Computation of parameters of a form grinding wheel for grinding of shaving cutter for plunge shaving of topologically modified involute pinion

The paper is targeting on the finishing of precision gears for low-noise/noiseless transmission for cars and light trucks. Transmission error is the predominant cause of gear noise. The application of a topologically modified pinion results in reduction of transmission error tip to two times. The required modification of the pinion tooth surface is provided on a plunge shaving operation with application of a shaving cutter of an appropriate design. A novel approach for computation of parameters of a form grinding wheel for grinding of the shaving cutter for plunge shaving of a precision involute pinion with topologically modified tooth surface is reported in the paper. The developed approach for computation of parameters of the form grinding wheel is focused on application of the shaving cutter grinder with a lack of CNC articulation. The problem under consideration is solved using the DG/K-based approach of part surface machining earlier developed by the author (The DG/K-approach is based on fundamental results obtained in differential geometry of surfaces, and in kinematics of multi-parametric motion of a rigid body in E-3 space (See Radzevich, S.P, Sculptured Surface Machining on Multi-Axis CNC Machine. Monograph, 1991, Vishcha Shkola publishers, Kiev (in Russian). See also Radzevich, S.P., 2001, Fundamentals of Surface Machining. Monograph, Rastan, Kiev (in Russian).) An analytical solution to the problem is discussed in the paper The solution has been used for developing software for the Mitsubishi ZA30CNC shaving cutter grinder for the needs of the automotive industry. Computer simulation reveals high accuracy of the ground shaving cutter.