Surface residual stress prediction and experimental validation in internal gear power honing via cross-sequence thermo-mechanical modeling

Internal gear power honing is a finishing process capable of generating high compressive residual stresses on gear tooth surfaces. This study develops a cross-sequence thermo-mechanical analytical model for predicting the surface residual stress in internal gear power honing. Gear honing experiments and XRD measurements of the near-surface residual stress component in the tooth lead direction were conducted to validate the model, with a maximum absolute deviation of approximately 29 MPa. The results show that this residual stress component varies only slightly with tooth lead position but exhibits nonlinear variation with tooth profile position. These findings support residual stress prediction and process parameter selection in internal gear power honing.