A CNC grinding method and envelope residual model for face gear

This paper proposes a grinding method for face gears with CNC machines. Interpolation formulas of CNC linkage are deduced based on a five-coordinate machine tool. An analytical model for predicting envelope residual when grinding face gears based on grinding disc wheel is developed. The generating laws of envelope residual for the envelope manner are investigated. The influence of tool feed magnitude on surface envelope residuals is analyzed in circumferential angle direction. The maximum envelope residual increases nonlinearly with incremental angle. A grinding experiment is performed on a CNC grinding machine. The tooth surface deviation indicates that the CNC grinding method is efficient. The variation trends of different feed magnitudes along circumferential angle direction coincide with the simulation results. Finally, the values of envelope residuals are verified by an envelope simulation with software AutoCAD. The study provides an effective approach for parameter selection of highly precise and efficient grinding of face gear.