Design and manufacture of gear cutting tools and gears with an arbitrary profile. (2nd report Trueing of wheel with NC dresser and form grinding of helical gears)

Abstract

By applying the theory in the 1st report, the authors proposed a method to calculate the exact profile of a form grinding wheel for finishing a helical gear with an arbitrary tooth profile. Using this method, they calculated the exact wheel profile which can produce an involute tooth profile with a tip relief at a transverse section of the involute helical gears. The wheel profile was generated by a single point diamond dresser using a universal NC milling machine with an attachment made by the authors. The tooth flank and root of test gears were ground at the same time to prevent occurrence of a notch which is apt to be produced at the boundary of ground and unground surfaces. The accuracy of the form-ground test gears was in the 0 class of JIS and their surface roughness was in the range of 0.5 to 1.0 μm Rmax.