The continuous generating grinding method for face gears based on general cylindrical gear grinding machine

This study achieves precision grinding of face gears in the general cylindrical gear grinding machine, meeting the increasing demand for efficiency and accuracy in face gear manufacturing. The machining motion of face gears is more complex than that of cylindrical gears, and the general gear grinding machine cannot meet the motion of continuous generating grinding of face gears. The worm forming dressing method based on virtual center distance is proposed to replace diamond wheel deflection with worm deflection, to solve that the diamond wheel cannot be deflected when dressing the crown worm wheel. The radial feed trajectory for grinding face gears is replanned to replace the linear feed with diagonal feed, to solve that the crown worm wheel cannot deflection horizontal during face gear grinding. Finally, the tooth surface errors caused by the misalignment of the crown worm wheel during grinding are analyzed, and the numerical simulation and machining experiments are conducted for worm dressing and face gear grinding. The results show that the shape of the dressed worm is consistent with the simulation results, and the deviation of the machined face gear is within the error range of grade 5 accuracy.