An identification method for a large-scale helical gear grinding process based on analysis of geometric errors

Ensuring high accuracy control of machine axes is crucial for achieving top-notch product quality. In the context of large-scale helical gear grinding, the interplay between geometric errors of individual axes can have a synthetical impact on gear accuracy. However, it is challenging yet vital to quantitatively describe the impacts on the surfaces of gear teeth. To address these limitations, an identification method is proposed that treats the machine axes and gear grinding process as a coupled entity. Initially, a model considering homogeneous transformation matrix (HTM) and tooth contact analysis (TCA) is constructed to establish the relationship between the geometric errors and TCA. Subsequently, geometric errors of the gear grinding machine axes are investigated and measured using the XM-60 multi axis calibrator system. The parametric equations of the disc and gear pair are then determined based on the axes of meshing theory, providing a foundation for solving nonlinear equations. Finally, the proposed method is implemented to analyze the path of the contact points and the transmission errors for machine axes. The findings of this study present the main conclusion: The path of the contact points can lead to the insertion or the deviation of the disc and gear pair. Therefore, this technique proves to be effective in managing geometric errors within a singular axis and offers valuable guidance for its installation and fine-tuning.