization was achieved through grey relational analysis. The results showed that radial feed dominates surface roughness variation. Residual compressive stress distribution follows tooth pitch ≈ tooth tip > tooth root, with feed rate significantly affecting tooth tip and tooth pitch stress while linear speed and radial feed govern root stress. Entropy-weighted grey relational analysis revealed radial feed exerts the greatest comprehensive influence on surface integrity. The optimal parameter combination balancing low roughness and high compressive stress was determined as: maximum linear speed 24 m/s, feed speed 1 000 mm/min, and radial feed 0.007 mm.