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

2011 ◽  
Vol 133 (4) ◽  
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.

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

2009 ◽  
Vol 131 (5) ◽  
Author(s):  
Chin-Lung Huang ◽  
Zhang-Hua Fong ◽  
Shi-Duang Chen ◽  
Kuang-Rong Chang
Keyword(s):  
Gear Tooth ◽  
Helical Gear ◽  
Tooth Profile ◽  
Order Correction ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Third Order ◽  
Profile Correction ◽  
Profile Accuracy ◽  
Gear Shaping

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.

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

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.

The Computation of Grinding Parameters for the Modified Shaper Cutter

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.

scholarly journals A correction method of screw rotor profile error based on parameter adjustment for grinding wheel dresser

2018 ◽  
Vol 10 (9) ◽  
pp. 168781401879897 ◽  
Author(s):  
Lijia Tao ◽  
Yu Xing ◽  
Mingxin Yuan ◽  
Sijie Chen
Keyword(s):  
Correction Method ◽  
Numerical Control ◽  
Grinding Wheel ◽  
Profile Error ◽  
Dressing Method ◽  
Parameter Adjustment ◽  
Rotor Profile ◽  
Wheel Profile ◽  
Screw Rotor ◽  
Screw Rotors

Accuracy of grinding wheel profile that is generated by form grinding theory and formed by grinding wheel dresser is a crucial factor affecting profile accuracy of screw rotors. A correction method for screw rotor profile error based on parameter adjustment for grinding wheel dresser such as diameter and distance of diamond rollers is proposed. Influence of diameter and distance of diamond rollers on grinding wheel profile and screw rotor profile based on theory of segmented dressing method is analyzed, and the adjustment method for parameters of grinding wheel dresser is presented. The results of the analysis provide a theoretical basis for error correction in screw rotor grinding. Grinding experiments for female rotor were performed due to the character that the female rotor has smooth bottom profile where the change of profile error is easy to observe. The experimental results show that the height difference between the long and short sides of rotor profile at the bottom of the rotor is significantly reduced from 0.22 mm to 0.034 mm by adjusting diameter of diamond rollers, and the distance between the long and short sides of the actual rotor profile is almost consistent with the theoretical one by measuring the distance again and adjusting its value in the computer numerical control system. These results verify the correctness of the correction method.

A Study on Reducing the Gear Tooth Profile Error by Finish Roll Forming

2003 ◽  
Author(s):  
Seizo Uematsu ◽  
Sung-Ki Lyu ◽  
Donald R. Houser ◽  
Ju-Suck Lim ◽  
Long Lu
Keyword(s):  
Gear Tooth ◽  
Tooth Profile ◽  
Roll Forming ◽  
Angle Error ◽  
Profile Error ◽  
Pressure Angle ◽  
Modification Factor ◽  
Profile Errors ◽  
Tooth Profile Errors ◽  
Evaluation Parameters

This paper deals with the tooth profile error of spur gears that have been finished by roll forming. First, we present experimental data that confirms that the tooth profile error is a synthesis of a concave error and a pressure angle error. Since various types of tooth profile errors appear in the experiments, evaluation parameters are introduced for rolling gears so that profile quality may be objectively evaluated. Using these evaluation parameters, the relationship among the tooth profile error, the addendum modification factor (A. M. factor), and the tool loading force are verified. The character of concave error, pressure angle error and tool loading force of finish roll forming by using a forced displacement method are verified. This study makes clear that the tool loading force of finish roll forming is a very important factor that affects involute tooth profile error. The results of the experiment and analysis show that the proposed method reduces both concave and pressure angle errors.

Transmission Errors and Noise of Spur Gears Having Uneven Tooth Profile Errors

1979 ◽  
Vol 101 (2) ◽  
pp. 268-273 ◽  
Author(s):  
I. Yuruzume ◽  
H. Mizutani ◽  
T. Tsubuku
Keyword(s):  
Testing Machine ◽  
Spur Gear ◽  
Tooth Profile ◽  
Spur Gears ◽  
Profile Error ◽  
Gear Noise ◽  
Transmission Errors ◽  
Profile Errors ◽  
Tooth Profile Errors ◽  
Gear Rolling

The problems of involute spur gear noise and transmission errors are studied by meshing m3, 40z spur gears. Five kinds of tooth profile errors, such as convex, concave and wave-like, were formed on the test gear teeth by grinding. The value of each tooth profile error is divided into 3 grades, according to the Gear standards of JIS. Transmission errors of 15 test gears and a master gear were measured by a single flank gear rolling tester with a planetary gear system. Gear noise and strains near tooth fillets were measured by running these test gears on a gear noise testing machine with a power absorbing system, in an anechoic room. This paper presents experimental results and studies of the influence of tooth profile error forms on single flank rolling errors, situation of tooth contacts and gear noise while running.

Probabilistic Analysis of the Surface Grinding Process

1984 ◽  
Vol 8 (4) ◽  
pp. 208-213 ◽  
Author(s):  
M.A. Younis ◽  
H. Alawi
Keyword(s):  
Rayleigh Distribution ◽  
Surface Grinding ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Workpiece Surface ◽  
Monte Carlo Techniques ◽  
Internal Parameters ◽  
Input Parameters ◽  
Wheel Profile ◽  
Special Purpose Computer

The surface grinding process is simulated by developing a special purpose computer package, where the grinding wheel surface is presented statistically by a Rayleigh distribution, and by using the Monte Carlo techniques. The effect of the grinding wheel profile and the kinematic input parameters on the internal parameters of the process and the workpiece surface roughness have been investigated. These are strongly related to the input parameters (νs,νw,a). The investigation shows that the active cutting edges represent only a small percentage of the total cutting edges (2% - 12%).

Study on Edge Contact Area and Surface Integrity of Workpiece in Point Grinding Process

2009 ◽  
Vol 407-408 ◽  
pp. 577-581
Author(s):  
Shi Chao Xiu ◽  
Zhi Jie Geng ◽  
Guang Qi Cai
Keyword(s):  
Surface Integrity ◽  
Contact Area ◽  
High Speed ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Edge Contact ◽  
Cylindrical Grinding ◽  
Theoretic Foundations

During cylindrical grinding process, the geometric configuration and size of the edge contact area between the grinding wheel and workpiece have the heavy effects on the workpiece surface integrity. In consideration of the differences between the point grinding and the conventional high speed cylindrical grinding, the geometric and mathematic models of the edge contact area in point grinding were established. Based on the models, the numerical simulation for the edge contact area was performed. By means of the point grinding experiment, the effect mechanism of the edge contact area on the ground surface integrity was investigated. These will offer the applied theoretic foundations for optimizing the point grinding angles, depth of cut, wheel and workpiece speed, geometrical configuration and size of CBN wheel and some other grinding parameters in point grinding process.

scholarly journals Study on the Effect of Grinding Pressure on Material Removal Behavior Performed on a Self-Designed Passive Grinding Simulator

2021 ◽  
Vol 11 (9) ◽  
pp. 4128
Author(s):  
Peng-Zhan Liu ◽  
Wen-Jun Zou ◽  
Jin Peng ◽  
Xu-Dong Song ◽  
Fu-Ren Xiao
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Service Life ◽  
Material Removal ◽  
Removal Rate ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Grinding Temperature ◽  
Grinding Efficiency

Passive grinding is a new rail grinding strategy. In this work, the influence of grinding pressure on the removal behaviors of rail material in passive grinding was investigated by using a self-designed passive grinding simulator. Meanwhile, the surface morphology of the rail and grinding wheel were observed, and the grinding force and temperature were measured during the experiment. Results show that the increase of grinding pressure leads to the rise of rail removal rate, i.e., grinding efficiency, surface roughness, residual stress, grinding force and grinding temperature. Inversely, the enhancement of grinding pressure and grinding force will reduce the grinding ratio, which indicates that service life of grinding wheel decreases. The debris presents dissimilar morphology under different grinding pressure, which reflects the distinction in grinding process. Therefore, for rail passive grinding, the appropriate grinding pressure should be selected to balance the grinding quality and the use of grinding wheel.

Calculation of Effective Ground Depth of Cut by Means of Grinding Process Model

2011 ◽  
Vol 496 ◽  
pp. 7-12 ◽  
Author(s):  
Takazo Yamada ◽  
Michael N. Morgan ◽  
Hwa Soo Lee ◽  
Kohichi Miura
Keyword(s):  
Process Model ◽  
Ground Surface ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Process ◽  
Wheel Wear ◽  
Elastic Deformations ◽  
Proposed Model ◽  
Effective Depth ◽  
Grinding Machine

In order to obtain the effective depth of cut on the ground surface, a new grinding process model taking into account thermal expansions of the grinding wheel and the workpiece, elastic deformations of the grinding machine, the grinding wheel and the workpiece and the wheel wear was proposed. Using proposed model, the effective depth of cut was calculated using measured results of the applied depth of cut and the normal grinding force.

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