Mathematical modeling and machining parameter optimization for the surface roughness of face gear grinding

Face gear is an important part in the power transmission of helicopter, but its grinding is a difficult problem. In order to enhance the finishing machining surface quality of face gear, the mathematical formula of the residual height of motion trajectory of abrasive grains was obtained, and the model of grinding surface roughness of face gear was corrected. In addition, machining parameter optimization for grinding surface roughness on a five-axis blade grinding machine was investigated by orthogonal experiment method. The experiment results indicated that disk wheel spindle speed and feed velocity of the disk wheel are more significant effect factors among the three factors. The calculation results of model showed that the maximum error comparing with the experiment results is not more than 13.5 %, which suggests that the mathematical model is reasonable.