Abstract

In this study, a mathematical model of the honing process for helical gears with external teeth was developed. The proposed novel method of obtaining the two-parameter envelope of a family of surfaces proved useful in simulated machining by means of a tool with a profile deviation. Based on performed simulations and industrial applications, it was found that this method can be useful in predicting the accuracy of machined gear and therefore can be used in the design process of honing tool for high precision aerospace gears. For the example provided, the average absolute prediction error of machined tooth profile was 0.28 µm.

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