Online gear hobbing error estimation based on shaft vibration signal analysis

This paper presents a method for online estimation of hobbing error based on the workpiece shaft vibration analysis. The hobbing vibration originates from the intermittent cutting process and directly influences the machining accuracy of gears. By analyzing the vibration data of workpiece shaft, the gear error estimation is completed. Firstly, mathematical models, combining tooth geometric characteristics with vibration displacements, for evaluating helical gear profile deviation, pitch deviation, and helix deviation are established. Secondly, an orthogonal experiment of gear machining is carried out and the vibration acceleration data of workpiece shaft are collected during processing. Finally, based on the vibration displacements obtained by frequency domain integration of acceleration data, the gear errors are estimated. The comparison between the estimation errors and the actual errors proves that the estimation model is effective. In addition, by analyzing the orthogonal experiment results and factors, and the spectrum analysis of acceleration signals, the order of the influence degree of machining parameters and the vibration characteristics under different parameters were obtained. The research results can provide theoretical and practical references for error compensation and parameter optimization of gear machining.