This paper proposes a method to study the machining error when one is generating gear grinding based on the mapping relationship between the grinding wheel surface and the tooth flank. The profile of the grinding wheel after grinding is collected, and the theoretical tooth flank is derived according to a model of generating gear grinding. By comparing the normal deviation of the theoretical tooth flank with the measured tooth flank, the machining error characteristics are identified. Firstly, the mathematical model of generating gear grinding is established according to a multi-body theory and coordinate transformation. Secondly, the experiments of the lead modification for helical gear were performed on a YW7232 CNC gear grinding machine. The tooth flank twist compensation function was turned off in experiments No. 1–No. 3, and it was turned on in experiments No. 4–No. 6, while the other process parameters kept the same. Then, the corresponding theoretical tooth flank data were derived from the grinding wheel surface which were measured using the laser profilometer LJ-V7000. Finally, the machining error characteristics were obtained by analyzing the difference between the theoretical and measured tooth flank deviations. The result of this paper can provide theoretical and practical references for the improvement of the gear grinding accuracy and gear modification design.
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