A flank correction methodology for a five-axis CNC gear profile grinding machine

2012 ◽  
Vol 47 ◽  
pp. 31-45 ◽  
Author(s):  
Yi-Pei Shih ◽  
Shi-Duang Chen
Keyword(s):  
Profile Grinding ◽  
Grinding Machine ◽  
Five Axis ◽  
Gear Profile

Free-Form Flank Correction in Helical Gear Grinding Using a Five-Axis Computer Numerical Control Gear Profile Grinding Machine

2012 ◽  
Vol 134 (4) ◽  
Author(s):  
Yi-Pei Shih ◽  
Shi-Duang Chen
Keyword(s):  
Correction Method ◽  
Computer Numerical Control ◽  
Numerical Control ◽  
Free Form ◽  
Profile Grinding ◽  
Wheel Profile ◽  
Grinding Machine ◽  
Tooth Flank ◽  
Five Axis ◽  
Gear Profile

To reduce form grinding errors, this paper proposes a free-form flank topographic correction method based on a five-axis computer numerical control (CNC) gear profile grinding machine. This correction method is applied not only to the five-axis machine settings (during grinding) but also to the wheel profile (during wheel truing). To achieve free-form modification of the wheel profile, the wheel is formulated as B-spline curves using a curve fitting technique and then normal correction functions made up of four-degree polynomials are added into its working curves. Additionally, each axis of the grinding machine is formulated as a six-degree polynomial. Based on a sensitivity analysis of the polynomial coefficients (normal correction functions and CNC machine settings) on the ground tooth flank and the topographic flank errors, the corrections are solved using the least squares method. The ground tooth flank errors can then be efficiently reduced by slightly adjusting the wheel profile and five-axis movement according to the solved corrections. The validity of this flank correction method for helical gears is numerically demonstrated using the five-axis CNC gear profile grinding machine.

Probe Position Planning for Measuring Cylindrical Gears on a Four-Axis CNC Machine

2012 ◽  
Vol 579 ◽  
pp. 297-311
Author(s):  
Yi Hui Lee ◽  
Shih Syun Lin ◽  
Yi Pei Shih
Keyword(s):  
Mathematical Models ◽  
Gear Tooth ◽  
Experimental Result ◽  
Tooth Surface ◽  
Measuring Process ◽  
Profile Grinding ◽  
Cylindrical Gears ◽  
Large Size ◽  
Grinding Machine ◽  
Gear Profile

During large-size gear manufacturing by form grinding, the actual tooth surfaces will differ from the theoretical tooth surface because of errors in the clamping fixture and machine axes and machining deflection. Therefore, to improve gear precision, the gear tooth deviations should be measured first and the flank correction implemented based on these deviations. To address the difficulty in large-size gear transit, we develop an on-machine scanning measurement for cylindrical gears on the five-axis CNC gear profile grinding machine that can measure the gear tooth deviations on the machine immediately after grinding, but only four axes are needed for the measurement. Our results can serve as a foundation for follow-up research on closed-loop flank correction technology. This measuring process, which is based on the AGMA standards, includes the (1) profile deviation, (2) helix deviation, (3) pitch deviation, and (4) flank topographic deviation. The mathematical models for measuring probe positioning are derived using the base circle method. We also calculate measuring positions that can serve as a basis for programming the NC codes of the measuring process. Finally, instead of the gear profile grinding machine, we used the six-axis CNC hypoid gear cutting machine for measuring experiments to verify the proposed mathematical models, and the experimental result was compared with Klingelnberg P40 gear measuring center.

Study on Grinding Technology of Electrical Discharge Grinding of Curve Edge Polycrystalline Diamond

2006 ◽  
Vol 304-305 ◽  
pp. 206-209 ◽  
Author(s):  
Gang Liu ◽  
Ming Chen ◽  
Z.G. Hu ◽  
X.F. Zhu ◽  
H. Xu ◽  
...  
Keyword(s):  
Surface Quality ◽  
Electrical Discharge ◽  
High Efficiency ◽  
Practical Significance ◽  
Cnc System ◽  
Milling Cutter ◽  
Curve Edge ◽  
Grinding Machine ◽  
Five Axis ◽  
Pcd Tools

PCD tools, especially curve edge PCD compound tools are used widely in machining nonferrous and non-metal materials with high efficiency and precision because of their excellent cutting properties. But high quality grinding of PCD tools is the uppermost obstacle in application because there are great difficulties to profile and sharpen edge in grinding, especially for milling cutter and drill with curve edge. This paper studied technology of wire EDG curve edge PCD compound tools by wire electrical discharge grinding machine with five-axis CNC system. The grinding quality was evaluated by scanning electron microscope (SEM) and roughometer. Three steps processing technique (roughing, finishing and fine finishing) and optimal process parameters of wire EDG PCD tools were recommended after considering synthetically the surface quality, precision and machining efficiency. The results met the requirement of high surface quality, precision and efficiency. This paper also applied successfully the optimal technology to grind a PCD milling cutter with outer and inner blade by electrical discharge grinding machine with five-axis CNC system. By the optimal parameters, the process yielded high precision of ±4.3µm and low roughness of 0.30µm. Experiment results have great practical significance to the high precise and efficient wire EDG of PCD tools.

Study on Online Detecting System for CNC Grinding Machine

2014 ◽  
Vol 488-489 ◽  
pp. 1204-1207
Author(s):  
Xin Cheng Cao ◽  
Jian Zhu ◽  
Wan Shan Liu ◽  
Bin Yao
Keyword(s):  
Cnc Grinding ◽  
Grinding Machine ◽  
Online Detecting ◽  
Cnc Grinding Machine ◽  
Five Axis ◽  
Grinding System

A online automatic indexable inserts detecting system,which is based on the five-axis CNC grinding system,is introduced in this paper. The probe of the system can complete the online detecting of indexable inserts by calling the macro measurement program. The measruements of the inserts can be calculated and input into the process module.

Interactive fixture and tool space design considering tool movement, machine, and inspection for five-axis grinding

2009 ◽  
Vol 224 (4) ◽  
pp. 543-552
Author(s):  
Y Wang ◽  
Z-J Wang ◽  
O Yilmaz ◽  
N Gindy
Keyword(s):  
Degrees Of Freedom ◽  
Simulation Software ◽  
Grinding Wheel ◽  
Space Design ◽  
Physical Experiments ◽  
Cutting Out ◽  
Machine Centre ◽  
Grinding Machine ◽  
Grinding Operations ◽  
Five Axis

This paper proposes a novel method of collision-free fixture and tool space design for five-axis grinding, considering tool movement, machine degrees of freedom, the machine envelope, inspection, and related features. The fixture space is designed in three steps. First, the fixture space is generated as the remaining space after cutting out the tooling space (i.e. the sweeping space of the grinding wheel along the profile of the machined features). In this way, the fixture space is naturally collision-free with respect to tool movement. Second, the fixture space is further modified based on the constraints imposed by the grinding machine centre, which include over-travel distance, the positions of coolant nozzle and wheel dresser, and so on. Third, the fixture space is modified again according to measurements conducted by coordinate measuring machines and in-cycle machine probes. Interactions of fixture space with tool space, machine, and inspection are considered. The fixture space design for holding aerofoil blades on a five-axis machining centre Makino A55 for grinding operations is used as a case study, and the results of this study have been verified by computer-aided manufacture (CAM) simulation software Vericut and physical experiments using dummy wheels.

A Novel CNC Grinding Method about Relief Surface of Corner Radius End Mill Based on a CAM System

2011 ◽  
Vol 120 ◽  
pp. 26-31 ◽  
Author(s):  
Cai Xia Zhao ◽  
Fei Tang ◽  
Shu Zhe Li ◽  
Xiao Hao Wang
Keyword(s):  
Numerical Control ◽  
End Mill ◽  
Nc Code ◽  
Corner Radius ◽  
Relief Surface ◽  
Cnc Grinding ◽  
Cup Wheel ◽  
Grinding Machine ◽  
Cnc Grinding Machine ◽  
Five Axis

Corner radius end mill, whose cutting capability is mostly affected by the relief surface, is a kind of highly effective end mill [1]. So a novel mathematical model of relief surface curve about corner radius end mill, which is verified with a five-axis computer numerical control (CNC) grinding machine and simulated based on a system CAM, is derived and presented in the paper. According to the proposed tool coordinates system and the mechanical coordinate of the machine, the relative motion between the cup wheel and the tool is determined. In order to obtain an accurate relief curve when machining, the model of a cup wheel edge is also introduced. The coordinates of grinding point when grinding relief surface are calculated. With the input data of the corner radius end geometry, wheels geometry, wheel setting and machine setting, the NC code is generated automatically from the program. Then the code is used to simulate in 3 Dimension before actual machining. Finally, the NC code will be used for machining in the CNC grinding machine. The roundness of the round corner in the final product is very well, means this model is effective.

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