A Transmission-Error-Based Gear Form-Grinding Method for Electrical Vehicles

Abstract A new gear form-grinding method based on a predesigned controllable second-order transmission error function is proposed to obtain stable contact performance of gear tooth surfaces and improve their reliability for electrical vehicles (EVs). The predesigned second-order transmission error function is assigned to a gear drive based on the design specifications of EVs. Mathematical models of modified gear tooth surfaces of the gear pair can be obtained by the predesigned second-order transmission error function. Moreover, a section profile of a form-grinding wheel for cylindrical involute gears can be determined by a coordinate transformation matrix during form-grinding and settings of computer numerical control form-grinding programs for this active design method. The proposed gear form-grinding is ultimately conducted on three cylindrical involute gear pairs to demonstrate its feasibility and effectiveness.