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Procedia Engineering 00 (2017)000–000
Procedia Engineering 00 (2017)000–000 www.elsevier.com/locate/procedia
ScienceDirect www.elsevier.com/locate/procedia
Procedia Engineering 206 (2017) 1087–1092

International Conference on Industrial Engineering, ICIE 2017

International Conference on Industrial Engineering, ICIE 2017
Mathematical Model for Assessing the Accuracy of Processed Gears
Mathematical Modelon
forGear
Assessing theMachines
Shaping Accuracy of Processed Gears
on Gear Shaping Machines
R.M. Khusainov*, R.R. Khaziev
R.M. Khusainov*, R.R. Khaziev
Kazan Federal University, 68/19, Pr. Mira, Naberezhnye Chelny 423812, The Russian Federation
Kazan Federal University, 68/19, Pr. Mira, Naberezhnye Chelny 423812, The Russian Federation

Abstract
Abstract
This paper examines the impact of the geometric and kinematic errors of gear shaping machines for the accuracy of processed
wheels.
This paperThere is a problem
examines the impactto establish a correlation
of the geometric between the
and kinematic errors
errors of the
of gear technological
shaping machinessystem
for thewith the gear
accuracy accuracy
of processed
parameters defined by standards. In this article, the equation of the machined surface is proposed
wheels. There is a problem to establish a correlation between the errors of the technological system with the gear accuracybased on the coordinate
transformation
parameters definedmatrices and equations
by standards. of article,
In this involutethe surface of the
equation of tool in the form
the machined of a matrix
surface equation.
is proposed basedOnonthethebasis of this
coordinate
equation the machine
transformation matricesoutput
and precision
equationsisofgiven in thesurface
involute form ofofmatrix equation.
the tool The impact
in the form of errors
of a matrix of the technological
equation. On the basis system
of this
elements is displayed
equation the by a matrix
machine output of variations,
precision is given incomponents
the form ofof whichequation.
matrix are the projection
The impact of of
errors onofthe
errors theaxis. Output errors
technological are
system
applied
elements is displayed by a matrix of variations, components of which are the projection of errors on the axis. Output errors area
on the machined surface via the projection on the line of action. Next, the obtained values are translated into
standardized
applied on the deviation
machinedof the gear accuracy.
surface This enables
via the projection onforecasting
the line oftheaction.
possibility
Next,ofthe
obtaining
obtained thevalues
productsareoftranslated
certain accuracy
into a
on this machine,
standardized as well
deviation ofas
thetogear
control the specific
accuracy. parameters
This enables of the technological
forecasting the possibilitysystem to ensure
of obtaining the the accuracy
products and stability
of certain accuracyof
the this
on process.
machine, as well as to control the specific parameters of the technological system to ensure the accuracy and stability of
© 2017
the2017 The Authors. Published by Elsevier B.V.
process.
© The Authors.
Peer-review Published by
under responsibility of Elsevier Ltd. committee of the International Conference on Industrial Engineering.
the scientific
© 2017 The under
Peer-review Authors. Published by
responsibility Elsevier
of machine; B.V.committee of the International Conference on Industrial Engineering
the scientific
Keywords: gear accuracy; gear shaping geometric
Peer-review under responsibility of the scientific committee accuracy.
of the International Conference on Industrial Engineering.
Keywords: gear accuracy; gear shaping machine; geometric accuracy.

1. Introduction
1. Introduction
As we know from classical theory of accuracy [1] a real gear can be seen as the product, reflected his tools
manufacturing
As we knowinaccuracies, which
from classical willof
theory occur during[1]
accuracy operation,
a real gearchanging
can betheseen
function
as themove unit reflected
product, [2,3]. Violation of
his tools
accuracy parameters
manufacturing of gears,
inaccuracies, i.e. will
which deviation geometric
occur during shapeschanging
operation, of the teeth from the
the function theoretical
move areViolation
unit [2,3]. caused byof
circumstances reflected
accuracy parameters of due to technological
gears, i.e. deviationreasons [4-6].shapes
geometric It is considered thatfrom
of the teeth the main influence on
the theoretical arethecaused
accuracy
by
circumstances reflected due to technological reasons [4-6]. It is considered that the main influence on the accuracy

* Corresponding author. Tel.: +7-927-495-1401

E-mail address:author.
* Corresponding rmh@inbox.ru
Tel.: +7-927-495-1401
E-mail address: rmh@inbox.ru
1877-7058 © 2017 The Authors. Published by Elsevier B.V.
Peer-review
1877-7058 ©under
2017responsibility
The Authors. of the scientific
Published committee
by Elsevier B.V.of the International Conference on Industrial Engineering .
Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering .

1877-7058 © 2017 The Authors. Published by Elsevier Ltd.

Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering.
10.1016/j.proeng.2017.10.599
1088 R.M. Khusainov et al. / Procedia Engineering 206 (2017) 1087–1092
2 R.M. Khusainov, R.R. Khaziev / Procedia Engineering 00 (2017) 000–000

of cut wheels have a kinematic error of the machine and tool error [7-9]. Influence of geometrical errors is studied
only on milling machines and lathes [10-15] and from these studies the methods of geometric errors measuring are
well-known, but without regard to its features on gear cutting machines.
On the other hand, error of gears are characterized by a set of parameters established by standards [16,17]. For
each degree of precision gears sets standards: the kinematic precision, smooth operation and tooth contact. The
consumer specifies its requirements in the form of performance standards. The manufacturer also has to deal with
production errors of the technological system, and it is difficult to associate these error tolerances in the drawing
[18]. This is especially true for gears, the complexity of the geometry and quality of which makes it difficult for a
preliminary assessment of the accuracy of manufacturing.

2. Modeling of the output accuracy of the machine tool

The proposed method for estimating the parameters of accuracy of cut wheels based on a functional approach to
the formation of gear errors, as well as on the application of the mathematical apparatus of the coordinate
transformation [19]. Shaping in this case can be represented as a transformation of tool movements through the
corresponding coordinate matrix elements of the technological system. This article discusses an example application
of this methodology to the cutting gear to gear shaping machine. Coordinate system in the annex to the gear shaping
machine is presented in Fig. 1.

Fig. 1. Coordinate system in the processing of gear shaping machine.

To form the surface of the tooth of the processed gear on this machine requires the following movements: Z -
reciprocation shaping cutter in the vertical direction; C - rotation of the workpiece; D - shaping cutter rotation. The
last two movements are connected by dependency:

D C  i (1)

zt
i (2)
zw

where zt -number of teeth shaping cutter, zw -number of teeth of the workpiece.

Since only the finishing pass affects on the accuracy of machined teeth, the movement of the radial feed is not
taken into account and believe the spacing between the tool and the workpiece is constant.
Transformation movements described by the following equation:

r0  AD  A X  AZ  AC  rcs (3)

where r0 -vector coordinates of the nominal surface of the workpiece; AD - the transformation matrix from the tool
rotation around its axis, AX - coordinate transformation matrix X (distance between the axis of the tool and the
 R.M. Khusainov et al. / Procedia Engineering 206 (2017) 1087–1092 1089
R.M. Khusainov, R.R. Khaziev / Procedia Engineering 00 (2017) 000–000 3

workpiece), AZ - matrix transformations on coordinate Z (vertical movement of shaping cutter), АС - the

transformation matrix from the workpiece's rotation around its axis; rcs - vector of the surface coordinates of the
cutting tool [20].
By calculating the composition of the above matrices, we get the matrix equation of nominal surface:

 X  cos(C )  rb  sin(C )  C  i  rb  cos(C ) 

 X  sin(C )  r  cos(C )  C  i  r  sin(C ) 
r0   b b  (4)
 z 
 
 1 

where rb –base circle radius.

Analyzing this equation, we can conclude that it represents a classical involute curve equation in matrix form,
shifted by the value of the axle distance X and converted by the value of the transmission ratio of conditional
engagement between the machine-tool cutter and processed gear. Thus, it shows the process of forming the surface
of processed gear on the gear-shaping machine.
During processing, each processing element generates a system error. Modelling the resulting error at the output
of the machine is made by adding to the equation of the nominal surface the matrixes describing the errors of each
element of the machine:

r ( AD ) AD  A X  AZ  AC  rcs  AD  ( A X ) A X  AZ  AC  rcs 

(5)
 AD  A X  ( AZ ) AZ  AC  rcs  AD  A X  AZ  ( AC ) AC  rcs

where δAD - workpiece rotation drive error matrix; δAX - matrix of interaxial distance setting errors; δAZ - matrix of
motion path along the z-axis errors; δAC - shaping cutter rotation drive error matrix.
Each matrix δA(i) represents a matrix variation movement and is as follows:

 0  Сi  Bi  xi 
 С 0  Ai  yi 
 Ai   i (6)
 Bi  Ai 0  zi 
 
 0 0 0 0 

The components of this matrix are the projections of errors of this machine element on the respective axes.

3. Adoption to the line of action

According to the classical theory of precision formation errors of the product should be considered through the
mechanism of action in its work [1,21]. In this case, the line of action is the line of machining engagement (Fig. 2).
The components of equation (5) are applied to this line. Projection on the line of action is performed by multiplying
the matrix column of error (5) on a matrix equation of normal to the involute surface:

rn
 ( z , C ) r ( z , C )  n (7).

The normal vector to the nominal surface is determined by the equation:

1090
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R.M. Khusainov, et al./ /Procedia
R.R. Khaziev ProcediaEngineering
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206 (2017)
(2017) 1087–1092
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 rb  sin(C)  X cos(C )  i  rb  sin(C )  C  i  rb  co s(C ) 

 
 rb 2  (i  1)2  ( X  C  i  rb ) 2 
 
r0 r0  rb  cos(C)  X sin(C )  i  rb  cos(C )  C  i  rb  sin(C ) 
n   (8)
C z  rb 2  (i  1)2  ( X  C  i  rb )2 
 
 0 
 
 0 

Fig. 2. The line of action in gear shaping.

The resulting expression due to the large volume and complexity is not given here. This expression describes the
inaccuracies of cutter position relative to the side surfaces of the teeth and can be converted into the parameters of
the accuracy of the gear being cut. Figure 3 shows a scan graphics errors when C changing from 0 to 2π and z from
0 up to the height of the tooth. The graphic was obtained in MathCAD Prime 3.1.

Fig. 3. Scan graphics errors.

As seen in the graph, the error function has a clearly defined fundamental wave having a period of one revolution
of the workpiece and the cyclical harmonics. Also, the graph has a slope height of the tooth, which characterizes the
influence of the distortions of the trajectory of the main motion cutter.
To determine the individual accuracy parameters of the gear the total error is decomposed into radial and
tangential components (Fig. 2). The radial component appears as a projection on an X axis of the total error on line
of gearing:
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R.M. Khusainov, R.R. Khaziev / Procedia Engineering 00 (2017) 000–000 5


R ( z , C ) rn ( z , C )  sin( ) (9)

The tangential component is regarded as a projection of the total error on line of gearing on axis Y and is written
in the following form:


T ( z , C ) rn ( z , C )  cos( ) (10)

4. Estimating the parameters of kinematic accuracy

A set of parameters of kinematic accuracy is determined by the basic harmonic errors. Therefore, to compare the
technological system errors and standard indicators of kinematic accuracy is necessary to explore the basic harmonic
functions and, that is, the change of these components in one revolution of the workpiece.
The difference between the largest and smallest values of radial component for one turnover of the gear gives the
magnitude of the pitch line run-out:

Frr max  R ( z, C )  min  R ( z, C ) (11)

0  C  2 0  C  2

The value of the corresponding error calculated by equation (9) in the MathCAD Prime 3.1 for the number of
teeth of the 51 and module 2 is 0.044 mm, which is typical for gears of this size to be processed on machines of
normal accuracy.
Similarly, the value of kinematic error is defined as the difference between the maximum and minimum values of
the tangential component on the interval from 0 to 2π.

Fr max  T ( z, C )   min  T ( z, C )  (12)

0  C  2 0  C  2

The value of the corresponding error calculated by equation (10) amounts to 0.122 mm that also matches the
parameters obtained on machines of this type.

5. Conclusions

The proposed approach allows to establish the relationship between the set of parameters of the accuracy of gear
and manufacturing errors. Equations and charts that describe this relationship show that despite the significant
impact of kinematic accuracy, the geometrical accuracy should not be neglected. This is especially seen in the graph
in Fig., In addition to the cyclic errors clearly displayed teeth bias due to non-perpendicularity of the cutter
movement trajectory to the table surface. It is possible to predict the accuracy of manufactured gears at the stage of
pre-production basing on the identified relationship. Thus, we can evaluate the possibilities for the implementation
of the existing production potential order or pick up the necessary means of technological equipment for the new
production

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