Kinematic Geometry Modelling On Continuous Generating Grinding Of Complex Gear Tooth Flanks

Continuous generating grinding with high precision, high efficiency and good stability has mainly been applied to medium and small module gears' finishing machining in batch. It's the most efficient method of all the gear grinding machining so far. As the gear development trend to high speed, high precision, high load, and low noise, due to modification the more complex the gear tooth flanks are, the higher the gear grinding demand is. It is a difficult problem of gear machining to manufacture the gear with complex tooth flanks in high efficiency and high precision. In this field, the domestic researches are still in the start stage, which has a gap to the high level abroad. This paper researches on kinematics geometry modelling of worm wheel and gear in the continuous generating grinding process. There is an important practical application value to develop high-efficiency and high-precision gear grinding machine with complex tooth flanks. The main research contents of the paper including the followings.Firstly, modelling on the gear tooth flanks with profile modification in continuous generating grinding. According to the various modification demands of involute gear, it builds a mathematic model on gear profile modification including the tooth shape and root. Analyzing the kinematic relationship between worm wheel and gear, it builds a kinematic geometry model of continuous generating grinding and computes the worm wheel profiles which is dealt to coordinate points for convenience of CNC machining then. According to the forming dressing process, it builds a model of couture dressing process, and discretionary gear profile modification can be manufactured.Secondly, modelling on the gear tooth flanks with lead modification in continuous generating grinding. The various positions and effects of lead modification is divided into three kinds, but a universal mathematic model of lead modification curve is built in this paper. Then it builds a craft model on lead modification in continuous generating grinding, which can realize the discretionary shapes of gear lead modification.Thirdly, modelling on the bias error of complex gear tooth flanks in continuous generating grinding. The mechanism of gear twist is analyst and a mathematic model of gear twist error is built. Then the distortion of gear's every lengthwise cross section is worked out and some compensation method aiming at the bias error is proposed.Finally, the models built in the paper is applied into the software development process of gear grinding machine's CNC system. The complex gear tooth flanks is grinded out in experiment, which proves the kinematic geometry models studied in the paper efficient and accurate.