A novel flank correction method for face gear ground by CNC worm wheel grinder

Abstract

Face gear will be widely used in the fields of intersecting shaft transmission due to its insensitivity to pinion axis misalignment. Considering the requirements of machining efficiency, face gear is mainly ground by worm wheel. However, due to the complexity of face gear tooth flank, worm wheel profile and grinder machining settings, the ground tooth flank accuracy is very difficult to meet the actual requirements. This paper proposes a novel flank correction method to improve face gear tooth flank accuracy based on computer numerical control (CNC) grinder. Firstly, the tooth flank is enveloped by worm wheel in a continuous indexing process. Secondly, the machining settings of grinder and a 5 × 9 measurement grid for coordinate measuring machine (CMM) are determined. Lastly, a high-order flank correction model is established and solved iteratively considering the measured tooth flank deviations, and the sum of squared errors of deviation is reduced by 91.6%. A machining simulation is carried out to verify the flank correction method. This method can significantly improve face gear tooth flank accuracy and provide a basis for its widespread promotion.