Novel Third-Order Correction for a Helical Gear Shaping Cutter Made by a Lengthwise-Reciprocating Grinding Process

Although the Isoform® lengthwise-reciprocating grinding process is considered as one of the most accurate methods for generating the tooth profile geometry of a helical gear shaping cutter, the tooth profile accuracy produced by the Isoform® with a straight cone grinding wheel is not accurate enough for high precision requirement. That is why the shaper cutter is used as a rough cutting tool for most cases. A third-order profile correction to the cone grinding wheel is proposed to increase the accuracy of the work gear profile. A novel topography is developed to schematically show the work gear tooth profile accuracy cut by a resharpened shaping cutter. The profile errors corresponding to the varied resharpening depth are shown in the topography with information of true involute form diameter and semitopping depth. The usable resharpening depth of the shaping cutter can be determined by this topography. The numerical result indicates that third-order correction reduces the profile error of the major cutter enveloping gear to submicro and extends the resharpening depth.

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Modified-Roll Profile Correction for a Gear Shaping Cutter Made by the Lengthwise-Reciprocating Grinding Process

Journal of Mechanical Design ◽

10.1115/1.4003683 ◽

2011 ◽

Vol 133 (4) ◽

Cited By ~ 3

Author(s):

Chin-Lung Huang ◽

Zhang-Hua Fong

Keyword(s):

Tooth Profile ◽

Roll Motion ◽

Grinding Wheel ◽

Grinding Process ◽

Profile Error ◽

Sensitivity Matrix ◽

Profile Correction ◽

Wheel Profile ◽

Profile Errors ◽

Gear Shaping

The tooth profile error of a gear shaping cutter made by the lengthwise-reciprocating grinding process (LRGP) is usually corrected by modifying the grinding wheel profile. However, such grinding wheel modification cannot eliminate the twisting profile error along the face of the shaping cutter. A kinematic modified roll motion for generating a shaping cutter is proposed to minimize such twisted profile errors even after cutter resharpening. The tooth profile errors of the work gears generated by the shaping cutter with various resharpening depths are represented as a novel topographic error map. Based on the error map and its sensitivity matrix, the roll ratio between the shaping cutter and the grinding wheel stroke is modified to reduce the twisted profile error as illustrated by the numerical examples. Combining this modified roll motion modification and the grinding wheel profile correction, the high accuracy resharpening depth of the LRGP helical shaping cutter is increased.

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SELECTION OF GEOMETRIC PARAMETERS OF GEAR AND GRINDING WHEEL TO ENSURE MAXIMUM GEAR TOOTH PROFILE ACCURACY

Machining Science and Technology ◽

10.1080/10910340500226749 ◽

2005 ◽

Vol 9 (3) ◽

pp. 369-381 ◽

Cited By ~ 3

Author(s):

Evgueni I. Podzharov

Keyword(s):

Gear Tooth ◽

Tooth Profile ◽

Geometric Parameters ◽

Grinding Wheel ◽

Profile Accuracy ◽

Selection Of

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Dimensional Changes by Heat Treatment of Helical Gear

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.535-536.271 ◽

2013 ◽

Vol 535-536 ◽

pp. 271-274

Author(s):

Jeongsuk Lim ◽

Sunghoon Kang ◽

Young Seon Lee

Keyword(s):

Heat Treatment ◽

Elastic Deformation ◽

Gear Tooth ◽

Three Dimensional ◽

Dimensional Change ◽

Helical Gear ◽

Tooth Profile ◽

Dimensional Changes ◽

Gear Teeth ◽

Experimental Works

The dimensional change of tooth profile by heat treatment of helical gear was investigated by experimental and numerical approaches. Especially, the three-dimensional elasto-plastic finite element (FE) simulation was adopted to analyze the elastic deformation during load, unloading, ejecting of workpiece. Quenching simulation was also carried out to investigate the change of tooth profile on the forged gear. In experiments, the amount of elastic deformation of the forged gear was quantitatively determined by comparing the tooth profiles on the forged gear and die. The dimensional change of the forged gear tooth after quenching was also evaluated from the comparision of the cold forged and quenched gear teeth. From experimental works, it was found that the amounts of dimensional changes after forging and quenching of helical gear are 10 and 10 μm, respectively.

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Development on Micro Precision Truing Method of ELID-Grinding Wheel (2nd Report: Application to Edge Sharpening of Large Wheel)

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.291-292.213 ◽

2005 ◽

Vol 291-292 ◽

pp. 213-220 ◽

Cited By ~ 1

Author(s):

Shao Hui Yin ◽

Wei Min Lin ◽

Yoshihiro Uehara ◽

Shinya MORITA ◽

Hitoshi Ohmori ◽

...

Keyword(s):

Surface Quality ◽

Grinding Wheel ◽

Grinding Process ◽

Grinding Wheels ◽

Elid Grinding ◽

Diamond Grinding ◽

Grinding Performance ◽

Profile Accuracy ◽

Large Wheel ◽

Edge Sharpening

In V-groove ELID grinding process, to achieve optimal grinding performance and satisfactory surface quality and profile accuracy, metal bonded diamond grinding wheels need to be carefully sharpened. In this paper, we applied the proposed new micro-truing method consisting of electro-discharge truing and electrolysis-assisted mechanical truing to sharpen the edge of large grinding wheels. The minimum wheel tip radiuses of 6.3 and 8.5µm were achieved for the #4000 and #20000 grinding wheels. The truing mechanisms and sharpening performance are also discussed.

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Disk Form Grinding Wheel 3D Parametric Modeling of Quadruple-Arc Gear Based on OpenGL

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.753-755.1258 ◽

2013 ◽

Vol 753-755 ◽

pp. 1258-1261

Author(s):

Zhong Yi Ren ◽

Bi Qiong Jiang

Keyword(s):

3D Model ◽

Gear Tooth ◽

Parametric Modeling ◽

Tooth Profile ◽

Grinding Wheel ◽

Grinding Method ◽

Form Grinding ◽

Generating Method ◽

Tooth Number

Arc-gear tooth profile is complex, especially quadruple-arc gear, it cant be grinding by generating method, form grinding method is still has some difficult in wheel dressing. In this article, the author use software VC++6.0 and OpenGL developed a new and special gear software, when the tooth number and modulus of arc-gear to be machined and grinding wheel diameter is given, this software can generate disk form grinding wheel 3D model,this software is useful to arc-gear form grinding wheel dressing.

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Influence of Tooth Profile Deviations on Helical Gear Wear

Journal of Mechanical Design ◽

10.1115/1.1899688 ◽

2004 ◽

Vol 127 (4) ◽

pp. 656-663 ◽

Cited By ~ 51

Author(s):

A. Kahraman ◽

P. Bajpai ◽

N. E. Anderson

Keyword(s):

Gear Tooth ◽

Helical Gear ◽

Tooth Profile ◽

Tooth Surface ◽

Surface Wear ◽

Mechanics Model ◽

Surface Slopes ◽

Tooth Surfaces ◽

Computation Algorithm ◽

Gear Contact

In this study, a surface wear prediction model for helical gears pairs is employed to investigate the influence of tooth profile deviations in the form of intentional tooth profile modifications or manufacturing errors on gear tooth surface wear. The wear model combines a finite-element-based gear contact mechanics model that predicts contact pressures, a sliding distance computation algorithm, and Archard’s wear formulation to predict wear of the contacting tooth surfaces. Typical helical gear tooth modifications are parameterized by an involute crown, a lead crown, and an involute slope. The influence of these parameters on surface wear are studied within typical tolerance ranges achievable using hob/shave process. The results indicate that wear is related to the combined modification parameters of a gear pair rather than individual gear parameters. At the end, a design formula is proposed that relates the mismatch of contacting surface slopes to the maximum initial wear rate.

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Research on Gear Cutter Tooth Profile for Semi-Topping: A Case of a Helical Gear

6th International Power Transmission and Gearing Conference: Advancing Power Transmission Into the 21st Century ◽

10.1115/detc1992-0054 ◽

1992 ◽

Author(s):

Y. Ariga ◽

Shiyeyoshi Nagata

Keyword(s):

Design Method ◽

Gear Tooth ◽

Helical Gear ◽

Tooth Profile ◽

Tooth Surface ◽

Gear Cutting ◽

Gear Cutter ◽

Conventional Design ◽

Wide Range ◽

Tooth Number

Abstract Gear tooth tips are frequently chamfered to prevent nicks or scuffing on the tooth surface. Some of the hob cutters and pinion cutters can be chamfered but many types of cutters should be used for a particular range of tooth numbers since the amount chamfering largely varies depending on the tooth number. However, intensive efforts in the design have made it possible to produce cutters with little variation of chamfering amount for a wide range of tooth numbers. The error in the amount of chamfering by a single cutter designed by the above method can be maintained within ±10 % for gears with tooth numbers ranging from 16 to 94. It was found that three cutters of the conventional design are required for keeping the error within the same range for cutting gears within a given range of tooth numbers. The paper describes the tooth design method of the hob cutter with little variation of chamfering amount along changes in number of teeth to be machined and demonstrates that chamfering errors are maintained within practically allowable ranges for profile shift cutting or helical gear cutting with the use of this cutter.

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Modelling and experiment of gear hob tooth profile error for relief grinding

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/09544054211017297 ◽

2021 ◽

pp. 095440542110172

Author(s):

Shuying Yang ◽

Weifang Chen ◽

Zhiqiang Wang ◽

Yanfeng Zhou

Keyword(s):

Prediction Model ◽

High Speed ◽

Tooth Profile ◽

Grinding Wheel ◽

Grinding Process ◽

Feed Speed ◽

Machining Parameters ◽

Profile Error ◽

Mechanical Coupling ◽

Axial Profile

Gear hob is an important tool that is most used in gear processing. Hob accuracy directly exerts an overwhelming influence on the quality of the processed gear. Generally, the hob tooth profile accuracy is mainly determined by relief grinding process. Studies on tooth profile errors of gear hobs caused by severe friction and cutting with the high-speed rotation of the wheel during the form grinding machining of hobs are limited. Thus, a theoretical model of the tooth profile error prediction under different machining parameters was established based on the analysis of coupling influence of high temperature and high strain rate on gear hobs in the relief grinding process. The model was completed on the basis of the dynamic explicit integral finite element method of thermo-mechanical coupling. Through the prediction model, the influence of the grinding depth ap, feed speed Vw and grinding speed Vs on the tooth profile error can be analysed. In addition, an algorithm for accurately calculate the grinding wheel axial profile by combining instantaneous envelope theory and hob normal tooth profile was proposed. The hob relief grinding experiments were carried out using the proposed grinding wheel profile algorithm. The relative error of the prediction obtained by comparing the calculation results of the prediction model with the experimental results is within 10%. Results prove the validity of the prediction model. This finding is greatly important for optimising the accuracy of hob relief grinding.

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The Computation of Grinding Parameters for the Modified Shaper Cutter

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.121-126.2701 ◽

2011 ◽

Vol 121-126 ◽

pp. 2701-2705

Author(s):

Chao Huang ◽

Guo Long Li

Keyword(s):

Coordinate System ◽

Relative Motion ◽

Tooth Profile ◽

Tooth Surface ◽

Grinding Wheel ◽

Grinding Process ◽

Grinding Parameters ◽

The Relationship

Grinding process is regarded as the most effective way to generate the tooth profile of spur shaper cutter. However, for the purpose of generating a tip chamfer of gear, the semi-topping is always required on the tooth surface of shaper cutter, which is difficult to process by grinding wheel. This paper proposes a method to compute the profile of grinding wheel which is used to process the spur shaper cutter with a semi–topping. Firstly, translate the points on the surface of shaper cutter into auxiliary rack; Secondly, building the relationship between the coordinate system of grinding wheel and coordinate system of auxiliary rack; Lastly, the points on the surface of auxiliary rack are translated into the coordinate system of grinding wheel based on the relative motion between the grinding wheel and shaper cutter.

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