While grinding the teeth of the helical gear using generation grinding process with Abrasive wheels, we occasionally find a bump on the profile of about 10 to 20 Microns. This is very difficult to detect and is often detected at the Customer assembly resulting in a whistling noise from the Engine or Gear box as the application case may be. We have run several simulation trials to reproduce the defect without any success. It would be helpful if anyone can guide me on their experience with this .
Unknown.... I suggest that your organization obtain one of these problematic gears and develop a a strategy to better identify when these "bumps" occur and how.
I would track tooling, machine that created the gear and operator to better understand trends and frequency.