A high-precision tool model for helical pinion cutters

The paper presents a new design method for producing accurate helical pinion cutters based on analysis of the tool and the grinding geometry. Both the design and manufacturing models are carefully derived and presented. By employing the plane envelope theory, the reference contour of the grinding wheel is determined and then modified by using the theory of mid-point and mid-line. The model provides accurate solutions for both the sectional contour of the grinding wheel and the maximum qualified length of the gear teeth that are needed for grinding high-precision helical pinion cutters. The proposed method is simple and straightforward and can be used to produce high-precision helical pinion cutters systematically. Two numerical examples are presented to illustrate the effectiveness of the proposed method. The modelling results indicate that the proposed method is practical, accurate and reliable for improving the accuracy and quality of various cutting tools.