Identification of crucial geometric errors of face gear grinding machine based on geometric error-tooth surface normal error model considering worm dressing

Abstract

The existence of geometric error (GE) of the grinding machine leads to a great decrease in the accuracy of worm dressing and face gear grinding. Currently, scarce researches consider the influence of GE of the grinding machine on the tooth surface normal error (TSNE) of face gears in the whole process from worm dressing to face gear grinding. For straightly disclosing the mapping laws between the GE and TSNE, the whole process from worm dressing to face gear grinding, and the interaction between the worm and face gear tooth surface are simultaneously considered to establish the GE-TSNE model (GE-TSNEM). Then, the crucial GEs are identified through global sensitivity analysis combined with actual GE measurement results. Finally, the validity of the identification results is verified. The results show that the crucial GEs in the whole dressing-grinding process can be effectively identified through one calculation by the GE-TSNEM. More than 25% of the crucial GEs originate from the worm dressing process, and the consideration of the worm dressing process is indispensable when establishing the GE-TSNEM. The correctness of the identification results and the validity of the method are verified as the total error reduction rates are higher than 75%.