Modified-Roll Profile Correction for a Gear Shaping Cutter Made by the Lengthwise-Reciprocating Grinding Process

The tooth profile error of a gear shaping cutter made by the lengthwise-reciprocating grinding process (LRGP) is usually corrected by modifying the grinding wheel profile. However, such grinding wheel modification cannot eliminate the twisting profile error along the face of the shaping cutter. A kinematic modified roll motion for generating a shaping cutter is proposed to minimize such twisted profile errors even after cutter resharpening. The tooth profile errors of the work gears generated by the shaping cutter with various resharpening depths are represented as a novel topographic error map. Based on the error map and its sensitivity matrix, the roll ratio between the shaping cutter and the grinding wheel stroke is modified to reduce the twisted profile error as illustrated by the numerical examples. Combining this modified roll motion modification and the grinding wheel profile correction, the high accuracy resharpening depth of the LRGP helical shaping cutter is increased.