The Error Compensation For Axial Modification Of Gear Form Grinding And Its Machining Simulation

With the development of modern industrial machinery, high-power, high-speed, heavy load has become the development trend of the gear transmission, but the traditional rolling and shaving process is difficult to meet the high-precision and the modification request of gear, which challenge the accurate, effective, smooth and reliable operation of gear parts in all environments. As a. main process of modification for hard- surface gears, form grinding technology gets more and more widely concerned by academia and industrya due to its convenient on modification, good versatility and high precision in machining. However, the gears manufactured by form grinding can not fully meet the job requirements in extreme conditions. Tooth form grinding with axial modification techniques can further reduce the concentration of stress under gear contact state, and reduce the noise generated by the gear transmission, then greatly improving the carrying capacity and the accuracy of gear transmission, and extend working life of the gear; Since a new movement added to the forming grinding with axial modification, the contact relationship between grinding wheel and gear becomes more complex, so issues such as the relationship between movement, the forming principle and also the accuracy of tooth surface need for new theories and supporting tools. In view of this, based on the experiment platform of economy form grinding machine which is researched by our group, the paper has focused on the technology research of gear form grinding with axial modification and its machining simulation, research on the theory, the general mathematical model and error compensation method of gear form grinding with axial modification, analyze its three-dimensional visualization by simulation processing in VERICUT. During the processing of gear form grinding with axial modification, all the analyses are order to provide theory and tool support for further study and practice of factory application. Specific contents are as follows:Firstly, baesd on the principle of gear form grinding its axial modification, the theory of gear form grinding with axial modification is deeply researshed, and then a general mathematical model of the entire process during tooth axial modification is established. The general mathematical model includes the calculation of grinding wheel shape and the reverse engineering of tooth surface, which lays the foundations for the realization of error compensation and the general accuracy expression of the geometric information.Secondly, this paper analyzes the generation reasons and influencing factors of tooth profile and surface error, then according to the evaluation standard of tooth profile error, established a compensation method of tooth profile deviation. Meanwhile, based on the establishment of evaluation standard for the tooth surface distortion and relative distortion error, this paper proposes error compensation method and its algorithm of tooth surface distortion and relative distortion, then verifies the effectiveness of the error compensation method with an example.Thirdly, according to the machining process of economical form grinding machine, the CNC system software of the machine tool with axial modification is developed. And in accordance with the proposed error compensation method in this paper, the error compensation software for economicical form grinding machine and other grinding system is developed, which is software support for axial modification and its error compensation.Finally, this paper creates and configures the virtual machining system of economical form grinding machine in VERICUT software, then the processing simulation of the helical gear form grinding with axial modification is successfully implemented, and the VERICUT software is used to the quality testing, error analysis for gear and the verification to error compensation. The data of quality testing and error analysis can provide important reference for real and do good to the promotion and application of economical form grinding machine and grinding machining process with axial modification.