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This paper proposes a topology modification method of generating gear grinding based on multi-axis linkage parameter optimization. In order to improve the accuracy of tooth flank modification in generating gear grinding and to reduce the transmission error of modified gear pair, a multi-objective optimization genetic algorithm is adopted to adjust machine movement. Firstly, according to the position and motion relationship among diamond wheel, worm wheel, and workpiece gear, the mathematical models of worm wheel dressing and generating gear grinding are established. The linkage relationships between motion axes are redefined to achieve topology modification. The radial feed F X 1 , tangential feed F Y 1 of worm wheel, and gear rotational angle φ g are defined as the fourth-order polynomial function of axial feed F Z 1 . Secondly, the transmission error model of modified gear is developed. And the polynomial coefficients of each axis are optimized with the objective of minimizing total tooth flank deviation and transmission error. Finally, the effectiveness of this method is verified by three numerical examples with different parameter groups. In addition, the diamond wheel and worm wheel used in the study are standard profile, which saves the cost of gear machining and improves the efficiency of production cycle. The research results could provide a theoretical reference for the improvement of generating gear grinding process. [ABSTRACT FROM AUTHOR]

Laser ablation is an effective and advantageous dressing method for dressing diamond grinding wheels. Previously, research on laser dressing has focused on parallel and convex face diamond wheels. Studies of the laser dressing model analysis and the sources of shape error for concave diamond wheels are less numerous. There is no research to analyse the source of the diamond wheel error from the optics itself. In this paper, a novel deflectable dual-laser misaligned tangential (DDLMT) dressing method was proposed for processing concave rectangular bronze-bonded diamond wheels. Using the DDLMT process, the slope effect error in dressing concave rectangular diamond wheels was basically eliminated. To analyse the causes of the slope effect error during profiling, a theoretical study of the laser radial and tangential dressing methods was carried out, and a mathematical model was established to analyse the laser energy loss mechanism. Experiments on different positions dressings were conducted to validate the mathematical model. The DDLMT dressing method offered a significant improvement in contour accuracy and more than doubled the dressing efficiency compared to single beam profiling. As the laser deflection angle increased, the angle deviation of the dressed right-angle contour gradually decreased. The least deviation of right-angle profile obtained was 0.51° when the deflection angle was 5°. The final PV value of the bottom contour was 11.83 μm, which had a better contour accuracy. The surface quality of the grinding wheel by DDLMT dressing is far better than that of radial dressing. The experimental results demonstrated the potential of the DDLMT dressing method for precision profiling diamond wheels. [Display omitted] • A novel deflectable dual-laser misaligned tangential dressing method was proposed. • A mathematical model was established to analyse the laser energy loss mechanism. • The least angle deviation obtained was 0.51° when the deflection angle was 5°. • The study demonstrated potential of the DDLT method for dressing grinding wheels. [ABSTRACT FROM AUTHOR]