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Research Papers

Novel Third-Order Correction for a Helical Gear Shaping Cutter Made by a Lengthwise-Reciprocating Grinding Process

[+] Author and Article Information
Chin-Lung Huang

Department of Mechanical Engineering, National Chung-Cheng University, 168 University Road, Min-Hsiung, Chia-Yi, Taiwan 621, R.O.C.

Zhang-Hua Fong

Department of Mechanical Engineering, National Chung-Cheng University, 168 University Road, Min-Hsiung, Chia-Yi, Taiwan 621, R.O.C.imezhf@ccu.edu.tw

Shi-Duang Chen, Kuang-Rong Chang

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

J. Mech. Des 131(5), 051008 (Apr 07, 2009) (8 pages) doi:10.1115/1.3087553 History: Received March 30, 2008; Revised January 14, 2009; Published April 07, 2009

Although the Isoform® lengthwise-reciprocating grinding process is considered as one of the most accurate methods for generating the tooth profile geometry of a helical gear shaping cutter, the tooth profile accuracy produced by the Isoform® with a straight cone grinding wheel is not accurate enough for high precision requirement. That is why the shaper cutter is used as a rough cutting tool for most cases. A third-order profile correction to the cone grinding wheel is proposed to increase the accuracy of the work gear profile. A novel topography is developed to schematically show the work gear tooth profile accuracy cut by a resharpened shaping cutter. The profile errors corresponding to the varied resharpening depth are shown in the topography with information of true involute form diameter and semitopping depth. The usable resharpening depth of the shaping cutter can be determined by this topography. The numerical result indicates that third-order correction reduces the profile error of the major cutter enveloping gear to submicro and extends the resharpening depth.

FIGURES IN THIS ARTICLE
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Copyright © 2009 by American Society of Mechanical Engineers
Topics: Gears , Errors , Grinding
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References

Figures

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Figure 1

Main underlying concept of the Isoform® shaper 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 shaper cutter

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Figure 4

Coordinate systems applied to a defining cutter face

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Figure 5

Helical motion of the cutter

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Figure 6

Geometry of the curve-form equivalent rack

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Figure 7

Coordinate systems of the shaping process

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Figure 8

Profile error of the major cutter enveloping gear without correction

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Figure 9

Profile error of the major cutter enveloping gear after first-order correction

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Figure 10

Profile error of the major cutter enveloping gear after second-order correction

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Figure 11

Profile error of the major cutter enveloping gear after third-order correction

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Figure 12

Profile error topography of the gears cut by an uncorrected shaper’s cutter faces

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Figure 13

Profile error topography of the gears cut by the third-order corrected shaper’s cutter faces

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Figure 14

The third-order correction effects for various helix angles

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