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 R_max.