Gear Grinding Processing

Developed for High-Precision

Gear Manufacturing
YUKIHISA NISHIMURA*1 YUJI ASHIZAWA*1
TOSHIFUMI KATSUMA*1 YOSHIKOTO YANASE*1
KOICHI MASUO*1

In recent years, many industries have been trying to introduce gear grinding machines, backed by the increasing demands for
low-noise gears in automotive transmissions and for high-precision large gears in construction machines, gearbox for wind turbine
systems, and printing machines. To address these demands, Mitsubishi Heavy Industries, Ltd. (MHI) has developed and added to its
product line-up two gear grinder products: the ZE series for mass production of small gears and the ZG series for medium and large
sized gears. This document describes the features of these products from the technical standpoint and explores the future prospects of
gear grinding because it is anticipated that more manufacturers will adopt this machining technique.

1. Introduction Wheel spindle

In recent years, from mass -produced small gears to Multi-thread

grinding wheel
medium and large sized gears, gear finishing technologies
are used after heat treatment to reduce vibrations and noise
from automotive transmissions or to improve the efficiency Tangential
feed Workpiece
and reduce the size of wind power generators. As for the
techniques for finishing gears after heat treatment, gear
grinding is commonly used in addition to carbide hobbing Axial feed
and honing.
To add ress t he d iversi f ied gea r- g r i nd i ng needs of
customers, MHI offers two lines of gear grinder products: the
ZE series for mass production of small gears and the ZG series
for medium and large sized gears. The following describes
Work spindle
the features of these products.

2. Features of the ZE series gear grinding machine

2.1 Diagonal grinding

Fig. 1 Schematic diagram of diagonal grinding
Gear grinders introduced into an automotive transmission Grinding wheel is fed axially into workpiece while
gear manufacturing line must satisfy productivity and tool being shifted in a tangential direction.
cost requirements in addition to machining accuracy. To
attain this, in ZE series gear grinding machines, we adopted
the continuous generating-grinding technique using a multi- constantly ground by new abrasives. ZE series grinders
thread grinding wheel. The use of diagonal grinding in provide the functionality to automatically dress the multi-
conjunction with the synchronized high-speed and high- thread grinding wheel using the rotary dresser and perform
precision control of the wheel and work spindles realizes diagonal grinding while sequentially shifting the portion of
high-accuracy and high-efficiency grinding. the grinding wheel that grinds the workpiece. Figure 2 shows
Figure 1 shows a schematic diagram of diagonal grinding. the transition of the tooth profile pressure angle when the
Diagonal grinding is a grinding technique in which the grinding wheel ground 40 workpieces between dressing
grinding wheel is fed into the workpiece in an axial direction cycles. According to the graph, the variation on both the
while being shifted along the tangential feed axis. This right and left flanks is 2 μm or less, which means that the
g r inding technique has advant ages in prevent ing the machine provides stable grinding precision even in high-
wear of the grinding wheel and improving the grinding volume gear production. Moreover, ZE series grinders can
efficiency with stable precision, because the workpiece is finish approximately 8,000 gears per grinding wheel because

*1 Machine Tool Division Mitsubishi Heavy Industries, Ltd.

Technical Review Vol. 45 No. 3 (Sep. 2008)
33
 Correction Measurement Correction
5
Profile angle deviation ( m)

: Deviation on right flank : 1.6 m result A result result B

: Deviation on left flank : 1.7 m
0 Right flank 0.5 m Right flank −2.7 m Right flank −14.0 m
Left flank 0.5 m Left flank −0.9 m Left flank −12.3 m

-5 Correction Correction
input value input value
-10 Right flank Right flank
+3 m −10 m

-15 Correction Correction

1 6 11 16 21 26 31 36
Left flank Left flank
No. of gears ground +1 m −10 m

Fig. 2 Transition of profile angle deviation between dressing cycles Fig. 4 Example of pressure angle correction
Transition of pressure angle when 40 workpieces were ground Correction amount is entered based on result of accuracy measurement.
continuously between dressing cycles.

it allows the dressing interval to be set to as many as 40 before and after pressure angle correction, respectively. To
workpieces. This means that the cost of grinding can be develop this function, we analyzed the relative positional
reduced to as low as 12 to 13 yen per workpiece. relationship between the two spindles when correcting the
2.2 Modification of tooth profile pressure angle pressure angle.
In the ZE series, to obtain a high-accuracy tooth profile, Figure 4 shows an example of correcting the pressure
the rotary dresser is set to almost the same position as that angle by entering the required correction amounts for
of the workpiece so that the grinding wheel is dressed on both tooth flanks into the NC system. It can be seen that
the machine in the same position and posture as when a the correction results almost reflect the input values. This
workpiece is ground. Because the dresser is set and adjusted function is becoming indispensable for customers in Japan
by an operator, there is a possibility of a setting error, which where the number of experienced operators is decreasing
in turn causes a profile pressure angle deviation. Although, and in overseas manufacturing plants without experts.
on competitors’ machines, the correction of the pressure 2.3 Machining simulation technologies
angle is accomplished manually by fine-adjusting the dresser In developing the ZE series, we created a machining
position, to help inexperienced operators, we developed simulation program based on the theory of meshing between
a functionality that completes this adjustment by simply threaded grinding wheel and workpiece and the existing
entering NC data. The process of fine-adjusting the dresser simulation technologies. A simulation example is shown
position is to change the relative positional relationship in Fig. 5. The figure represents the shapes of both tooth
with the grinding wheel and this is achieved by using the flanks at three points along the face width when the leads
NC system to move each axis to correct the grinding wheel are crowned. These are biased flank shapes in which the
position with the dresser fixed. Figure 3 is a schematic tooth profile pressure angle changes in the direction of the
diagram that illustrates this function. Figures 3 (a) and 3 (b) face width. The simulated data was very close to the actual
show the relative positions of the wheel and dresser spindles machining data collected from the grinders, so we decided to
use the program to simulate various machining applications.

(a) Before pressure angle correction

m : Wheel spindle
z z Plane 2 Tooth profile
Plane 1
m y y Crowning
I : Dresser spindle
o1 D o2 I
z y x Plane 1 Plane 2 : yz plane
x : Axis angle 10 μ
(Grinding wheel side) (Dresser side)

(b) After pressure angle correction

Lead
m’ : Wheel spindle
: Swivel angle
z z Plane 2’
Plane 1’
m’ y I’ y m’ is located on Plane 1’
I’ is located on Plane 2’
o1 o2
x x Plane 1’ and Plane 2’
are parallel : Locus of grinding points
(Grinding wheel side) (Dresser side) (with same normal vector) (points of contact)

Fig. 3 Pressure angle correction Fig. 5 Simulation of generating grinding

Mitsubishi Heavy Industries, Ltd.

Technical Review Vol. 45 No. 3 (Sep. 2008)
34
 2.4 Machining example of automotive transmission Tooth profile correction patterns
gears (ZE24A)
Using the ZE24A grinder, we finished a final gear (module
of 2.5, number of teeth 74, and face width 25 mm) with a
cycle time of 1.5 minutes and the accuracy of the finished
gear was JIS N1 grade for the tooth profile and lead and JIS
N3 grade for the pitch, respectively. The machining result is
shown in Fig. 6.

Machining example using ZE24

Tooth profile accuracy
Lead correction patterns

1. Straight 2. Crowning

3. Relief 4. Side crowning

Fig. 7 Tooth profile and lead correction patterns

Lead accuracy Tooth profile and lead can be entered and corrected in an easy,
conversational manner.

Workpiece (Gear)
C

Lead
Z
Tooth profile
Workpiece specifications
25

Module 2.5
No. of teeth 74 Measuring probe X
Face width 25 mm
Pressure angle 20°
Helix angle 30° RH

Fig. 6 Machining result

An automotive final gear was finished in 1.5 minutes to JIS N3-grade
accuracy.

Fig. 3 Result of thermal analysis of spindle

3. Features of ZG series gear grinding machines

3.1 Tooth profile and lead correction

ZG series grinding machines use vitrif ied grinding
wheels, which can be dressed into any shape on the machine
for complex tooth prof ile correction. Moreover, these Fig 8 On-machine measuring system and measurement result
grinders can correct the lead of gear teeth by controlling Tooth profile, lead, pitch can be measured.
the amount of radial infeed of the grinding wheel. ZG
series grinders provide the standard tooth profile and lead
patterns shown in Fig. 7 and allow the operator to specify which the replacement and measurement of the workpiece
the preferred tooth profile and lead in an easy, conversational is time-consuming, there is a strong demand for the on-
manner. machine measuring capability. In addition to the on-machine
3.2 On-machine measurement measurement function, ZG series grinders also provide
For medium- and large-sized gear grinding machines on the ability to calculate the correction amount automatically

Mitsubishi Heavy Industries, Ltd.

Technical Review Vol. 45 No. 3 (Sep. 2008)
35
from the measurement result in an effort to automate jobs Qw’ (mm 2/s)=ΔX (mm) × F (mm/min)/60
that require operator experience. Figure 8 shows the Where,
appearance of the measuring system and an example of a ΔX (mm): Amount of radial infeed
measurement result. F (mm/min): Axial feedrate
3.3 Bias modification Using the above formula, optimal radial infeed amount
In profile grinding, the grinding wheel makes a line and feedrate values are set for each cycle. Next, the cutting
contact with the workpiece and its direction is different from volume limit is set according to the grinding wheel in use,
the locus of the points of contact in generating grinding. This and then the dressing interval is calculated automatically
also appears as a difference in the flank shapes. Particularly, from the cutting conditions as follows.
when you crown a helical gear, generating grinding and Dressing interval =
profile grinding produce opposite trends of biased f lank Cutting volume limit (mm3/mm)/Amount of removed flank
shapes. Because many customers want to modify biased (mm3/mm)
flank shapes as desired, in profile grinding, we provide the Using the above formula, an optimal dressing interval
ability of flank shape modification that controls the contact is set based on the specifications of the grinding wheel
lines and machine operations. On the ZG series, bias and workpiece. Figure 10 shows an example of how the
modification is accomplished by the motion of the additional grinding conditions are set automatically.
tangential wheel feed axis during grinding. Figure 9 shows
an example of bias modification and its simulation result.
(Set value)
Q'w Cutting
volume limit
(mm3/mms) (mm3/mm)
Total radial infeed
Rough grinding 5.0 600 0.826 (mm)

( )
2.0 300 Amount
Semi-finish grinding
of radial infeed
Finish grinding 1.5 300

(Grinding conditions)
Amount No. of
of radial grinding Feedrate Dressing
infeed cycles (mm/min) Grinding pass interval
(mm) (No. of teeth)
(times)

Before bias modification After bias modification Rough 0.121 6 2 479 Conventional/ 15
grinding Climb
Simulation of profile grinding
Semi-
finish 0.06 1 2 000 Conventional 30
grinding
Finish
grinding 0.04 1 2 250 Conventional 45

Before bias
modification After bias modification Fig. 10 Automatic calculation of grinding conditions

Fig. 9 Example of bias modification

Tooth profiles were made almost equal at top, middle, and 3.5 Machining example (1)
bottom of face width. Figure 11 shows an example of grinding a large gear
using the ZG1000 grinder.
We finished a large gear (module 5, number of teeth
3.4 Machining support software 162, face width 95 mm, grinding stock in tooth thickness
In order to grind the tooth flanks of the workpiece with 0.45 mm) with a cycle time of 3 hours 45 minutes, and the
high accuracy, it is important to set grinding and dressing accuracy of the finished gear was JIS N2 grade (JIS N0 grade
conditions. In particular, in profile grinding, the operator for the cumulative pitch).
needs to speci f y t he d ressi ng i nter va l appropr iately 3.6 Machining example (2)
because a grinding cycle may include several dressing In gear grinding, as with other types of grinding, the
cycles. Therefore, ZG series grinders provide the ability to surface roughness is also an important factor in addition
automatically calculate grinding conditions in the formula as to the accuracy of the tooth profile and lead. Since, in gear
shown below as a means to assist unskilled operators. lubrication, the oil film parameter λ (= film thickness/surface
Regarding the grinding conditions, the recommended roughness) is closely related to the lubrication effects and
conditions are calculated automatically based on the specific damage to the flank surface, the improvement of the surface
cutting rate Qw’ and the grinding stock as follows: roughness has a large impact on the improvement in the

Mitsubishi Heavy Industries, Ltd.

Technical Review Vol. 45 No. 3 (Sep. 2008)
36
 performance and life expectancy of a gear. On these points,
JIS
left PROFILE right
Tip the Mitsubishi ZG1000 gear grinder has achieved a surface
roughness of Ra 0.3 μm in large gear grinding. Figure 12
20
m Tooth profile error
Left flank 2.9
Va500:1
Right flank 2.4 shows a machining example.
Vb2:1 (JIS N1 grade)
4. Development of future gear grinding technologies
5
mm
Root
4.1 ZE15/24A (Generating gear grinding machine)
Top
left LEAD right (1) Bias grinding
20
m As mentioned above, even in generating grinding,
Lead error
Va500:1
Left flank 1.7 crowning a gear tooth causes the tooth profile to be
Vb0.5:1
Right flank 2.5 biased. However, in response to today’s customer
(JIS N1 grade)
20
needs, we find it necessary to develop technologies to
mm
Hottom control this bias.
Pitch error (2) Improvement in grinding speed
JIS Tooth to tooth spacing fp lett

Single pitch error

20 m Left flank 2.6 To accomplish high productivity and cost reduction,
500:1
Tooth to tooth total accumulative Fp left (JIS N2 grade) there is a strong demand for high-speed grinding.
Cumulative pitch error Although the grinding speed V has been approximately
Left flank 5.0
20 m
(JIS N0 grade)
60 m/s -1 conventionally, it is now approximately 75
500:1
Tooth to tooth spacing fp right
m/s -1 in practical use. In the future, it is anticipated
Single pitch error
20 m Right flank 1.9 that this will be increased to as high as 90 m/s -1. The
500:1
Tooth to tooth total accumulative Fp right
(JIS N1 grade) reduction of the non-cutting time in a grinding cycle is
Cumulative pitch error also a requirement.
Right flank 5.9
20 m
4.2 ZG400/1000 (Profile gear grinding machine)
500:1 (JIS N0 grade)
(1) Line-up of large gear machines
Workpiece specifications In the market of gearbox for wind turbine systems,
Module 5 mm Helix angle 15.4° there is an increasing need for gear machines that
No. of teeth 162 Outer diameter 850 mm can handle a workpiece diameter of φ1,000 mm or
Pressure angle 20° Face width 95 mm
larger to support the target workpiece diameter of
approximately 1.5 to 2.5 m.
Fig. 11 Machining example of a large gear (Machining result)
Finished gear was finished to a machining accuracy of JIS N2 (2) On-machine measuring system with higher precision
grade. and higher speed
On a large gear gr inding machine, unloading
and then reloading a workpiece is time-consuming.
Therefore, it is becoming more important to develop an
Left flank Right flank
on-machine measuring system improved in accuracy
Ra 0.24 m Ra 0.21 m
Roughness curve Roughness curve and speed.
Evaluation length 4.0 mm Evaluation length 4.0 mm (3) Adoption of a direct drive technology
c=0.8 mm×5 c=0.8 mm×5 It is c onsidered ne c es s a r y t o adopt a d i re c t
×2K ×2K
drive technology because high-precision control is
×20 ×20
impossible if any clearance exists in each axis.
Vertical 5.0 m/cm Vertical 5.0 m/cm
Horizontal 500.0 m/cm Horizontal 500.0 m/cm (4) Ease of workpiece centering
For large gears, facilitating the centering of the
workpiece is an important technology because it is
difficult and time-consuming.
(5) Development of production support systems
T here is an increasing demand for production
support systems that assist customers in simulating
the tooth profile, estimating the grinding accuracy,
automatically calculating the grinding conditions, and
more.

5. Conclusion

For gears used in automobiles, construction machines,

wind turbine systems, and general industrial machinery,
Fig. 12 Machining example of a large gear (surface roughness) there is an increasing need for high accuracy and customers

Mitsubishi Heavy Industries, Ltd.

Technical Review Vol. 45 No. 3 (Sep. 2008)
37
are seeking high-precision, easy-to-use, and low-cost gear
grinding machines. To address this, for the grinding
of relat ively sma l l gea rs (φ25 0 m m or less) used for
automobiles, we developed gear grinders that feature high
efficiency, high precision, and low running cost by adding
diagonal grinding and other capabilities to conventional Yukihisa Nishimura Yuji Ashizawa Toshifumi Katsuma
generating gear grinding techniques. As a result, more
automobile gear manufacturers are introducing our machines
into their manufacturing lines. On the other hand, for the
grinding of φ500 mm or larger gears used in construction
machines, wind turbine system, and so on, we offer a line-
up of profile gear grinding machines with additional tooth Yoshikoto Yanase Koichi Masuo
prof ile/lead cor rect ion and on-machine measurement
capabilities to improve operability and more customers are
introducing them into their gear machining facilities. We
will continue to offer gear grinding machines that feature
higher efficiency, higher precision, lower running cost, and
easier operation.

Mitsubishi Heavy Industries, Ltd.

Technical Review Vol. 45 No. 3 (Sep. 2008)
38