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Research Papers: Design of Direct Contact Systems

Gear Flank Modification Using a Variable Lead Grinding Worm Method on a Computer Numerical Control Gear Grinding Machine

[+] Author and Article Information
Zhang-Hua Fong

Chair Professor
Mechanical Engineering;
President,
National Chung-Cheng University,
168, University Road,
Min-Hsiung, Chia-yi 621, Taiwan
e-mail: imezhf@ccu.edu.tw

Gwan-Hon Chen

Department of Mechanical Engineering,
National Chung-Cheng University,
168, University Road,
Min-Hsiung, Chia-yi 621, Taiwan
e-mail: mr.taroz@gmail.com

1Corresponding author.

Contributed by the Power Transmission and Gearing Committee of ASME for publication in the JOURNAL OF MECHANICAL DESIGN. Manuscript received March 8, 2016; final manuscript received June 14, 2016; published online June 30, 2016. Assoc. Editor: Qi Fan.

J. Mech. Des 138(8), 083302 (Jun 30, 2016) (10 pages) Paper No: MD-16-1195; doi: 10.1115/1.4033919 History: Received March 08, 2016; Revised June 14, 2016

Tooth crowning of a ground helical gear is usually done by adjusting the radial feed with respect to the axial feed of the grinding worm on the modern CNC gear grinding machine. However, when the amount of crowning and the helical angle of the gear are large, this method always results in a twisted tooth flank. Hence, in this paper, we propose a tooth flank crowning method for helical gears, which uses a diagonal (combined tangential and axial) feed on a grinding machine with a variable lead grinding worm (VLGW) obtained by adjusting the axial feed of the dressing disk with respect to the rotation angle of the grinding worm. Since all the required corrective motions for the proposed VLGW method are existing CNC controlled axes on modern gear grinding machines, it can easily be implemented without extra cost to modify the grinder hardware. Three numerical examples are presented to show the validation of the proposed method and its ability to reduce tooth flank twist even in the case of a large helical angle, with a particularly significant reduction on a crowned helical gear.

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References

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Figures

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Fig. 1

Definition of axes on a gear grinding machine [20]

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Fig. 6

Tooth flank sensitivity topographies for small changes in the design variables, δ=−0.01

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Fig. 2

Coordinate system of the schematic generation mechanism for grinding worm dressing

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Fig. 4

Coordinate system of the schematic generation mechanism for gear grinding

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Fig. 3

EGB of a CNC gear grinding machine [8]

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Fig. 10

Tooth surface deviation topography modified by VLGW, example 2

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Fig. 11

Tooth contact analysis for example 2; gear 1 is modified by the VLGW method, and gear 2 is a standard involute gear

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Fig. 5

Normal deviation topography for the tooth surface of work gear: (a) digitized as a grid mesh on work gear tooth surface and (b) normal deviation topography for work gear

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Fig. 7

Tooth surface deviation topography modified by second-order radial feed, example 1

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Fig. 8

Tooth surface deviation topography modified by second-order radial feed, example 1

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Fig. 9

Tooth contact analysis for example 1; gear 1 is modified by the radial feed method, and gear 2 is a standard involute gear

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Fig. 12

Target tooth surface modification topology, example 3

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Fig. 13

Tooth surface deviation topography by VLGW, example3

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Fig. 14

Tooth contact analysis for example 3; gear 1 is modified by the VLGW method with combined crowning, and gear 2 is a standard involute gear

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