Theory analysis for application of disk tool of long radius in face gear machining

A method of face gear machined by long radius disk (profile of involute) tool (hob or grinding wheel) without feed motion was proposed aiming at improvement of processing efficiency of face gear machined by such tools. By coordinate transformation the derivation of equations of working flank and fillet surfaces of tooth was based on the design of disk tool and theory analysis of applying the disk tool without feed motion in the face gear machining. To reduce the errors of working flank and even avoid flank interference caused by such method of face gear manufacturing, another motion which rotated in a small angle rang was added into the process of face gear machining. Tooth contact analysis (TCA) was applied to demonstrate the meshing performance of the face gear cut by such method. Numerical examples illustrate that disk tool of long radius with additional motion is able to manufacture face gear with high-precision working flank (the max error of working flank is 19 μm), and the meshing performance of such face gear drive demonstrated by TCA is not second to that face gear drive wit theoretic working flank.