A precision generating grinding method for face gear using CBN wheel

In order to improve the machining accuracy and production efficiency of face gear, a generating grinding method for face gear using cubic boron nitride (CBN) wheel is studied in this paper. The mathematical model of the CBN wheel profile is derived based on face gear grinding principle and theory of gearing. Taking the demands of machine motion during face gear grinding into account, a five-axis face gear grinding machine is developed. Then, the mathematical model of the ground face gear and the grinding method are proposed based on the structure of the machine. For reducing the face gear tooth profile errors induced by installation errors, an error analysis model of face gear grinding is established; the effects of installation errors on tooth profile errors are analyzed. The CBN wheel was manufactured, and the grinding experiments were performed on the self-developed grinding machine. The processing parameters of face gear grinding were amended according to the tooth flank measurement results obtained from coordinate measuring machine. The ground tooth profile deviation was reduced significantly after processing parameters amendment. Experiment results demonstrate that the generating grinding method is an effective approach to achieve the precision grinding of face gear.