Research Papers

Modified-Roll Profile Correction for a Gear Shaping Cutter Made by the Lengthwise-Reciprocating Grinding Process

[+] Author and Article Information
Chin-Lung Huang

 300 Luren Precision Co., Ltd., No. 1-1, Li Hsin 1st Road, Hsinchu Science Park, Hsinchu, Taiwan, R.O.C.

Zhang-Hua Fong

Professor621 Department of Mechanical Engineering,  National Chung-Cheng University, 168 University Road, Min-Hsiung, Chia-Yi, Taiwan, R.O.C.imezhf@ccu.edu.tw

J. Mech. Des 133(4), 041001 (May 03, 2011) (7 pages) doi:10.1115/1.4003683 History: Received April 21, 2010; Revised February 21, 2011; Published May 03, 2011; Online May 03, 2011

The tooth profile error of a gear shaping cutter made by the lengthwise-reciprocating grinding process (LRGP) is usually corrected by modifying the grinding wheel profile. However, such grinding wheel modification cannot eliminate the twisting profile error along the face of the shaping cutter. A kinematic modified roll motion for generating a shaping cutter is proposed to minimize such twisted profile errors even after cutter resharpening. The tooth profile errors of the work gears generated by the shaping cutter with various resharpening depths are represented as a novel topographic error map. Based on the error map and its sensitivity matrix, the roll ratio between the shaping cutter and the grinding wheel stroke is modified to reduce the twisted profile error as illustrated by the numerical examples. Combining this modified roll motion modification and the grinding wheel profile correction, the high accuracy resharpening depth of the LRGP helical shaping cutter is increased.

Copyright © 2011 by American Society of Mechanical Engineers
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Figure 1

Isoform® shaping cutter grinding method

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Figure 2

Spatial relationship between the reciprocating grinding wheel and the equivalent rack

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Figure 3

Coordinate systems applied to the generation of a helical shaping cutter

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Figure 4

Coordinate systems applied to define the resharpened cutting faces

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Figure 5

Helical motion of the shaping cutter

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Figure 6

Coordinate systems of the shaping process

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Figure 7

Topographic error map for a work gear cut by the original shaping cutter

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Figure 8

Topographic error map for a work gear cut by the shaping cutter with a modified roll motion

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Figure 9

Topographic error map for a work gear cut by a shaping cutter with a third-order form correction on the grinding wheel

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Figure 10

Topographic error map for a work gear cut by a shaping cutter with a modified roll motion and a third-order form correction



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