拓扑修形斜齿轮齿面插齿修正

A method based on a lengthwise-reciprocating point contact grinding shaping cutter by a cone grinding wheel was proposed to improve the accuracy and life of the shaping cutter and to finish topologically modified helical gears by shaping. First, a gear shaping profile model was developed based on meshing theory and the kinematic relationship between grinding wheel and cutting tool. Then, corrections of a pressure angle, axial profile and generating motion for the grinding wheel were proposed to minimize twisted profile errors from the cutter on effective resharpening depth. The radial position and the total stroke times for the cone grinding wheel were determined by equal roughness grinding method to improve the grinding efficiency. The helical gear shaping model with two degree of freedom was established, and actual object flank modification for gear was derived based on the surface error from shaped gear without modified gear shaping and the given target normal modification of the gear. Finally, with shaping cutter corrections parameters (pressure angle, axis profile for grinding wheel and modified roll motion for generating a shaping cutter) and shaping process corrections parameters (rotation angle of shaped gear and center distance between shaping cutter and shaped gear), the sensitivity of these corrections parameters was derived based on the topographic normal deviation on the gear tooth flank. Besides, the corrections parameters were determined by minimizing the flank errors as a target.