An Innovative Flexible-Honing Method with Dampers for Long-Life, Mass-Machining of Face Gears

To further exert the technical advantages of face gears, high-end equipment puts forward the need for the long-life mass-machining of face gears. However, the commonly used technique of hard honing is more sensitive to installation errors and impact loads, and soft honing has insufficient removal ability to the margin, so the quality of the gear’s life is difficult to guarantee. To solve this contradiction, this paper introduces a damper to honing and proposes a flexible honing method for face gears. First, to reveal the flexible honing mechanism, the tooth-surface model of face-gear honing is derived, and the mathematical model for face-gear flexible honing is established. Second, to clarify the influence of flexible honing parameters on the quality of the tooth surface, a roughness model of the honing surface is established, and the influence of flexible honing parameters on roughness is analyzed. Third, by analyzing the influence of roughness under the action of honing parameters on the stress of the tooth surface, the parameters for flexible honing are determined. Finally, the effectiveness of the method is verified by flexible honing machining and testing.