In the paper, polishing free-form surfaces of die are studied with magnetic abrasive finishing. The principle of magnetic abrasive finishing free-form surface, the design of magnetic pole, the composition and categories of magnetic abrasive are introduced. Through digitizing of free-form surface by using trimmed NURBS, based on residual roughness, machining accuracy and other parameters, the offset variable of free-form surface, which is the path of magnetic pole, is derived with the computer aided geometric design theory. These will provide theoretic foundation for the realization of finishing free-form surfaces of die automatically.

Using electroplating CBN hard gear-honing-tools with standard involute, the vicinity of the workpiece tooth pitch circle will be a “mid concave” error, the root of the tooth will be a “dig root” error generally. For the formation factors of the error are more complex, it is difficult to calculate errors with an exact analytical method. To this end, by using Pro/E and ANSYS software, the contact analysis of electroplating CBN hard honing process was simulated. The honed tooth surface normal deformation analysis was the important means to determine extent of tooth profile error, through the normal deformation analysis based on simulation results, the location and extent of normal deformation was determined. Practice shows that the location and extent of the normal deformation has been a certain relationship with processing gear tooth profile errors. It is provided a theoretical basis to make the gear-honing tooth surface modification as possible.

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