A Reliability-Enhanced Forming Grinding Method of Cylindrical Involute Gears for Electrical Vehicles

Abstract

A new form-grinding method of cylindrical involute gears for electrical vehicles (EVs) is proposed to obtain stable contact performance of gear tooth surfaces and improve their reliability based on a predesigned controllable second-order transmission error function. The predesigned second-order transmission error function is assigned to a gear drive based on design specifications of EVs. Mathematical models of modified gear tooth surfaces of the gear pair can be obtained by the predesigned second-order trans-mission error function. Moreover, a section profile of a form-grinding wheel for cylindri-cal involute gears can be determined by a coordinate transformation matrix during form-grinding and settings of computer numerical control form-grinding programs for this active design method. This approach is ultimately conducted on three cylindrical involute gear pairs to demonstrate its feasibility and effectiveness.