Analysis and Compensation for Gear Accuracy with Setting Error in Form Grinding

Abstract

In the process of form grinding, gear setting error was the main factor that influenced the form grinding accuracy; we proposed an effective method to improve form grinding accuracy that corrected the error by controlling the machine operations. Based on establishing the geometry model of form grinding and representing the gear setting errors as homogeneous coordinate, tooth mathematic model was obtained and simplified under the gear setting error. Then, according to the gear standard of ISO1328-1: 1997 and the ANSI/AGMA 2015-1-A01: 2002, the relationship was investigated by changing the gear setting errors with respect to tooth profile deviation, helix deviation, and cumulative pitch deviation, respectively, under the condition of gear eccentricity error, gear inclination error, and gear resultant error. An error compensation method was proposed based on solving sensitivity coefficient matrix of setting error in a five-axis CNC form grinding machine; simulation and experimental results demonstrated that the method can effectively correct the gear setting error, as well as further improving the forming grinding accuracy.

Influence of sensitive pose errors on tooth deviation of cylindrical gear in power skiving

“…According to Fang et al, 12 the tooth surface deviations d (f ha , f fa , f hb , f fb , F p , 6 f pt ) are calculated in transverse section; as shown in Figure 3, tooth deviation of any point P(x p , y p ) is determined by the normal distance PB between actual tooth surface and theoretical tooth surface. Here, the formula for the point P with respect to theoretical tooth surface at B is given by…”

“…However, the cumulative pitch deviation, F p ( ł 6 0.02 mm), is sensitive to workpiece eccentric error, the maximum pitch deviation is twice as much as the eccentric error, while the single flank deviation, 6 f pt ( ł 6 0.002 mm), is insensitive to workpiece eccentric error. In fact, the influence of gear eccentric error on tooth deviation is the same as used in other gear cutting method, such as gear grinding method in Fang et al, 12 because the rotary center of gear is off machine center. Figure 5 shows the influence of cutter eccentric error (e 2 = 0.02 mm) on tooth deviation.…”

“…At present, with regard to error modeling and error analysis of gear machine tools, the literature mainly focus on geometric error modeling and thermal error modeling of gear hobbing and gear grinding. [12][13][14] Only Guo et al 15 studied the influences of tool setting errors on gear skiving accuracy by discussing the micromorphology of the generated tooth surface. In fact, power skiving is different from the traditional gear generating method as a new gear cutting method.…”

Modeling and adaptive compensation of tooth surface contour error for internal gearing power honing

“…Kc determines the coupling and compensation effects of the tooth surface contour error for the ECCC. M and N represent the error coupling and control quantity decoupling modules, which are defined by equations (11) and (12), respectively e = ½e C1 , e C2 , e Z1 Á M ð11Þ…”

“…Some classical error modeling methods for machine tool processing, such as Denavit-Hartenberg (D-H), rigid body kinematics, homogeneous transformation matrix (HTM) and screw theory, have been developed in previous research works. [8][9][10] Fang et al 11 established the model of tooth profile deviation, helix deviation and cumulative pitch deviation using HTM via changing gear eccentricity error, gear inclination error and gear resultant error. Chen et al 12 established a comprehensive error model of six-axis computer numerical control (CNC) spiral bevel gear grinding machine by utilizing the multi-body system theory and HTM.…”