Diamond Roller—A Comprehensive Technical Guide to Gear Machining

Automotive transmission gears: high efficiency, low backlash, high precision

In the automotive transmission gear sector (where the number of domestic manufacturers remains limited), the key requirements are:

High processing efficiency

Close meshing (small side clearance)

Small gear runout (reduces vibration)

High grinding accuracy

These characteristics directly affect shift quality, torque capacity, and the overall service life of the transmission.

Principle of worm gear grinding: utilizing the kinematics of worm and worm gear.

Worm grinding simulates the relative motion between the worm and the worm wheel. 
Here, the grinding wheel replaces the worm gear. By synchronizing the rotation of the worm (grinding wheel) with that of the gear workpiece, the tooth surfaces are machined.

This process trues the grinding wheel to the exact profile of the gear tooth space and then performs continuous generating motion—making it ideally suited for high-volume, high-precision automotive gears.

Three Forms of Forming, Grinding, and Dressing Rollers

1. Double-plate single-face dressing
2. Double-plate, double-sided dressing
3. Single-piece trimming

Three types of dressing rollers for worm gear grinding:

1. Single tooth
2. Single-tooth plus tip modification
3. Multi-tooth

At a specific grinding wheel speed, periodic protrusions form on the wheel surface.

This protrusion will be replicated on every gear tooth surface, resulting in waviness (waviness marks) along the tooth profile.

Core Advantages:

Single-pass dressing: eliminates the need for multiple roller changes or staged dressing, significantly reducing grinding wheel dressing time and making it ideal for high-volume production lines.

High-precision gear finishing: The roller directly forms the tooth-tip relief, root fillets, and pressure-angle correction, eliminating the need for subsequent additional finishing operations.

Superior tooth surface quality: Full-contact dressing eliminates tool-mark defects on the grinding wheel surface, resulting in low gear tooth waviness and reduced transmission noise.

Long service life: Utilizes high-concentration CVD diamond particles, offering excellent wear resistance and making it ideal for high-volume gear production (a single roller can be reconditioned thousands of grinding wheels).

Applicable scenarios:

Forming Grinding of Automotive Transmission Gears (DCT, AT, CVT)

High-precision gear mass production (e.g., reduction gears for new-energy vehicles)

Low-noise gears with tip relief, root fillets, and helix crowning

Electroplating process: Manufactured using electroplating, with CVD diamond particles embedded in the top layer, resulting in high abrasive protrusion and sharp cutting performance—ideal for high-efficiency dressing.

Structural Design: Includes four Φ11 holes, 6.5 mm deep, and six 6.6 mm through-holes, all evenly distributed, for easy installation and positioning.

Applicable Machine Tools and Processes:

This roller can be used for dressing grinding wheels in form grinding (single-tooth or multi-tooth) and worm-wheel grinding, and is particularly well suited for the mass production of automotive transmission gears with small to medium modules, such as those used in DCTs, CVTs, and AMTs.

Modulus range : m = 5 ~ 6.5, suitable for gears in medium- to heavy-duty automotive transmissions and transmission gears in construction machinery.

Process Options : Can be manufactured as a single-tooth roller (suitable for complex gear modification and wide tooth widths) or a duplex roller (suitable for high-efficiency, large-volume gear修整).

Electroplating process : The CVD diamond particle electroplating process is employed (refer to the technical requirements in the corresponding drawings), resulting in a diamond layer with high bond strength and long service life.

Accuracy class : Diamond profile runout ≤ 0.003 mm, dynamic balancing grade ≤ G0.4 at 2,800 r/min, ensuring that the gear tooth profile exhibits no waviness after grinding wheel dressing.

Application Scenarios : Dressing of form-grinding wheels for large-module gears, such as automotive transmission output gears, construction-equipment final-drive gears, and wind-turbine yaw gear rings.

Core Advantages ：

High flexibility : A disc gear can be machined via programming to produce complex tooth profiles with varying module, pressure angle, relief edges, and chamfers.

Low ripple mark : Because trajectory refinement is performed via continuous scanning, it eliminates the periodic protrusions caused by conventional multi-roller tool-change marks or roundness errors.

Especially suitable for worm gear grinding. Modern worm gear grinding machines, such as those from Niles, Gleason, and Hofler, are increasingly employing disc wheels for continuous trajectory dressing to reduce tooth surface waviness and enhance dressing efficiency.

Typical Applications ：

Continuous Dressing of Worm Gear Grinding Wheels (as a Replacement for Dual-Disc Single-Sided/Dual-Disc Double-Sided Rollers)

Flexible Manufacturing of Small-Batch, Multi-Variety Gears

High-precision gears requiring addendum modification and root chamfering (e.g., transmissions for new-energy vehicles).

E-mail:

saisudiamond@gmail.com

Tel: 
+8617339586706

Address: 

No.921, 300 Meters West Of The Intersection Of Xiangjiang West Road And Chuangye Road, Yuanhui District, Luohe City, Henan Province, China