A novel gear flank modification methodology on internal gearing power honing gear machine

In order to reduce the impact of load fluctuation, noise and vibration, the tooth surface of the gear in the high speed transmission gearbox is usually modified along the lead and profile direction. In this paper, a method for lead and profile crowning tooth flank of work gear is proposed by setting the movement of A and B axes as two fourth order polynomial functions of axial feed of work gear in the internal gearing power honing. Diamond dressing gear used for honing stone in dressing process is standard involute, and it is not necessary to design an especial diamond dressing gear for each different modified gear. The sensitivity matrix of polynomial coefficients is calculated by the normal deviation of the gear tooth surface, and the influence of the variation of polynomial coefficients on the tooth surface is studied. The honed tooth surface can be approximated to the given tooth surface by adjusting the polynomial coefficients through least squares estimation with the aim of minimization of the tooth surface errors based on sensitivity matrix. The effectiveness of this crowning tooth flank modification method is confirmed numerically using a helical gear on the internal gearing power honing machine.