Continuous generating grinding has become an important gear processing method owing to its high efficiency and precision. In this study, an adaptive design model is proposed for the continuous generation of beveloid gears in common gear grinding machines. Based on this model, a method for determining the installation position and grinding kinematics is developed alongside an analytical meshing model for grinding contact trace and derivation of key grinding parameters. By combining these aspects, a general mathematical model for the continuous generation of beveloid gears is presented, comprising the entire grinding process from worm wheel dressing to the evaluation of grinding deviation. The effects of the worm and dressing wheel parameters on the grinding deviation were analysed, facilitating the development of an approach to improve the grinding accuracy. The presented procedure represents a novel design method for the continuous generation of beveloid gears in common gear grinding machines, facilitating the appropriate selection of worm and dressing wheel parameters.
The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-022-00388-z
Bing Cao
,
Guo-Long Li
,
Alessandro Fortunato
,
Heng-Xin Ni
. Continuous generating grinding method for beveloid gears and analysis of grinding characteristics[J]. Advances in Manufacturing, 2022
, 10(3)
: 459
-478
.
DOI: 10.1007/s40436-022-00388-z
1. Beam AS (1954) Beveloid gearing. Mach Des 26:220-238
2. Mitome K (1985) Conical involute gear:part 3. Tooth action of a pair of gears. Bull JSME 28:2757-2764
3. Mitome K (1986) Inclining work-arbor taper hobbing of conical gear using cylindrical hob. J Mech Transm Autom Des 108:135-141
4. Mitome K (1993) Infeed grinding of straight conical involute gear. JSME Int J Ser C Dyn Control Robot Des Manuf 36:537-542
5. Li G, Jiang P, Cao B et al (2018) Generating grinding method of beveloid gears with conical worm wheel. Comput Integr Manuf Syst CIMS 24:1138-1146
6. Cao B, Li G (2019) Effect of installation errors on beveloid gears' precision ground by cone-shape worm wheel. Forsch Ing 83:727-739
7. Cao B, Li G (2021) Computerized design of plunge shaving tool for beveloid gears and plunge shaving characteristic analysis.Mech Mach Theory 161:104325. https://doi.org/10.1016/j.mechmachtheory.2021.104325
8. Komatsubara H, Mitome K, Ohmachi T (2002) Development of concave conical gear used for marine transmissions (1st Report, Principle of generating helical concave conical gear). JSME Int J Ser C 45:371-377
9. Liu C, Tsay C (2002) Mathematical models and contact simulations of concave beveloid gears. J Mech Des 124:753-760
10. Wu SH, Tsai SJ (2009) Geometrical design of skew conical involute gear drives in approximate line contact. Proc Inst Mech Eng C J Mech Eng Sci 223:2201-2211
11. Wu S, Tsai S (2009) Contact stress analysis of skew conical involute gear drives in approximate line contact. Mech Mach Theory 44:1658-1676
12. Liu C, Tsay C (2002) Contact characteristics of beveloid gears. Mech Mach Theory 37:333-350
13. Liu S, Song C, Zhu C et al (2018) Effects of tooth modifications on mesh characteristics of crossed beveloid gear pair with small shaft angle. Mech Mach Theory 119:142-160
14. Brecher C, Löpenhaus C, Brimmers J (2016) Function-oriented tolerancing of tooth flank modifications of beveloid gears. Procedia CIRP 43:124-129
15. Brecher C, Röthlingshöfer T, Gorgels C (2008) Manufacturing simulation of beveloid gears for the use in a general tooth contact analysis software. Prod Eng Res Devel 3:103-109
16. Xu Z, Kim J, Kim L et al (2015) Study on modular modeling and performance evaluation of a conical gear for marine transmission system. Int J Precis Eng Manuf 16:1123-1128
17. Dietz C, Wegener K, Thyssen W (2016) Continuous generating grinding:machine tool optimisation by coupled manufacturing simulation. J Manuf Process 23:211-221
18. Zhou W, Tang J, Chen H et al (2019) Modeling of tooth surface topography in continuous generating grinding based on measured topography of grinding worm. Mech Mach Theory 131:189-203
19. Wu Y, Hsu W (2014) A general mathematical model for continuous generating machining of screw rotors with worm-shaped tools. Appl Math Model 38:28-37
20. Brecher C, Brumm M, Hübner F (2015) Approach for the calculation of cutting forces in generating gear grinding. Procedia CIRP 33:287-292
21. Litvin FL, Fuentes A, Zanzi C et al (2002) Face-gear drive with spur involute pinion:geometry, generation by a worm, stress analysis. Comput Methods Appl Mech Eng 191:2785-2813
22. Klocke F, Brumm M, Reimann J (2013) Modeling of surface zone influences in generating gear grinding. Procedia CIRP 8:21-26
23. Böttger J, Kimme S, Drossel W (2019) Simulation of dressing process for continuous generating gear grinding. Procedia CIRP 79:280-285
24. Fong Z, Chen G (2016) Gear flank modification using a variable lead grinding worm method on a computer numerical control gear grinding machine. J Mech Des 138(8):083302. https://doi.org/10.1115/1.4033919
25. Wu YR, Fan CW (2013) Mathematical modeling for screw rotor form grinding on vertical multi-axis computerized numerical control form grinder. J Manuf Sci Eng 135(5):051020. https://doi.org/10.1115/4025339
26. Jia K, Guo J, Zheng S et al (2019) A general mathematical model for two-parameter generating machining of involute cylindrical gears. Appl Math Model 75:37-51
27. Merritt HE (1951) Gears, 3rd edn. Isaac Pitman & Sons, London
28. Litvin FL, Fuentes A (2004) Gear geometry and applied theory. Cambridge University Press, Cambridge
