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This paper introduces an approximate grinding method (AGM) and tooth flank deviation correction strategies for helical face gears (HFGs) generated by grinding worm, addressing the issue of singularities on the grinding worm thread surface that hinders HFGs grinding properly. Firstly, the tooth flanks of the face gear and grinding worm are derived, and singularities on the grinding worm are determined. Then, based on the grinding generation theory of HFGs, the AGM is proposed to solve the challenge of grinding HFGs with a large helix angle. Next, the tooth flank deviation of HFG generated by the grinding worm with the AGM is investigated; meanwhile, the tooth contact pattern and transmission error analysis are conducted. In addition, the correction method of the HFG tooth flank deviation is researched. Finally, a grinding experiment is performed and demonstrates the validity of the theoretical analysis of the AGM. [ABSTRACT FROM AUTHOR]

This paper delves into the generation of helical face gears using a grinding worm. It investigates the computerized generation process and explores the inherent geometric constraints associated with the application of a grinding worm for helical face gears. An approximate grinding method, tailored for helical face gears featuring large helix angles, is proposed, with an evaluation of the resulting theoretical deviations. Furthermore, a novel rapid computational approach for determining the bearing contact of helical face gear pairs is introduced and validated through Finite Element Analysis (FEA). The subsequent analysis comprehensively examines the effects of the machine tool positioning errors on tooth flank deviations, bearing contact, and transmission errors. A sensitivity matrix is developed to elucidate the relationship between machine tool positioning errors and the tooth flank deviations, leading to the proposition of a correction method for theoretical generating deviations. Finally, the paper introduces a tooth flank modification method for helical face gears and the meshing performance is highly improved. [Display omitted] • An approximate grinding method for face gear with large helix angle is introduced. • A rapid tooth contact analysis method for helical face gear pair is proposed. • The influences of positioning errors on tooth flank deviation are studied. • A correction method for tooth flank deviation of helical face gear is investigated. • The meshing performance is improved by applying tooth flank modification. [ABSTRACT FROM AUTHOR]