Method of designing gear-honing-wheel geometries (Validation based on fundamental theory and honing experiments)

The present paper describes a method for determining geometries of gear-honing wheels used in the final process for manufacturing automotive transmission gears. Inappropriate geometries of gear-honing wheels could cause large undulations on finished gear-tooth flanks, and the finished gear would be out of the required accuracy. In such cases, the geometries of gear-honing wheels are required to be modified iteratively until the finished gears have sufficient accuracy. The change in meshing stiffness of a gear-honing wheel and a finished gear significantly affects the rotational synchronization. The poor rotation synchronization could cause the large undulation on a finished gear-tooth flank, to be different from the target micro geometries. This paper presented a geometrical approach that was proposed for a determination method of gear-honing-wheel geometries. The method allows the meshing stiffness to be balanced. Gear-honing wheels designed with the proposed method induced the desired micro geometries of finished gear-tooth flanks in gear-honing experiments. Therefore, the proposed method with the geometrical approach could be useful for the determination of gear-honing-wheel geometries.