A method for grinding face gear of double crowned tooth geometry on a multi-axis CNC machine

The stability requirement of bearing contact and a favorable function of transmission errors motivates the investigation of design and manufacture technology of the face-gear drives. Application of a grinding disc wheel with axial profile modification and a longitudinal ease-off topography design of face gear tooth flanks could be proper utilized to obtain a double crowned tooth geometry, which results in the pre-designed bearing contact and desired transmission errors. With the profile crowned tooth geometry of the gear generated by the modified wheel cutter, finding of the execution motions to generate the tooth geometry with the longitudinal ease-off topography design on a multi-axis Computer Numerical Control (CNC) machine with the same tool is a major issue. Therefore, a universal method on the Design Optimization Techniques is proposed to obtain the execution motions for such problem. The proposed optimization methodology is also applicable for the tooth flank error correction by a worm hob or a grinding cutter on the CNC generator. With the term of additional movement of execution motion is defined, a detailed description of additional movements for the ease-offs of the real crowned tooth geometry is also investigated. The feasibility of proposed method is validated by numerical examples.