关键词: 成形磨齿机, 几何误差, 齿面误差, 误差识别, 全局敏感性分析

Abstract: To reveal mapping rules between geometric errors and tooth surface errors and to identify crucial errors affecting grinding precision in the gear profile grinding machines,an identification method for crucial errors was proposed based on the geometric-error-to-tooth-surface-error model and the global-sensitivity-analysis Morris method.The tool volumetric error model was constructed by using homogeneous transformation matrices for five-axis CNC gear profile grinding machines,and the geometric-error-to-tooth-surface-error model was established based on conjugate grinding theory.The Morris method was utilized to quantify the sensitivity of geometric errors and identify the crucial errors and sensitive components.The effectiveness of the identified results was verified through the modification simulation of crucial errors and the machining experiment with error compensation.The result showed that the proposed method could effectively identify crucial errors of the gear grinding progress and that was superior to the existing identification method based on the tool volumetric error model.It could provide the reliable theoretical basis for the accuracy enhancement of sensitive components and the accurate compensation of crucial errors to improve grinding precision efficiently.

Key words: gear profile grinding machines, geometric errors, tooth surface errors, error identification, global sensitivity analysis