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Formation mechanism study on tooth surface of two gear finishing processes: combined theoretical and experimental approaches

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Abstract

As the necessary conditions, high precision and good mechanical performance gear is very important for a high speed and precision transmission system. To meet the requirement of the performance, gear finishing processes including gear honing and gear grinding have been mainly adopted. To compare the tooth surface of these two gear finishing processes, this paper gives the formation mechanism of gear tooth surface texture and conducts some comparative experiments on the gear surface texture and residual stress. Based on the spatial engagement principle and the discrete points of work-piece gear tooth spiral involute surface, the tooth surface contact area models of gears from the two processes are built, respectively, and the prediction models of honing paths and grinding paths are generated according to the velocity vector of the sampling points on tooth surface. Then the contrast and verification tests of the prediction models are carried out on internal gearing power honing machine and worm wheel gear grinding machine, respectively. Results indicate that the predicted curve shape honing paths and the longitudinal linear shape grinding paths of tooth surface are both similar to the experiment ones, respectively. Furthermore, some detailed quantitative analyses of tooth surface qualities including surface texture and tooth surface residual stress has been finished. It is found that the surface roughness value of gear grinding work-piece gear tooth surface is lower than that of gear honing process and the distribution of compressive residual stress on gear tooth surface is associated with the principles and parameters of the two processes. This research has theoretical and instructional significance for the improvement of gear honing and grinding processes.

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Abbreviations

(H) and (G):

Gear honing and gear grinding

r b1 :

The base circle radius of work-piece gear

λ 1 :

The generating angle of involute at the contact point

v O1 :

The velocity vector of the contact point on the tooth surface of work-piece gear

v O2 :

The velocity vector of the contact point on the tooth surface of honing wheel or grinding wheel

v 12 :

The relative velocity vector of a random contact point in coordinate system S(O − x − y − z)

n :

The tooth surface normal vector in coordinate system S(O − x − y − z)

r O1 :

The position vector of contact points on work-piece gear tooth surface in coordinate system S(O − x − y − z)

r O2 :

The position vector of contact points on honing wheel tooth surface in coordinate system S(O − x − y − z)

r 1 :

The position vector of contact points on work-piece gear tooth surface in coordinate system S1(O 1 − x 1 − y 1 − z 1)

β :

The helix angle of work-piece gear

m n :

The module of work-piece gear

v z :

The feed velocity of Z 1 axis

β :

The helix angle of work-piece gear

m n :

The module of work-piece gear

Σ:

The crossed axis angle between work-piece gear and honing wheel or grinding wheel

N 1 :

The tooth number of work-piece gear and grinding wheel

N 2 :

The tooth number of grinding wheel

φ 1 :

The rotation angle of work-piece gear

φ 2 :

The rotation angle of honing wheel or grinding wheel

w O1 :

The angular velocity vector of work-piece gear in coordinate system S(O − x − y − z)

w O2 :

The angular velocity vector of honing wheel in coordinate system S(O − x − y − z)

M OP :

The coordinate transmission matrix from Sp(O p − x p − y p − z p) to S(O − x − y − z)

M O1 :

The coordinate transmission matrix from S1(O 1 − x 1 − y 1 − z 1) to S(O − x − y − z)

r O1 :

The position vector of contact points on work-piece gear tooth surface in coordinate system S(O − x − y − z)

r O2 :

The position vector of contact points on honing wheel or grinding wheel tooth surface in coordinate system S(O − x − y − z)

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Acknowledgements

The authors would like to thank the National Natural Science Foundation of China (51575154) and National Science and Technology Major Project (2013ZX04002051) for supporting this research under Grant.

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Authors and Affiliations

  1. School of Mechanical Engineering, Hefei University of Technology, Hefei, 230009, People’s Republic of China

    Jiang Han, Bin Yuan, Dongling Wang, Chaohong Sun & Lian Xia

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  1. Jiang Han
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  2. Bin Yuan
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  3. Dongling Wang
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  4. Chaohong Sun
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  5. Lian Xia
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Correspondence to Lian Xia.

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Technical Editor: Márcio Bacci da Silva.

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Han, J., Yuan, B., Wang, D. et al. Formation mechanism study on tooth surface of two gear finishing processes: combined theoretical and experimental approaches. J Braz. Soc. Mech. Sci. Eng. 39, 5159–5170 (2017). https://doi.org/10.1007/s40430-017-0872-z

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  • DOI: https://doi.org/10.1007/s40430-017-0872-z

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