Dimensional optimisation of the flat-faced grinding wheel to achieve interference free and rigid gear grinding

Higher gear-grinding accuracy can be obtained by using a flat-faced grinding wheel (FGW) and a generating method. However, the phenomenon of interfering with the adjacent tooth will happen when an unsuitable outer-edge width of the FGW is dressed. In order to optimise the shape of the FGW and further improve its rigidity and grinding accuracy, studies on the relative motion trajectory of the FGW, the correlations of the maximum outer-edge width (wmax) with the head frame setting angle (HSA, αy) and the adjustment quantity (E) in the feed direction were conducted. Finally a motion simulation and a grinding experiment verified the reasonability of the mathematical model and several improved measures to achieve interference free and rigid gear grinding were obtained. The results have important significances on formulation of scientific ultra-precision gear-grinding processes. [Received 23 February 2014; Revised 23 October 2014; Accepted 02 December 2014]