New method for calculating face gear tooth surface involving worm wheel installation errors

• Published in: Journal of Central South University Vol. 24; no. 8; pp. 1767 - 1778
• Main Authors: Cui, Wei, Tang, Jin-yuan
• Format: Journal Article
• Language: English
• Published: Changsha Central South University 01-08-2017; Springer Nature B.V
• Subjects: Computer simulation; Engineering; Errors; Finite element method; Gear machining; Gear teeth; Gears; Grinding wheels; Machining; Metallic Materials; Numerical controls; Position errors; Three dimensional models; VERICUT; face gear; worm wheel installation errors; error analysis; grinding
• ISSN: 2095-2899; 2227-5223
• DOI: 10.1007/s11771-017-3585-7

The machining principle and realization method for the continuous generative grinding face gear by a worm wheel are introduced. Based on a five-axis linked CNC grinding machine, a new method is presented to deprive the equation of face gear error tooth surface by assuming the tool surface as the error surface, where actual tool installation position error is introduced into the equation of virtual shaper cutter. Surface equations and 3-D models for the face gear and the worm wheel involving four kinds of tool installation errors are established. When compared, the face gear tooth surface machined in VERICUT software for simulation based on this new method and the one obtained based on real process (grinding face gear by using a theoretical worm wheel with actual position errors) are found to be coincident, which proves the validity and feasibility of this new method. By using mesh planning for the rotating projection plane of the face gear work tooth surface, the deviation values of the tooth surface and the difference surface are acquired, and the influence of four kinds of errors on the face gear tooth surface is analyzed. Accordingly, this work provides a theoretical reference for assembly craft of worm wheel, improvement of face gear machining accuracy and modification of error tooth surface.