An efficient honing method for face gear with tooth profile modification

Abstract

To improve the production efficiency of the face gear, this paper studies a honing method for face gear with tooth profile modification and proposes a face gear honing principle. Based on the honing principle, a mathematical model of the face gear honing cutter is derived. The tooth profile of the honing cutter is modified by controlling the longitudinal modification coefficient of the generating rack cutter. Then, the tooth flank equation of the honed face gear is derived according to the machine structure. To ensure the face gear accuracy, an error analysis model including the axial, tangential, and radial tool setting errors is presented, and the effects of tool setting errors on the face gear geometry errors are analyzed. The honing cutter is manufactured, and the face gear honing experiments are performed. The measurement results of the tooth surface deviations indicate that the maximum deviation decreases from 39.4 to 15.1 μm by amending the processing parameters. The experimental results prove that the honing method is an effective approach to improve the production efficiency of the face gear.