Key Takeaways & Executive Findings
- •• A flexible higher-order gear topology modification technique based on electronic gearbox is proposed to solve additional axis motion problems in higher-order topology modification. • Two-parameter topology gear surface equation and grinding model are established, with axial and tangential feeds expressed as fifth-order polynomials. • An improved electronic gearbox model combining polynomial interpolation enables gear topology modification without changing grinding wheels. • Experimental validation confirms the method's feasibility for continuous generative grinding with worm grinding wheels, significantly improving machining precision and efficiency.
Abstract
Gear flank modification is essential to reduce the noise generated in the gear meshing process, improve the gear transmission performance, and reduce the meshing impact. Aiming at the problem of solving the additional motions of each axis in the higher-order topology modification technique and how to accurately add the different movements expressed in the form of higher-order polynomials to the corresponding motion axes of the machine tool, a flexible higher-order gear topology modification technique based on an electronic gearbox is proposed. Firstly, a two-parameter topology gear surface equation and a grinding model of wheel grinding gears are established, and the axial feed and tangential feed are expressed in a fifth-order polynomial formula. Secondly, the polynomial coefficients are solved according to the characteristics of the point contact when grinding gears. Finally, an improved electronic gearbox model is constructed by combining the polynomial interpolation function to achieve gear topology modification. The validity and feasibility of the modification method based on the electronic gearbox are verified by experimental examples, which is of great significance for the machining of modification gears based on the continuous generative grinding method of the worm grinding wheel.
1. Introduction
Gears are a vital fundamental component in the industry, widely used in aerospace, rail transport, new energy vehicles, and other industries. The processing quality of gears directly determines the service performance of the equipment, so the transmission system of high-end equipment puts forward higher requirements for the precision processing of gears [1]. The method named continuous generation grinding has significant advantages in industrial applications due to its high processing efficiency and machining accuracy [2]. To improve the gear transmission performance (load distribution, noise, vibration, etc.), it is usually necessary to modify the gear [3].
The traditional tooth profile modification is generated by the interpolation movement of the workpiece and the radial direction of the grinding wheel relative to the workpiece gear along the tooth profile modification curve [4]. However, the flank modification of the helical gear will produce a distortion change of the tooth profile angle from the top to the bottom of the gear flank, resulting in deviation of the gear flank. That is the phenomenon of gear flank distortion [5]. When using the generating grinding method to modify the topology of the helical gear flank, it has generally been simplified into tooth lead modification and tooth profile modification in the machining process. In the traditional machining process, when the workpiece gear needs to achieve tooth profile modification, it is necessary to modify the gear flank of the grinding wheel tool to the conjugate gear flank corresponding to the modified gear flank of the gear. It not only reduces production efficiency but also increases the processing cost. At the same time, it is hard to achieve the unification of design and manufacture. Therefore, how to accurately modify gear tooth flanks of any topology without changing grinding wheels has become a critical issue in gear modification machining technology.
Aiming at the above problems, scholars have carried out relevant research mainly from the computer numerical simulation of tools and workpieces, high-order polynomial modification technology, and gear flank deformation suppression. Among them, in terms of numerical simulation of cutting tools and workpieces, scholars used computer technology to simulate the gear flank of workpiece cutting tools and the forming process of gears. LITVIN et al [6] and LIN et al [7] discussed the necessary and sufficient conditions for the two-parameter envelope of the tool surface and applied the process of machining helical gears with grinding wheels. HE et al [8] proposed a two-parameter point-vector (PV) envelope method, established the point-vector envelope principle and approximation algorithm, and applied the approach to the calculation process of the left and right tooth profiles of grinding wheels. The experimental results show that the method can be used to calculate and process any gear tooth profile with high machining accuracy. CHIANG et al [9] proposed a simplified two-dimensional numerical simulation method that can be used to simulate the grinding process of cylindrical gears.
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Tian Xiao-qing, Lu Yi-guo, You Tong-fei, Tang Jian-ping, Rui Xiao-yu, Li Guang-hui, Xia Lian, Han Jiang (2025). Gear flank modification and precision control based on electronic gearbox. Journal of Central South University. https://doi.org/10.1007/s11771-025-5881-y
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Frequently Asked Questions
What is the electronic gearbox-based gear flank modification technique?
The technique is a flexible higher-order gear topology modification method that uses an electronic gearbox model combined with polynomial interpolation to achieve gear flank modification without changing the grinding wheel. It expresses axial and tangential feeds as fifth-order polynomials, enabling precise control of additional machine tool axis motions.
How does the proposed method solve the problem of higher-order topology modification?
By establishing a two-parameter topology gear surface equation and a grinding model, and solving polynomial coefficients according to point contact characteristics, the method constructs an improved electronic gearbox model that accurately adds higher-order polynomial motions to the machine tool axes.
Why is gear flank modification important in gear manufacturing?
Gear flank modification reduces noise during gear meshing, improves transmission performance, and lowers meshing impact. It is essential for high-end applications such as aerospace, rail transport, and new energy vehicles.
What are the advantages of the continuous generation grinding method?
Continuous generation grinding offers high processing efficiency and machining accuracy, making it advantageous for industrial gear manufacturing. The proposed modification method is compatible with this process using a worm grinding wheel.
Can the modified gears be produced without changing grinding wheels?
Yes, the key significance of this research is that it allows accurate modification of gear tooth flanks of any topology without changing grinding wheels, thereby reducing production costs and improving efficiency.
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